1. CRANES, SLINGS, & YOU
They can do a lot of work 34

2. They can do a lot of damage
CRANES, SLINGS, & YOU
They can do a lot of damage 34

3. Review the manufacturers specific inspection requirements!
Idle Cranes
Cranes that have been idle, must be inspected and tested before being placed back in service using the criteria that applies to periodic inspection. Special attention should be given to the hook, lifting chain and wire rope.
Review the manufacturers specific inspection requirements! 34

4. Altered Cranes
Cranes that have been altered or repaired must be inspected and tested. If load sustaining parts are altered or repaired, a load test should be conducted to verify the rated load capacity of the crane. Report issued by a qualified person and kept on file. 35

5. Load Testing
When load testing, the test load cannot exceed 125 percent of the rated load. Hoists & cranes should be operated a number of times at various positions. Report issued by testing organization giving the conditions under which system was load tested. 37

6. Preventive Maintenance
Clean & lube wire rope & chain
Adjusting brakes
Checking & filling gear cases levels
Replacing any contaminated oils
Lube bearings, gears, pinions, linkages, & shafts
Adjusting operation of limit switches
Clean & replace pitted/burned electrical contacts
Cleaning or replacing air & fluid filters
Inspecting all controls & warning systems 38

7. General Pre-Op Test Disconnects are known before any test
Get help if you’re not familiar with the cranes
Follow manufacturers recommendations
Follow Checklist
Inspect electrical controls
Check for obstructions in crane’s travel path
Test proper operation of controls
Observe for smooth operation of components
Never unwind spool completely
Check upper & lower limit switches 39

8. Hook Pre-op Test Replace if deformed or cracked
Check for proper function of safety latch
Inspect for twists from plane of unbent hook
Check for proper swivel
Hook repair is not recommended
Emergency hook repair must be performed only under competent supervision
After any hook repairs, hook must be load tested before being returned to normal service 40

9. Rope Pre-op Test Reduction in rope diameter
Broken or worn outside wires
Corroded or broken wires at end of connections
Severe kinking, crushing, cutting or unstranding
Corroded, cracked, bent, worn, or improperly applied end connections 41

10. Lockout-Tagout Review individual crane requirements
Integrate lockout & maintenance requirements
Lockout-tagout training
Written program established & reviewed
Ask manufacturer for lockout device recommendations
Devices not always interchangeable between different cranes
LOCKED
OUT
This Lock/Tag may
only be removed by
NAME: __________
DEPT : __________
COMPLETION
DATE: ___________
TIME: ____________
DON’T OPERATE
DANGER 42

11. Crane Safety Basics 2
TON
Never allow a co-worker between a fixed object and a load!
DANGER
WORKING
CRANES 45

12. Fatalgram
The feeder was lowered to the ground, resting in an unsecured position. The feeder rolled on its side, pinning the victim against the wall of an adjacent control booth. 47

13. Fatalgram
The employee was in the process of loading a conveyor onto the trailer of his truck using the truck's crane. The cable attached to the conveyor slipped off the hook of the crane causing the conveyor to bounce off the trailer and crush the victim who was standing between the crane and the trailer. He died from crushing injuries. 47

14. Safe Working Radius
Know the safe travel radius of the crane. Contact with electrical sources or other hazards can result in catastrophic consequences. 47

15. Load Chart 47

16. Crane Safety Basics
Even when properly trained, equipment properly maintained, & employees work in a safe manner, accidents can still occur because crane operations are dependant on mechanical devices that can fail. The results can be catastrophic. You are the only controlling influence that can minimize the hazard. Your life literally is in your own hands! 49

17. Operator Requirements
No history of unsafe acts in workplace
Mature & safe attitude
Ability to react quickly in an emergency
Drug & alcohol free
Good depth perception
Good hearing and vision
Thoroughly trained
Understand lift requirements
No medication that will interfere with operation 50

18. Safe Practices Test controls & brakes at start of shift
Don’t operate unsafe cranes or hoists
Test brakes by a short lift to ensure control
Move loads only after being signaled by designated, qualified signaler 51

19. Safe Practices Never carry loads over anyone
Never carry loads past anyone
Signalers in line-of-sight of operator
No riders on loads or hooks
No unauthorized person operating crane
Lockout before maintenance or repairs
Frequently inspect cranes 52

20. Safe Practices Hook directly over load before lifting
Document & maintain inspection records
Check warning devices & signals
Signalers must watch load
Operators must watch signalers
Know travel path in advance of lift
Know where to set down load
Will new location support weight 53

21. Fatalgram
The employee was using a truck equipped with a hydraulic boom to position a tire on the hub of a caterpillar loader. The tire fell off the hook and struck the employee on his head and neck. 53

22. Fatalgram
Three steel plates weighing nearly 6,000 pounds were tied together by one nylon strap. They were lifted about 5 feet by a crane in order to slide a second strap around them. The truck driver walked under the suspended load, and at that moment, the strap around the steel plates broke. The plates fell striking the victim. He died from head injuries. 53

23. Fatalgram
A cement take-up pulley weight for a conveyer was being lifted into position by a crane. To lift the weight, straps were attached to four pins that had been set into the cement weight. The employee was riding on the 3,000 pound weight as it was being lifted. One of the pins pulled out of the weight causing the employee to lose his balance and fall 35 feet to the ground. He died from sustained injuries. 53

24. Signaler Safe Practices
Only one person is designated signaler
Maintain line-of-sight with operator
Operator acknowledges every signal
Stop operation if comprehension is lost
Operators must watch signalers
Plan in advance where load is going
Will new location will support the weight 54

25. Leaving or Parking Raise hooks to limit switches
Place controls in “off” position
Place main power switch in “off” position
Visual check for dangerous conditions
Report defects immediately
Tagout defective equipment immediately
Report cranes not in operation
Follow manufacturer’s recommendations. 55

26. Lifting Factors Size, weight, & center of gravity of load
Number of sling legs
Angle sling makes with horizontal line
Rated capacity of sling
History of care & usage of sling 56

27. Size, Weight, & Center of Gravity
Crane hook must be directly above center of gravity
If crane hook is too far to one side of center of gravity, dangerous tilting and unequal stress to sling leg will result 57

28. Capacity of Sling
Rated capacity varies depending upon type of sling, size of sling, & type of hitch
Consult with manufacturer
Older slings must be used with additional caution
Sling charts based on new sling usage. 59

29. Care & Usage
Mishandling & misuse of slings are leading cause of sling-related accidents
Proper care essential for maximum service & safety
Always protect slings with cover saddles, burlap padding or wood blocking to prevent sharp bends & cutting edges. 60

30. Estimating Load Weight
Use a Dynamometer
Check shipping papers
Check nomenclature plates
Use industry standard tables or charts
Consult equipment manufacturer
Estimate using weights of similar loads
Never lift based on a guess
Stay within 50% of cranes rated capacity when estimating loads 61

31. Rigging & Slings Chains Wire Rope Fiber Rope
Synthetic Web
Cargo Nets.
Each type has advantages and disadvantages! 62

32. Rigging & Slings
Consult with manufacturer concerning load capacities, usage methods, restrictions and other pertinent data for specific types of slings 63

33. Rules for Slings Never load in excess of rated capacity
Never use a damaged sling
Never pull sling from a suspended load
Never shorten with knots
Suspended loads clear of everyone
Suspended loads clear of obstructions
Hands & fingers clear of loads
Protect slings from sharp edges of load
Think before you affect a load. 64

34. Remove from service if:
Wire Rope Inspection
Remove from service if:
10 distributed broken wires
Five broken wires on one strand
Kinking, crushing, or bird caging
Evidence of heat damage
End attachments cracked, deformed, or worn
Hooks opened > 15% of the normal throat opening or twisted > 10% 65

35. Remove from service if:
Chain Inspection
Remove from service if:
Defective or questionable welds
Bending or elongation of chain links
Cracked or deformed links
Missing or removed identification tags
End attachments cracked, deformed, worn
Other suspected unsafe conditions 66

36. Remove from service if:
Web Sling Inspection
Remove from service if:
Acid or caustic burns
Age deterioration (drying/cracking)
Melting or charring of sling surface
Snags, tears or cuts exposure of colored thread
Missing or removed identification tags
Other suspected unsafe conditions 67

37. After The Lift Clean sling Check for damage
Follow proper storage rules
Leave in good condition for next lift
Report damaged or defective slings
Follow proper disposal or replacement procedures 68

38. Slings Storage Dry environment, out of sunlight Off floor or ground
Hung from hooks to prevent tangling and easy access
Away from electrical sources
By type - don’t mix steel chain slings with synthetics
In a controlled area 69

39. Sling Angles
Consult with the sling manufacturer concerning how sling angles affect load capacities for different types of slings.
1000lb 70

40. Sling Angles Angle of sling affects sling load capacity
Greater sling angle, greater stress
Multiple sling affects load capacity
Type of sling used is a factor
Consult with manufacturer for proper usage.
1000lb 71

41. Two Slings
The use of two slings, each supporting the same amount of weight and having the same support angle results in equal distribution of the load weight.
500lbs
1000lb
0 Angle 74

42. Sling Angle With Vertical Stresses Per Sling Leg 1000 lbs Total Load
Sling Angles
Sling Angle With Vertical
Stresses Per Sling Leg 1000 lbs Total Load
1000lb 30
577lbs
30 Angle 72

43. Sling Angles
1000lb
707lbs
45 Angle
1000lbs
1000lb
60 Angle 73

44. Sling Angles
The carrying capacity decreases as the spread between the slings increases. To determine the capacity of each sling in a bridle hitch: B A
Measure the distance on one sling for the same number of units as the capacity of the sling in tons (Distance A).
Measure the vertical distance from the point located in to the load in tons. (Distance B).
The number of units in this vertical distance (B) is the working load for the sling. 75

45. Sling Angles A B A = 2 ft. (or any unit) (2 Ton Sling Capacity)
B = 1.5 ft.
Working Capacity of Each Sling = 1.5 Tons
Note: The individual sling capacity must be more than half of the total load weight 76

46. Protecting Slings
Protect slings against sharp edges 78

47. HAND SIGNALS Hoist load: Forearm vertical Forefinger pointing up
Move hand in small horizontal circular motion 79

48. HAND SIGNALS Lower load: Arm downward Forefinger pointing down
Move hand in small horizontal circular motion 80

49. HAND SIGNALS Boom Travel: Arm extended forward
Hand open and slightly raised
Make pushing motion in the direction of travel 81

50. HAND SIGNALS Stop: Arm extended Palm down
Move arm sideways, rapidly back & forth 83

51. HAND SIGNALS Emergency stop: Both arms extended Palms down
Move both arms sideways rapidly back & forth 84

52. Protective Equipment Appropriate for the particular hazards
Maintained in good condition
Properly stored when not in use
Kept clean, fully functional, and sanitary 85