Overhead Cranes

SAFE WORK METHOD STATEMENT – Part 1

Company Details

Company Name: ABN:

Contact Name, Position, and Phone number:

Address:

Project Details

Project: Area:

Job Address:

Job Description:

Activity: Overhead Crane - Bridge and Gantry Cranes

Relevant workers must be consulted in the development, approval and communication of this SWMS SWMS Approved by of 15 Name: (Include names of workers who were consulted in relation to this SWMS)

Signature: Job Title: Date:Name:

Signature:

Date:

Personnel responsible for monitoring and managing activity:Overall Risk Rating after Controls

4 Acute 3 High

2 Moderate 1 LowALL PERSONS INVOLVED IN TASK MUST HAVE THIS SWMS COMMUNICATED TO THEM PRIOR TO WORK COMMENCING

Regular inspections and observations will be conducted by ______________to ensure SWMS is being complied with. Daily Tool Box Talks will be undertaken to identify, control and communicate additional site hazards. Work must cease immediately if incident or near miss occurs. SWMS must be amended in consultation with relevant persons. Amendments must be approved by ______________ and communicated to all affected workers before work resumes. SWMS must be made available for inspection or review as required by WHS legislation. Record of SWMS must be kept as required by WHS legislation (until job is complete or for 2 years if involved in a notifiable incident).

DOCUMENT NO: S8.2.13.0177 ACTIVITY: Overhead Crane REVIEW NO: DATE:Authorised By:Signature: © SafetyCulture All rights reservedDate: Page 1 – Version 8.2

Personal Protective Equipment

AS 1319-1994 Safety signs for the occupational environment reproduced with permission from SAI Global under licence 1210-c062. Standards may be purchased at http://www.saiglobal.com

Day Operations – Normal Requirements:Safety footwear, hand protection, gloves.As Required:High visibility clothing, hard hat.

Ensure all PPE meets relevant Australian Standards. Inspect, and replace PPE as needed.

Safety NotesThis SWMS covers the standard operation of a Bridge Crane or Gantry Crane. These cranes can be referred to as “Overhead Cranes”.This SWMS does not cover the operation of Container Cranes, Concrete Placement Units/Cranes, Elevated Work platforms or Mobile Cranes.This SWMS does not cover the lifting of people, including the lifting of people in workboxes.Dedicated SWMS should be developed for these tasks, and for any risks not covered in this SWMS. Companion SWMS include: Work on Construction Sites, Work on/near Mobile Plant, Noise Control.

Main hazards:- Loss of load - crushing, entrapment- Being struck by moving plant, parts or load- Crane collapse/malfunction- Noise

DOCUMENT NO: S8.2.13.0177 ACTIVITY: Overhead Crane REVIEW NO: DATE:Authorised By:Signature: © SafetyCulture All rights reservedDate: – Version 8.2

Foot Protection

High Visibility

Head Protection

Hand Protection

http://www.saiglobal.com/

Task BreakdownPossible Safety or

Environmental Hazards

RB Control Measures to Reduce risk RAResponsible

Officer

NOTE: RB = Risk Rating before controls implemented - RA = Risk Rating after controls are implementedPlanning Personal Injury:

- Loss of load - crushing, entrapment

- Being struck by moving plant, parts or load

- Crane collapse/malfunction

- Hearing LossLegislation Breach

3H Consultation in relation to hazards and risks.Ensure:- Consult with the person you are carrying out the work for on the potential

hazards and risks associated with the task. - If represented by an elected health and safety representative, the

representative is included in any consultation- Any other persons on site (trade or otherwise) who are effected by the

same matter are consulted and co-operative arrangements are made (e.g. co-ordination or alternative measures)- Document consultation and action items.

Liaise with Principal Contractor to establish the following on-site systems and procedures are in place:- Health and Safety rules - Induction for all workers – site specific- Supervisory arrangements - Communication - Injury reporting- Hazard reporting- Personal Protective Equipment - Exclusion Zones - Risk Assessments- SWMS and JSA’s.

Assess the exposure of operators to noise, including the frequency of exposure to noise levels that exceed the legislated Exposure Standard while operating an Overhead Crane within a noisy work environment and determine required controls such as Audiometric Testing and PPE. Refer to Noise Control SWMS for detailed information regarding the prevention of hearing loss and legislative requirements.

Check with individual State Regulators to determine Bridge or Gantry Crane operator licensing requirements. In general:Operators - High risk work licences An operator must hold a high risk work licence to operate a Bridge Crane or

2M





Officer

NOTE: RB = Risk Rating before controls implemented - RA = Risk Rating after controls are implementedPlanning – continued

Personal Injury:- Loss of load -

crushing, entrapment




3H Gantry Crane that is: - Controlled from a permanent cabin or control station on the crane, or - Remotely controlled where the remote control (including pendant controls)

has more than 3 powered operations.

A high risk work licence is required to remotely operate, for example, by way of pendant or radio, a Bridge or Gantry Crane that has: - A single hoist with 4 powered operations, e.g. traverse, travel, hoist and

rotate - Multiple hoists with 4 or more powered operations, e.g. two non-

synchronised hoists would typically have at least 5 powered operations (traversingx2, hoistingx2, and travelling).

A high risk work licence is not required to remotely operate a Bridge or Gantry Crane that only has a maximum of three powered operations. E.g. traverse, travel and hoist.

Bridge and gantry cranes Licence (CB):Covers the operation of Bridge and Gantry cranes controlled from a permanent cabin or control station on the crane and those which are remote controlled having more than 3 powered operations (hoist, raise and lower equals one operation), including the application of load estimation and slinging techniques to move a load.

A dogging or rigging high risk work licence is required by: - Any person other than a licenced bridge or gantry crane operator who

exercises judgement in the selection of slings, slinging techniques, the weight of the load, or its centre of gravity when slinging a load on a bridge or gantry crane, or

- Any person who directs a bridge or gantry crane operator in the movement of the load when the load is out of view of the operator.

A dogging or rigging licence may not be required if the lift does not require the person slinging the load to exercise judgment. E.g. SWP for undertaking routine, repetitive lifts has been developed and approved by a competent person and the worker slinging the load has been provided with training to allow them conduct the work safely. Check with your State Regulator.

2M





Officer

NOTE: RB = Risk Rating before controls implemented - RA = Risk Rating after controls are implementedPlanning – continued

As Above 3H Monitoring:PCBU’s/foremen/principal contractors monitor the use of Bridge and Gantry Cranes to ensure that the safe systems of work are being maintained by the operators.

2M

Preparation Personal Injury:- Loss of load -




Legislation Breach

3H Ensure site induction is provided for operators before final preparations for work commences.

Ensure all operators attend the site induction & toolbox talks and follow site safety procedures. Be aware of any new hazards present on the day

Ensure correct overhead crane and working environment selected:- Type, size, weight of loads- Frequency of use- Layout of workplace (Hazardous Chemicals stores, offices etc.)- Separation from plant/workers (establish exclusion zones)- Minimum clearances met (1.8m above working mezzanines)- Physical constraints of the workplace- Adequate lighting- Unobstructed view of loads.

Ensure: - Bridge Crane has been design certified if SWL is greater than 10 tonnes- Gantry Crane has been design certified if SWL is greater than 5 tonnes.

Include safety features:- Anti-collision (if more than 1 crane operating on same runway)- Deceleration (limit switches and 2-stage deceleration)- Load limiting devices- Upper and lower limit devices- Anti-fall devices- Service platforms (appropriate stairs, handrails etc.)- Covered electrical components- SWL (safe work load) displayed.

Select suitable lifting gear:- For required WLL (work load limit)- For nature of loads

2M





Officer

NOTE: RB = Risk Rating before controls implemented - RA = Risk Rating after controls are implementedPreparation – continued

As Above 3H - Check potential for damage (to load or lifting gear)All of the lifting gear must have the WWL or SWL displayed and have a colour-coded tag attached by the service technician.

Note: Do not use fibre rope for lifting gear.

2M

Pre-Operational Inspection & Set Up






3H Signage: Ensure sufficient warning signs indicating that an overhead crane is in use and signs are easily seen by other workers in the work zone.

Personnel. Ensure:- Sufficient fully trained and competent workers are available to operate the

overhead crane in use- Overhead Crane Operator must be familiar with the manufacturer’s

operation manual for the overhead crane in use.- Trained and qualified Dogman available as required- PPE is worn, including suitable hearing protection if required- All workers are familiar with the Risk Assessment and SWMS- Communication system between workers is set up to ensure safe work

practices.

Inspect work area:- Clear of stored materials- Travel path clear for operator - no trip hazards, obstructions- Unobstructed view of load- Persons/mobile plant are prevented from entering (barricades, lights, signs

etc.) - exclusion zone operational.

Inspect the Bridge or Gantry Crane:- SWL clearly marked- Required maintenance undertaken- Safety devices present and working- Control labelled correctly and clearly- No hydraulic leaks- Tracks are free from damage- End-stops are free from damage.

2M





Officer

NOTE: RB = Risk Rating before controls implemented - RA = Risk Rating after controls are implementedPre-Operational Inspection & Set Up – continued






3H Inspect lifting gear:Synthetic Slings. Check:- Labelled with legible WLL- Visible damage - wetness, mould, tears, failed stitching, burns, UV damage - Possible damage through heat, chemical exposure- Damaged lifting eyes, terminal attachments or end fittings.

Chains. Check individual links for:- Elongation of links - Deformation of links - Cuts, dents, gouges, cracks- Excessive wear or corrosion- Twists.

Flexible Steel Wire Rope Slings (FSWRS):- Marked with SWL/WLL- Check construction and lay of rope- Excessive wear or abrasion, fatigue, damage, stretching, - Corrosion or rust- Twists- Birdcaging- Multiple broken wires in one spot (cut)- Excessive wear such as abrasions from running over the drum or sheaves- Any slight discolouration - may indicate corrosion or lack of sufficient

lubrication- Diameter reduction under load- Crushing or flattening in any section of the rope.

Hooks:- Safety latches in place and undamaged, open correctly- Marked with SWL/WLL- Look for cracks, gouges, excessive wear.

Block - check that block is level and free from damage, wear or looseness in assembly or fittings.

2M





Officer

NOTE: RB = Risk Rating before controls implemented - RA = Risk Rating after controls are implementedPre-Operational Inspection & Set Up – continued






3H Note: If any defects reported on crane and/or lifting gear – apply lock-out/tag-out procedures and report immediately.

Check log book entries and complete log book entries as required.

If Hearing protection is required, ensure:- It is worn by all persons throughout the period of exposure to noise- It is suitable for the type of working environment and the work tasks- It s comfortable and correctly fitting for the worker- It is regularly inspected and maintained to ensure it remains in good, clean

condition- Workers wearing hearing protection can see any nearby hazards and/or

hear mobile plant warning devices, and directions from crane operators.

If handling hazardous chemicals or materials the overhead crane operator shall be familiar with the Safety Data Sheets, the location of eye wash stations and emergency equipment in the event of a spill, and relevant emergency procedures.

2M

Operation Personal Injury:- Loss of load -





4A Planning the lift:Develop safe work instructions specific to task (type of load).

Weight of load must not exceed any part of overhead crane SWL and lifting gear WLL. Example: If crane is 2T, sling is 2T, but lifting hook is 1T – then load must not exceed 1T.

Check overhead crane controls functioning correctly before starting the first lift.Ensure:- Hoist rope is not wrapped around load- Lifting gear securely seated on hook. (No twist that could cause the load to

swing.)- When attaching D Shackles do not over-tighten. Finger tight and back off ¼

of a turn. - Hooks on chain slings should always face outwards- Load is secured and balanced.

WARNING: Never allow anyone to walk under or place any part of their body under a raised load at any time.

3H





Officer

NOTE: RB = Risk Rating before controls implemented - RA = Risk Rating after controls are implementedOperation – continued






4A Never talk to, distract or approach an Overhead Crane Operator during a lift.

Doing the Lift. Overhead Crane Operators:- Never rush a lifting job- Maintain full attention to the task- Control buttons should be used smoothly throughout the lift- Position the hoist directly above where the load is to be placed- Remove any slack from the sling, chain, or cable slowly before lifting a load- Load to be checked when lifted slightly. Reposition the sling if required- Do not pull the hoist by its pendant cable- Raise the load sufficiently to clear any obstructions- Do not push or pull on the load- The load should hang vertically below the hoist at all times- Always keep the load as close to the ground as possible. Never raise the

load any higher than necessary- Avoid swinging the load- If the load swings, correct it by moving the load in the direction of the swing

when it is at the end of its arc – if it is safe to do so, i.e., no potential to hit people or equipment.

- Always keep the load in clear view. If this is not possible the lift shall be carried out with the aid of another suitably trained and competent worker, working under the operator’s instructions e.g. Dogman

- Never leave a load suspended and unattended. If you need to leave a load, lower the load and chock at ground level, master switch in the off position.

Shutdown:- Lower any raised load to ground level- Chock load if necessary- Disconnect the hook from the load- Remove all lifting gear from load (slings, shackles, etc.) - Raise crane hook up to almost maximum height- Locate the crane to a safe position- Ensure that pendant / remote control is in off position and place in a

designated area – shackle box is ideal

3H





Officer

NOTE: RB = Risk Rating before controls implemented - RA = Risk Rating after controls are implementedOperation – continued

As Above 4A - Turn power off at main isolation switch- Place all lifting gear in a designated area – this should be a rack that is off

the ground, out of the weather and direct sunlight- Lifting gear should be checked while placing on rack- Any defective equipment must be taken out of service immediately- Any defects shall be reported to the supervisor soon as possible.

3H

Maintenance Personal InjuryLegislation Breach

3H Conduct maintenance as per manufacturer’s instructions and as required by AS 2550.3 – 2011 Cranes, hoists and Winches – Bridge, gantry, portal (including container cranes), jib and monorail cranes.

Maintenance to be undertaken by trained and competent persons.

Third Party Inspections – to be carried out as required by AS 2550.3 – 2011

Major Inspections - Competent person to assess and determine level of inspection required. May include mechanical (10 years), structural (25 years)Periodic Inspection (not exceeding 12 months). Example:- Deformed, cracked, corroded members- Loose bolts, rivets- Cracked/worn sheaves/drums- Distorted parts- Wear of brake system- Wear of chain drive sprockets- Electrical testing- Safety devices/limit switches- Rated load testing.

Chains:- Withdraw any chain, terminal links, hooks, shackles, rings or other

equipment from service immediately if it has defects. Clearly mark the chain with a tag stating that it must not be used until it has been inspected by the manufacturer

- If the chain does not bear certifying tags or stamped markings it must be removed from service.

Store all lifting equipment off the ground and away from heat, chemicals exposure, corrosive environment and direct sunlight.

2M





Officer

NOTE: RB = Risk Rating before controls implemented - RA = Risk Rating after controls are implementedMaintenance – continued

Personal InjuryLegislation Breach

3H Ensure log book kept. Include:- Inspection records- Significant events - Checks, adjustments, replacement of parts, breakdowns, repairs and other

irregularities

Immediately withdraw from service Bridge or Gantry Cranes that have safety - related defects.

Bridge or Gantry Crane Repairs:If possible, the manufacturer’s recommendations must be sought prior to repairs to the overhead crane being done. If it is not practicable to contact the overhead crane manufacturer, a competent person or engineer must make a written assessment on the suitability of repair and/or replacement parts.

Repair must be carried out by a qualified person in accordance with directions from either the manufacturer or the competent person and under supervision of a competent person.

Repaired components must be appropriately tested prior to being returned to service.

Decommission any Bridge or Gantry Crane that cannot be repaired or is not going to be repaired.

2M

Emergency Procedures

Personal InjuryLegislative Breach

3H Develop and implement an emergency response plan for the site. Include:

- Assembly points- Communication- Consultation methods- Responsible persons- Emergency contacts - names and phone numbers- First aid equipment- Fire Extinguishers – accessible & serviced

Develop site-specific rescue procedures/SWMS.

Ensure all workers on-site are trained and familiar with emergency and evacuation procedures.

2M





Officer

NOTE: RB = Risk Rating before controls implemented - RA = Risk Rating after controls are implementedReview Legislative Breach 2M To ensure controls are implemented effectively:

- Toolbox /pre-work meetings will undertaken- Relevant persons will be consulted on hazards and contents of

SWMS, work plans and other applicable information- Controls will be monitored throughout works:

o Spot checkso Consultationo Scheduled audits

- Corrective actions will be recorded and rectified in a timely manner- SWMS will be reviewed and updated accordingly (in consultation with

relevant persons)

Ensure all controls are reviewed as per the following:- If controls failed to reduce risk adequately- Changes to workplace occur that create new / different risks where

controls may no longer be effective- New hazards identified- Consultation with relevant persons indicate review is needed- A Health and Safety Representative (HSR) requests a review in line

with the requirements of the WHS Regulations 2011.

1L

References:

Work Health and Safety Act 2011 Work Health and Safety Regulations 2011 Safe Work Australia (2011) – Code of Practice: Managing the Risk of Plant in the Workplace Safe Work Australia (2011) – Code of Practice: Managing Noise and Preventing Hearing Loss in the Workplace Safe Work Australia (2011) – Code of Practice: How to Manage Work Health and Safety Risks Safe Work Australia (2011) – Code of Practice: WHS Consultation, Cooperation & Coordination Safe Work Australia (2012) – DRAFT Code of Practice - Cranes AS 2550.3 – 2011 Cranes, hoists and Winches – Safe Use – General requirements AS 2550.3 – 2011 Cranes, hoists and Winches – Bridge, gantry, portal (including container cranes), jib and monorail cranes WorkSafe Victoria – Guide - Working Safely with Bridge/Gantry Cranes DECD NSW - Overhead travelling crane – Safe Operating Procedure

SAFE WORK METHOD STATEMENT – Part 2DOCUMENT NO: S8.2.13.0177 ACTIVITY: Overhead Crane REVIEW NO: DATE:Authorised By:Signature: © SafetyCulture All rights reservedDate: – Version 8.2

Formal Training, Licences required for workers undertaking this task:

Duties of workers undertaking this task:Training in the following safe work procedures/ SWMS / training modules

is required:(All workers to be trained in relevant procedures.)

Example: - Licence to Perform High Risk Work

(operating certain plant, equipment)- TAFE or other recognised training

organisation- Construction Induction Card

Example: (Name): Operator(Name: Clean-up crew (Name): Supervisoretc.

Site-specific inductionsTraining in this SWMSNature of hazards / risksEmergency proceduresConsultation

Details of Supervisory Arrangements for workers undertaking this task:

Details of regulatory permits/licences, Engineering Details/Certificates/WorkCover

Approvals:Relevant Legislation, Codes of Practice:

Example: - Suitably qualified supervisors for job- Direct on-site supervision - Remote site – communication

systems/ schedule - Audits- Spot Checks, etc.- Reporting systems

Example:- Local council permits- Building Approvals- EPA approvals/permits- Certain plant to be registered with State

Authority

PPE to comply with relevant Australian Standards

- Work Health and Safety Act 2011- Work Health and Safety Regulations 2011- Codes of Practice

Construction Work Managing the Risk of Plant in the Workplace Managing Noise and Preventing Hearing Loss in the Workplace How to Manage Work Health and Safety Risks WHS Consultation, Cooperation & Coordination

- Australian Standards: AS 2550.3 – 2011 Cranes, hoists and Winches – Safe Use – General

requirements AS 2550.3 – 2011 Cranes, hoists and Winches – Bridge, gantry, portal

(including container cranes), jib and monorail cranes AS 3775.2:2004 Chain Slings – Grade T – Care and Use (plus

amendment 1 – 2006) AS 1353.2:1997 Flat Synthetic - Webbing Slings – Care and Use AS1666.2:2009 Wire Rope Slings – Care and Use AS 2741:2002 Shackles (plus amendment 2- 2008) AS 4024:2006 Safety of Machinery

Plant/Tools/Equipment: (List plant and equipment to be used on the job.)

Maintenance Details for plant / equipment used on job (Include cranes, forklifts, electrical equipment etc.)

Example: Electric jackhammer As per manufacturer’s recommendations. Electrical tested/tagged every 3 months.

SAFE WORK METHOD STATEMENT – Part 3: Overhead Crane


This SWMS has been developed in consultation and cooperation with workers and relevant Persons Conducting Business or Undertaking (PCBU). I have read the above SWMS and I understand its contents. I confirm that I have the skills and training, including relevant certification to conduct the task as described. I agree to comply with safety requirements within this SWMS including safe work instructions and Personal Protective Equipment described.

Name Qualifications Signature Date Time Employer

Review No. 1 2 3 4 5 6 7 8 9

Name and initials

Date

RISK ASSESSMENT: Part 4

HB 436:2004 Risk Management Guidelines Tables 6.3 – 6.8 reproduced with permission from SAI Global under licence 1210-c062. Standards may be purchased at http://www.saiglobal.com


http://www.saiglobal.com/

References: Safe Work Australia (2011) - Code of Practice: How to Manage Work Health and Safety Risks, AS/NZS 31000 -2009 Risk Management Principles and guidelines.

Steps 1 Determine Likelihood – What is the possibility that the effect will occur?

Criteria Description

Almost certainExpected in most circumstances

Effect is a common result

LikelyWill probably occur in most circumstances

Effect is known to have occurred at this site or it has happened

Possible Might occur at some timeEffect could occur at this site or I’ve heard of it happening

Unlikely Could occur at some timeEffect is not likely to occur at the site or I have not heard of it happening

RareMay occur in exceptional circumstances

Effect is practically impossible

Step 3 Determine the risk score

LikelihoodConsequences

Insignificant Minor Moderate Major Catastrophic

Almost certain

3 High 3 High 4 Acute 4 Acute 4 Acute

Likely 2 Medium 3 High 3 High 4 Acute 4 Acute

Possible 1 Low2

Medium3 High 4 Acute 4 Acute

Unlikely 1 Low 1 Low2

Medium3 High 4 Acute

Rare 1 Low 1 Low2

Medium3 High 3 High

Step 2 Determine Consequence - What will be the expected effect?

Level of Effect Example of each level

Insignificant/AcceptableNo effect – or so minor that effect is acceptable

MinorFirst aid treatment only; spillage contained at site.

ModerateMedical treatment; spillage contained but with outside help.

Major Extensive injuries; loss of production

Catastrophic Death; toxic release of chemicals

Step 4 Record risk score on worksheet (Note – Risk scores have no absolute value and should only be used for comparison and to engender discussion.)

Score Action

4A: Acute

ACT NOW – Urgent - do something about the risks immediately. Requires immediate attention.

3H: High Highest management decision is required urgently

2M: Moderate Follow management instructions.

1L: Low

OK for now. Record and review regularly, and if any equipment/ people/ materials/ work processes or procedures change.


Overhead Cranes

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