Pedestal Mounted Crane Training Sample

7/24/2019 Pedestal Mounted Crane Training Sample

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PEDESTAL MOUNTED CRANE SAFETY TRAINING

RIGGING OPERATIONSANATOMY HAZARDSINTRODUCTION

INTRODUCTION ANATOMY STABILITY SAFE OPERATIONS HAZARDS

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ALL TRAINING MATERIALS CAN BE RE-USED & CUSTOMIZED

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Accountability

The material presented within this course is foreducational and training purposes only. All partiesinvolved in the development, distribution andmaintenance of this course shall be held harmless fromany incident resulting from misuse of the contentbeyond the guidelines and purposes herein stated.

Before you begin you should understand that it is yourresponsibility to adhere to the laws and regulationspresented within the following course and itscorresponding materials. Likewise, it is your furtherresponsibility to strictly follow any additional guidelinesspecific to your own workplace. Good Luck & Stay

Safe!

Note to Instructors: the first few slides in this presentation can be drawn upon as desired

and used to initiate dialog as to the importance of safety training and operator

responsibility. If you choose to skip these slides, the official presentation begins on slide 12.


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Why Safety Training?

Its required everywhere you go.


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Why Safety Training?


1. Training reduces the risk of accidents and

injuries to you and those you work with

2. Training reduces operating costs (How?)

3. OSHA requires itno matter who you are or

how long youve been operating.

Its as easy as 1, 2, 3!


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Welcome to the Hard Hat Training series. Today you will learn about pedestal cranes that aremounted on maritime docks and vessels. We will strive to provide information that will

increase your knowledge and help to make you a better operator.

INTRODUCTION


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Cranes are the workhorses that have increased the economic growth and productivity inconstruction, mining, logging, maritime, production and service facilities. It is not uncommon

while driving in urban areas to see mobile cranes, tower cranes and maritime cranes all in ashort period of time, performing a wide variety of jobs.


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Maritime cranes are essential in the on and off load of products, machinery and the manufacture

and repair of ships and boats.


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From large gantry cranes used to lift containers on and off ships to small swinging jibs used

for lifting much smaller loads, training is needed to ensure safe operation and productivity.


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During this training we will cover the anatomy of these cranes and stress the importance of

inspecting them each day before it is put into service.


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We will talk about lifts that are critical lifts and the additional planning that is required.


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We will discuss the more common hazards associated with cranes in the maritime industry.


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We will discuss some basic rigging principles and how to safely inspect and use lifting slings

and other common lifting hardware.


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We will discuss the safety considerations of making a lift and the importance of good

communication and proper hand signals.


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Upon completion of this training, you should be familiar with the types of cranes used by yourcompany, have an increased knowledge of how to inspect and safely operate them, and be ableto recognize the common hazards that surround their use.


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Strictly defined, a maritime crane is any type of crane that works around or is mounted on adock, vessel or in a shipyard and is used for on and off-loads of marine vessels or the repair andconstruction of ships.


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Pedestal mounted cranes are perhaps the most common found on board vessels and docks.


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Swinging jib cranes are the simplest dock crane that often consist of just a fixed boom, manual

swing and electric winch for the hoist line.


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Some larger ships and many derrick barges have lattice boom, friction cranes that have

capacities from 25 tons to over 250 tons.


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Portal cranes (sometimes called whirleys) and container cranes are perhaps the most visible,

sticking out against the horizon like huge mechanical dinosaurs.


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These are the main OSHA standards concerning cranes involved in maritime operations butcertainly not all of them. Many states have additional standards as do some industries such as

offshore oil platforms, etc.

Maritime Crane Regulations


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OSHA requires cranes to be inspected at the beginning of each day that it is in use. This is

sometimes referred to as a pre-shift or frequent inspection.


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The operator or a designated person is required to do this inspection but they do not have to

be lengthy. You are basically looking for obvious things that might be wrong with the crane.


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These are the main components of the pedestal crane that we will discuss.

ANATOMY


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Typically, the operator station is found near the pedestal or in an area overlooking the hatch or

the dock. Others are attached to the turret of the crane and rotate with the crane as it swings.

ANATOMY


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Before engaging the power switch, make sure that the controls are in the neutral position.Each lever should be marked correctly and not stick. If any control is stuck on when the power

switch is turned on then that control is live and could have severe consequences.

ANATOMY


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Other cranes have pendant controls that also allow the operator to run the crane from differentlocations but are limited to the length of the pendant. Inspect the pendant daily for frays,

broken connectors and that the controls are properly marked.

ANATOMY


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Turret section components

ANATOMY


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The crane is only as strong as the structure it is mounted on. Check the supports, gussets andwelds that attach it to the dock or vessel. If it is mounted on a wooden dock then the timbers

need to be checked from time to time and replaced if they show signs of dry rot or weakness.

ANATOMY


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Cracks in the paint around the bolt or loose washers are a sure indication that there has been

movement and that the bolt should be replaced.

ANATOMY


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Components of the Boom

ANATOMY



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The boom tip should be examined for bends and twists. Grooves in the sideplates or in theflanges of the sheaves are a sure sign of side loading. Severe grooves will require the sheaves

of the boom tip to be rebuilt or replaced.

ANATOMY



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Also, very common is an assortment of brands of rotation-resistant wire rope. The non-rotating characteristic is secured by building into the rope two layers of strands, one havingRight Lay and the other Left Lay. The tendency of one layer of strands to rotate in onedirection is counteracted by the tendency of the other layer of strands to rotate in the

opposite direction.

ANATOMY



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All wire rope, if left on the crane long enough will eventually fatigue and fail. Heavy loads will

accelerate the wear of wire rope.

ANATOMY



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Always check the spooling on the drum before each lift. Bad spooling is usually the result ofslack in the line when the block or hook is laid on the ground. Cranes with an insufficientheadache ball or weight on the hoist line will have more problems spooling correctly because

there is not enough tension on the line.

ANATOMY



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Two-blocking the hoist line may cause birdcaging for the same reason. As the hook is broughtinto the boom tip it can overstress the wire rope and when released abruptly it can become

birdcaged.

ANATOMY



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Hook Assembly Components

ANATOMY



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RIGGING OPERATIONSANATOMY HAZARDSINTRODUCTION ANATOMY HAZARDS

OSHA statistics have shown that there is certain inherit dangers associated with crane operationseven during normal working conditions. We will discuss five of the most common hazardsassociated with pedestal crane operation and show how to recognize these hazards and avoid or

minimize them. They are: two blocking, hit by fallen load, hoisting personnel, view obstruction,and poor rigging practices.

6 Common Hazards



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Some companies simply consider a critical lift as one that is near the maximum capacity ofthe crane. 75% of the capacity is a common figure used. However, there could be some othersituations that would make a lift more dangerous than others. If any of the following

conditions are present then the lift should be planned and precautions put in place.



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Two-blocking occurs when the hoist block or hook assembly comes into contact with the upperblock or boom tip, causing the hoist line to break and the hook and load to fall, endangeringworkers below. Consider the following accident:

Two-blocking the Crane



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The following accident profiles will show how quickly things can go wrong when lifts are notplanned properly. Add to that a few safety procedures that were ignored and fatalities orinjuries were the result. These profiles were taken from the OSHA website. The names ofthe company, equipment, and location have been omitted.



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What went wrong?



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What went wrong?



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A trial lift of an empty basket will be conducted by the crane operator to insure the personneltransfer system is rigged properly and fully functional to each location it is to be hoisted or

positioned.



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Safe use of a crane is compromised when the vision of an operator, rigger or signaler is blocked,and employees cannot see what the others are doing.

Operator's View Obstructed



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RIGGING OPERATIONSANATOMY HAZARDSINTRODUCTION ANATOMY HAZARDS RIGGING

What went wrong?



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The advantages of synthetic slings are their comparative low cost, light weight and the pliabilityof its fabric. The slings we will discuss in this section are web slings, round slings and fiber rope

slings.



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Fiber rope slings are made from natural and synthetic materials and are formed by 3 strandswrapped around each other or multiple strands woven together. Because there are so manytypes of materials that are used to make them it is essential that you know the type of materialand its capacity before use.



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Eyes in fiber ropes are formed by splicing it back on itself with at least four full tucks. Only a

competent person should perform this procedure.



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A program for the inspection of lifting slings is your best safeguard against sling damage and

abuse.

Synthetic Sling Inspection



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Check the stitching to see if the sling has been overloaded, putting stress on the stitchingcausing it to pull out. Another way to damage the stitching is to put the eye of the sling over

a hook or shackle that is too wide.



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Wire rope slings are very durable and can be used in a variety of situations. They also have

their limitations. Theyre not as pliable as synthetic slings and tend to become kinked if put

into a tight choker. Inspect each sling before use for the following:

Wire Rope and Chain Sling Inspection



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Capacity tags are required and must have the capacity, a description of the sling, size of chainand sling length, and manufacturer.



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All shackles used for lifting must have the safe working load or working load limit printed onthe shackle body as well as the manufacturer and country where it was made. Never use ashackle that is not load rated or is without these markings.



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This chart shows the reduction of the capacity of the shackle when it is pulled to the side.

Note that there is no reduction if there is a 120-degree included angle or more.



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Shouldered eyebolts can be used for side picks but only inline with the eye of the bolt and withmajor reductions in the capacity. For example if you were to attach a sling to an eyebolt at a45 degree angle, you will loose 70 percent of its capacity.



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Swivel hoist rings are a great substitute for eyebolts. Their load rating is the same at allangles. The bail will swivel and line itself up with the sling. Always make sure have the rightbolt size and length and that you know the load rating.



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Basic Rigging Practices

Before you make the lift there are certain things you must take into consideration. To lift a loadsafely you must know the weight of the load, where its center of gravity is and the stresses thatwill be imposed on the load and the rigging gear as you make the lift.



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Here is the weight of some common materials. Understand that if you are using approvedcalculations, it will be very difficult to get an exact weight. If by using these calculations youdetermine that the weight of the load is close to the maximum capacity of the crane then youshould probably take the time to weigh it just to make sure you are not going to overload the

crane.



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The definition of the center of gravity is: 'a point in an object around which all the weight ofthat object is evenly distributed. Determining the center of gravity in a load is key to saferigging and lifting.

Load's Center of Gravity



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Anyone that is an operator of lifting devices should have a thorough understanding of slingangles and the stresses that low angles can put on a sling and the compression it can have on

a load.

Sling Angles



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All that is needed to calculate these stresses is the weight of the object and a measuring tape.As shown in the slide above, the length of the sling is divided by the height of the slingconnection to the top of the load. The answer is then multiplied by that portion of the load thatit would support and this will be the stress in the sling.



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The ideal sling angle should be 60-degrees or more and by ANSI standards should never bebelow 30-degrees. An easy way to determine if you have at least a 60-degree sling angle is totake the sling that you would want to use and stretch it out between the two pick points onthe load. If the sling is equal to or longer than the distance between the two pick points, thenthe angle will be 60 degrees or more. If the sling is shorter then you should probably

calculate the stress the sling will see before preceding or choose longer slings.



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If more control is needed, wrap the sling around the load twice before threading it through theopposite eye. This hitch is called a double-wrap choker and will provide even more controlsince it provides more contact area to the load.



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It is usually unwise to use just one sling to lift a load, especially loose materials or long,unbalanced loads. Most vertical hitches are used in tandem with a lifting beam or in a bridle.



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A 3-leg bridle will have more capacity than a 4-leg bridle. This is because there is equal legloading on a 3-leg bridle. On a 4-leg bridle, two of the legs will be supporting most of the loadwhile the other two legs mostly provide balance. Hence, the capacity of a 4-leg bridle will be

equivalent to a two-leg bridle.



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SAFE OPERATION GUIDELINES

OPERATIONS

Before you operate a crane you must be trained and authorized, be familiar with the type of craneyou are going to use, and you should have read the operator's manual and understand the safe

operation portion of it.



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RIGGING OPERATIONSANATOMY HAZARDSINTRODUCTION ANATOMY

There should be a warning label attached to thependant controls. Follow all warning labels and signson the crane. If labels are missing or illegible,replace them.

Need Pendant Warning Tags?Pictured Right: 8.75x2.5 flexible, heavy duty

vinyl tags (English on front/Spanish on back).

Available through Safety Provisions, Inc.:

1 for $10 or in packs of 10 for $90.00 + shipping.



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RIGGING OPERATIONSANATOMY HAZARDSINTRODUCTION ANATOMY HAZARDS RIGGING OPERATIONS

Inspect the crane at the beginning of the shift. Never use a crane in need of repairs.



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The wire rope should be inspected daily, especially how it is spooled on the drum. Insure thatthe running crane is reeved with sufficient parts of line for the lift.



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On cranes that have load charts for different capacities you need to know the radius of the pickand placement of the load to prevent overloading.



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OSHA regulation states, the employer shall ensure that the operator does not leave his positionat the controls while the load is suspended. Always put the load down and secure it beforeleaving the area.



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Do not load the hook tip. Insure that the slings are not loose and the eyes are in the saddle ofthe hook.



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Before hoisting the load, check for unsecured or loose parts that might shift or fall. Start liftsslowly and avoid shock loading. Make sure the load comes up level.



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Tilting up panels or walls improperly can also be dangerous. Never attempt to yard or drag aload. And especially never attempt to yard or drag a load to the side. This will damage thepinion gear on the swing motor.



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Never hoist a load over the heads of employees. Never allow a rigger to stand under a load as itdescends for the purpose of controlling it. Use a tag line instead.



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If this cannot be accomplished, a signal system should be used. Standard signals will be shownin this training; however, it may be necessary to create special signals in certain circumstances.



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RIGGING OPERATIONSANATOMY HAZARDSINTRODUCTION ANATOMY OPERATION RIGGING

Need Hand Signal charts?Pictured 5x14 all-weather vinyl decals available

through Safety Provisions, Inc. 1 for $12 or in packs

for 5 for $45.00. (orange or green). Glossy wallet

cards also available (as is or with your logo).

A hand signal chart with the standard hand signals for the type of crane you are operatingis required to be posted on the crane or in the work area. Below is a typical hand signalchart used for cranes.



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RIGGING OPERATIONSANATOMY HAZARDSINTRODUCTION ANATOMY STABILITY HAZARDS RIGGING/OPER

The following hand signals have corresponding video clips, which can be used to furtherclarify any confusion pertaining to how a sign should be given. To access these clips refer tothe Hand Signal folder located in the Poster, Other folder. Follow the Content Map to

locate them if needed.



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Swing Boom. This signal is given by pointing the hand in the desired direction of travel. Tryto keep your thumb down so as not to confuse it with the boom up signal. An alternate versionof this sign consists of bringing your arm in front of you, across your torso, again pointing in

the desired direction of travel.



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Boom Up/Boom Down. The signal for raising or lowering the boom is given byholding your arm out to one side with you thumb up or down with the other fingers

folded in.


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Telescope In/Out. The signal to telescope is given by raising your arms in front of youwith your thumbs pointing in toward each other for telescoping in or out and away fromeach other for telescoping out.



ANATOMY HAZARDS RIGGING OPERATIONS


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Cranes, like all equipment, can inflict serious injury or death when misused or abused. Impropertraining, poor operation, failure to perform preventive maintenance, and failure to inspect can

have serious consequences.



ANATOMY HAZARDS RIGGING OPERATIONS


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Safety is the responsibility of everyone involved in crane operations, from operators tomaintenance personnel. You can help ensure safe operation of cranes by knowing and

Pedestal Mounted Crane Training Sample

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