CRANES, SLINGS,
& YOU
They can do a lot of work
CRANES, SLINGS,
& YOU
They can do a lot of damage
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!
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.
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.
Preventive
Maintenance
1.
2.
3.
4.
5.
6.
7.
8.
9.
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
General Pre-Op Test
1. Disconnects are known before any test
2. Get help if you’re not familiar with the cranes
3. Follow manufacturers recommendations
4. Follow Checklist
5. Inspect electrical controls
6. Check for obstructions in crane’s travel path
7. Test proper operation of controls
8. Observe for smooth operation of components
9. Never unwind spool completely
10.Check upper & lower limit switches
Hook Pre-op Test
1.
2.
3.
4.
5.
6.
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
7. After any hook repairs, hook must be load
tested before being returned to normal
service
Rope Pre-op Test
1. Reduction in rope diameter
2. Broken or worn outside wires
3. Corroded or broken wires at end of
connections
4. Severe kinking, crushing, cutting or
unstranding
5. Corroded, cracked, bent, worn, or
improperly applied end connections
Lockout-Tagout
1. Review individual crane requirements
2. Integrate lockout & maintenance
requirements
3. Lockout-tagout training
4. Written program established & reviewed
5. Ask manufacturer for lockout device
recommendations
6. Devices not always interchangeable
between different cranes
DANGER
LOCKED
OUT
DON’T OPERATE
This Lock/Tag may
only be removed by
NAME: __________
DEPT : __________
COMPLETION
DATE: ___________
TIME: ____________
Crane Safety Basics
Never allow a co-worker
between a fixed object
and a load!
DANGER
WORKING
CRANES
2
TON
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.
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.
Safe Working Radius
Know the safe travel
radius of the crane.
Contact with
electrical sources or
other hazards can
result in catastrophic
consequences.
Load Chart
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!
Operator
Requirements
1.
2.
3.
4.
5.
6.
7.
8.
9.
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
Safe Practices
1. Test controls & brakes at start of shift
2. Don’t operate unsafe cranes or hoists
3. Test brakes by a short lift to ensure
control
4. Move loads only after being signaled by
designated, qualified signaler
Safe Practices
1. Never carry loads over anyone
2. Never carry loads past anyone
3. Signalers in line-of-sight of operator
4. No riders on loads or hooks
5. No unauthorized person operating crane
6. Lockout before maintenance or repairs
7. Frequently inspect cranes
Safe Practices
1. Hook directly over load before lifting
2. Document & maintain inspection records
3. Check warning devices & signals
4. Signalers must watch load
5. Operators must watch signalers
6. Know travel path in advance of lift
7. Know where to set down load
8. Will new location support weight
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.
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.
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.
Signaler Safe
Practices
1. Only one person is designated signaler
2. Maintain line-of-sight with operator
3. Operator acknowledges every signal
4. Stop operation if comprehension is lost
5. Operators must watch signalers
6. Plan in advance where load is going
7. Will new location will support the weight
Leaving or Parking
1. Raise hooks to limit switches
2. Place controls in “off” position
3. Place main power switch in “off” position
4. Visual check for dangerous conditions
5. Report defects immediately
6. Tagout defective equipment immediately
7. Report cranes not in operation
8. Follow manufacturer’s recommendations.
Lifting Factors
1. Size, weight, & center of gravity of load
2. Number of sling legs
3. Angle sling makes with horizontal line
4. Rated capacity of sling
5. History of care & usage of sling
Size, Weight, &
Center of Gravity
1. Crane hook must be directly above
center of gravity
2. If crane hook is too far to one side of
center of gravity, dangerous tilting and
unequal stress to sling leg will result
Capacity of Sling
1. Rated capacity varies depending upon
type of sling, size of sling, & type of hitch
2. Consult with manufacturer
3. Older slings must be used with additional
caution
4. Sling charts based on new sling usage.
Care & Usage
1. Mishandling & misuse of slings are
leading cause of sling-related accidents
2. Proper care essential for maximum
service & safety
3. Always protect slings with cover saddles,
burlap padding or wood blocking to
prevent sharp bends & cutting edges.
Estimating Load
Weight
1. Use a Dynamometer
2. Check shipping papers
3. Check nomenclature plates
4. Use industry standard tables or charts
5. Consult equipment manufacturer
6. Estimate using weights of similar loads
7. Never lift based on a guess
8. Stay within 50% of cranes rated capacity
when estimating loads
Rigging & Slings
1. Chains
2. Wire Rope
3. Fiber Rope
4. Synthetic Web
5. Cargo Nets.
Each type has
advantages and
disadvantages!
Rigging & Slings
Consult with manufacturer concerning
load capacities, usage methods,
restrictions and other pertinent data for
specific types of slings
Rules for Slings
1. Never load in excess of rated capacity
2. Never use a damaged sling
3. Never pull sling from a suspended load
4. Never shorten with knots
5. Suspended loads clear of everyone
6. Suspended loads clear of obstructions
7. Hands & fingers clear of loads
8. Protect slings from sharp edges of load
9. Think before you affect a load.
Wire Rope
Inspection
Remove from service if:
1. 10 distributed broken wires
2. Five broken wires on one strand
3. Kinking, crushing, or bird caging
4. Evidence of heat damage
5. End attachments cracked,
deformed, or worn
6. Hooks opened > 15% of the normal
throat opening or twisted > 10%
Chain Inspection
Remove from service if:
1. Defective or questionable welds
2. Bending or elongation of chain links
3. Cracked or deformed links
4. Missing or removed identification tags
5. End attachments cracked, deformed, worn
6. Other suspected unsafe conditions
Web Sling
Inspection
Remove from service if:
1. Acid or caustic burns
2. Age deterioration (drying/cracking)
3. Melting or charring of sling surface
4. Snags, tears or cuts exposure of colored
thread
5. Missing or removed identification tags
6. Other suspected unsafe conditions
After The Lift
1. Clean sling
2. Check for damage
3. Follow proper storage rules
4. Leave in good condition for next lift
5. Report damaged or defective slings
6. Follow proper disposal or replacement
procedures
Slings Storage
1. Dry environment, out of sunlight
2. Off floor or ground
3. Hung from hooks to prevent tangling
and easy access
4. Away from electrical sources
5. By type - don’t mix steel chain slings
with synthetics
6. In a controlled area
Sling Angles
Consult with the sling manufacturer
concerning how sling angles affect load
capacities for different types of slings.
1000lb
1000lb
1000lb
Sling Angles
1. Angle of sling affects sling load capacity
2. Greater sling angle, greater stress
3. Multiple sling affects load capacity
4. Type of sling used is a factor
5. Consult with manufacturer for proper
usage.
1000lb
1000lb
1000lb
Two Slings
The use of two
500lbs
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
Sling Angles
Sling Angle
With Vertical
0
5
10
15
20
25
30
35
40
45
50
55
60
80
Stresses Per Sling Leg
1000 lbs Total Load
500
502
508
518
532
552
577
610
653
707
778
872
1000
2880
577lbs
577lbs
30
1000lb
30 Angle
Sling Angles
707lbs
707lbs
1000lbs
1000lb
45 Angle
1000lbs
1000lb
60 Angle
Sling Angles
The carrying capacity decreases as the spread between the
slings increases. To determine the capacity of each sling in
a bridle hitch:
A
B
Measure the distance on one sling for the same number
of units as the capacity of the sling in tons (Distance A).
2. Measure the vertical distance from the point located in to
the load in tons. (Distance B).
3. The number of units in this vertical distance (B) is the
working load for the sling.
1.
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
Protecting Slings
Protect slings
against sharp
edges
HAND SIGNALS
Hoist load:
1. Forearm vertical
2. Forefinger pointing up
3. Move hand in small
horizontal circular
motion
HAND SIGNALS
Lower load:
1. Arm downward
2. Forefinger pointing
down
3. Move hand in small
horizontal circular
motion
HAND SIGNALS
Boom Travel:
1. Arm extended forward
2. Hand open and slightly
raised
3. Make pushing motion
in the direction of travel
HAND SIGNALS
Stop:
1. Arm extended
2. Palm down
3. Move arm sideways,
rapidly back & forth
HAND SIGNALS
Emergency stop:
1. Both arms
extended
2. Palms down
3. Move both arms
sideways rapidly
back & forth
Protective
Equipment
1. Appropriate for the particular hazards
2. Maintained in good condition
3. Properly stored when not in use
4. Kept clean, fully functional, and sanitary