Seminar

on

Safe Working with EOT and Mobile Crane

22nd March 2013
Venue: JRDTTI Noamundi

Organised by:
Directorate General of Mines Safety
Chaibasa Region

Hosted by:
Noamundi Iron Mine
M/s Tata Steel Ltd.

CONTENTS

Messages
Papers
Brief Report on fatal incident due to Mobile Crane
at Sarda Mines
Paper on safe working with crane by Mr. P K Singh,
DDMS (Mechanical), SEZ Ranchi
Paper on safety features, provision in mobile Crane
by TIL
Paper on safe working with mobile crane by SAIL
Paper on Code of Practice for inspection &
maintenance of mobile and EOT crane by Tata Steel
Paper on safe working with mobile crane by Rungta
Gr. Of Mines

Seminar on Safe Working with EOT & Mobile Crane

Seminar on Safe Working with EOT & Mobile Crane

D B Sundara Ramam
General Manager (Ore, Mines and Quarries)

MESSAGE
In our highly mechanized world, cranes are the workhorses that have
increased productivity and economic growth in mining, construction
and maintenance of production and service facilities.
Statistics show, however, that there are inherent hazards that occur
during normal working circumstances. A crane can be a very
dangerous piece of equipment.
I am happy to learn that under the aegis of DMS, Chaibasa Region, a
seminar on Safe Working with EOT and Mobile Crane is going to be
organised for operating and maintaining the cranes in a much safer
way. I hope this seminar will serve as a guide for safety in all types of
cranes.
I wish this endeavour a great success.

D B Sundara Ramam

Seminar on Safe Working with EOT & Mobile Crane

SAFETY IN MOBILE CRANES

By- P.K.Singh, D.D.M.S.(Mech) South Eastern Zone
------------------------------------------------------------------------------------------------------------------------------------GENERAL
This chapter applies to commercial truck mounted cranes; crawler cranes; locomotive
cranes; wheel-mounted cranes, multiple control stations; wheel-mounted cranes, single control
station; and any variation that retains the same fundamental characteristics. These cranes have a
superstructure capable of rotating 360 degrees mounted on a carrier and have boom raising and
lowering capabilities.
OPERATOR
TRAINING/QUALIFICATION
Operators of mobile cranes shall be trained and qualified .
LOAD LIMITS
a. Since the load rating for mobile cranes may be based on stability and hydraulic or structural
competence, load ratings established by the manufacturers shall not be exceeded in operational
application.
b. No crane shall be loaded beyond its rated capacity, except for load test purposes..
c. When loads are to be handled that are limited by hydraulic or structural competence rather than
by stability, the appointed person shall ensure that the weight of a load approaching rated capacity
has been determined within -10 percent, +0 percent before it is lifted
LOAD RATING CHART
a. Durable rating chart(s) with legible letters and figures shall be provided with each crane and
attached in a location accessible to the operator while at the controls. The data and information to
be provided on these charts shall include, but not be limited to, the following:
1. A full and complete range of manufacturers crane load ratings at all stated operating radii, boom
angles, work areas, and all stated boom lengths and configurations, jib lengths and angles (or offset),
as well as alternate ratings for use and non use of optional equipment on the crane, such as
outriggers and extra counterweights, that affect ratings.
2. A work area chart for which capacities are listed in the load rating chart .
3. Where ratings are limited by structural, hydraulic, or factors other than stability, the limitations
shall be shown and emphasized on the rating charts.
4. In areas where no load is to be handled, the work area figure and load rating chart shall state that
information.
b. In addition to the data required on the load rating chart, the following information shall be shown
either on the rating chart or in the operating manual:
1. Recommended parts of the hoist reeving, and size and type of rope for various crane loads.
2. Recommended boom hoist reeving diagram, where applicable; size, type, and length of rope.
3. Tire pressure, where applicable.
4. Cautionary or warning notes relative to limitations on equipment and operating procedures,
including indication of the least stable direction.
5. Position of the gantry and requirements for intermediate boom suspension, where applicable.
6. Instructions for boom erection and conditions under which the boom, or boom and jib
combinations, may be raised or lowered.
7. Whether the hoist-holding mechanism is automatically controlled or manually controlled, whether
free-fall is available, and whether any combination of those exists.
8. The maximum telescopic travel length of each boom telescopic section.
9. Whether sections are telescoped with power or manually.
10. The sequence and procedure for extending and retracting the telescopic boom section.

Seminar on Safe Working with EOT & Mobile Crane

11. Maximum loads permitted during the actual boom-extending operation and any limiting
conditions or cautions.
12. Hydraulic relief valve settings specified by the manufacturer.
LOAD HOIST BRAKES
When power-operated brakes that have no continuous mechanical linkage between the actuating
and braking means are used, an automatic means shall be provided to set the brake to prevent the
load from falling in event of loss of brake-actuating power.
POWER-CONTROLLED LOWERING
A power-controlled lowering system shall be provided and shall be capable of handling rated loads
and speeds as specified by the manufacturer of the crane.
BOOMS
a. Booms, boom sections, and jibs shall be clearly identified and shall be used only for the purpose
recommended by the manufacturer.
b. Lattice booms shall meet the performance requirements As per ISI specification.
COUNTERWEIGHT
a. Cranes shall not be operated without the ballast or counterweight being in place as specified by
the crane manufacturer. Under specific conditions, such as during crane assembly, unusual boom
configurations, etc., the crane manufacturers recommendations for the amount of ballast or
counterweight shall be adhered to.
b. Ballast or counterweight as specified by the manufacturer shall not be exceeded.
RERATING
a. Cranes may be modified or rerated providing such modifications are analyzed thoroughly by a
qualified engineer or manufacturer of cranes. Such action must be approved by the safety
organization.
b. When rerated, crawler, truck, and wheel mounted cranes shall be tested .
c. A rerating test report shall be readily available.
d. No cranes shall be rerated in excess of the manufacturers original load ratings.
MAINTENANCE HISTORY
The maintenance history of the crane shall be retained throughout it service life.
INSPECTIONS
GENERAL
Equipment shall operate with a smooth, regular motion without any hesitation, abnormal vibration,
or irregularity. There shall be no apparent damage, excessive wear, or deformation of any loadbearing part of the equipment. All safety devices, load indicators, boom angle and radius
indicators,controls, and other operating parts of the equipment shall be checked during each
inspection and shall be in good working order.
INITIAL INSPECTION
Prior to initial use, all new or modified cranes shall be inspected.Periodic Inspection, by a qualified
person to ensure compliance with the applicable provisions . Dated and signed inspection reports
shall be kept on file and shall be readily available.
DAILY PREOPERATIONAL CHECK
a. Operators or other designated personnel shall visually inspect items such as the following each
day or prior to use if the crane has not been in regular service (records are not required):
1. All control mechanisms for maladjustment interfering with proper operation.

Seminar on Safe Working with EOT & Mobile Crane

2. Crane hooks and latches for deformation, cracks, and wear.

3. Hydraulic systems for proper oil level.
4. Lines, tanks, valves, pumps, and other parts of air or hydraulic systems for leakage.
5. Hoist ropes for kinking, crushing, and corrosion.
6. Booms for damage or deformation of structural components.
b. Operators or other designated personnel shall examine deficiencies and determine whether they
constitute a safety hazard.
MONTHLY INSPECTION
a. The operator or other designated person shall visually inspect the following items for damage,
wear, or other deficiency that might reduce capacity or adversely affect the safety of the crane:
1. Critical items such as brakes and crane hooks.
2. Hoist ropes.
b. Lower the hook block to its lowest position and examine for any condition that could result in an
appreciable loss of strength.
c. Hooks for cracks, deformation, damage from chemicals, latch engagement (if provided), and
evidence of heat damage.
d. A hoist rope with any of the conditions noted in the replacement criteria shall be removed from
service and replaced.
e. Signed and dated inspection records shall be kept on file and shall be readily available.
f. Before the crane is returned to service, correct deficiencies that could reduce its capacity or
adversely affect its safety.
FREQUENT INSPECTION
a. Operators or other designated personnel shall visually inspect the crane at daily to monthly
intervals (records are not required).
b. Preoperational Check, include the following:
1. All control mechanisms for maladjustment, excessive wear, and contamination by lubricants or
other foreign matter that could interfere with proper operation.
2. All safety devices for malfunction.
3. Electrical apparatus for malfunctioning, signs of excessive deterioration, and accumulation of dirt
or moisture.
4. Tires for recommended inflation pressure.
5. Boom sections for damaged, deformed,or missing structural members or parts.
c. Operators or other designated personnel shall examine deficiencies and determine whether a
more detailed inspection is required.
PERIODIC INSPECTION
a. Complete inspections of the crane shall be performed by a qualified person at 1- to 12-month
intervals, depending on the cranes activity, severity of service, and environment.
b. The qualified inspector shall examine deficiencies and determine whether they constitute a
hazard.
c. Dated and signed inspection records shall be kept on file and shall be readily available.
Cranes
Inspect for:
a. Deformed, cracked, or corroded members in the crane structure and entire boom.
b. Bolts, rivets, nuts, and pins for being loose or absent.
c. Check for suspect/counterfeit parts (see Terminology and Definitions, Chapter 1).

Seminar on Safe Working with EOT & Mobile Crane

d. Cracked or worn sheaves and drums.

e. Hooks damaged from chemicals, deformation, or cracks, any visibly apparent bend or twist from
the plane of the unbent hook, or any distortion causing an increase in throat opening of 5% not to
exceed 14 in. unless otherwise recommended by the manufacturer. Dye-penetrate, magnetic
particle, or other suitable crack-detecting inspections should be performed at least once a year.
f. Worn, cracked, or distorted parts such as pins, bearings, shafts, gears, rollers, and locking devices.
g. Excessive wear on brake and clutch system parts, linings, pawls, and ratchets.
h. Load, boom angle, and other operating aids over their full ranges for any significant inaccuracies
(if calibration is required, it shall be done by a qualified person).
l. Steering, braking, and locking devices, for malfunctioning.
m. Excessively worn or damaged tires.
n. Rust on piston rods and control valves when crane has been idle.
Hydraulic and Pneumatic Hose, Fittings, and Tubing
Inspect for:
a. Evidence of leakage at the surface of the flexible hose or its junction with the metal couplings.
b. Blistering or abnormal deformation of the outer covering of the hydraulic or pneumatic hose.
c. Leakage at threaded or clamped joints that cannot be eliminated by normal tightening or
recommended procedures.
d. Evidence of excessive abrasion or scrubbing on the outer surface of a hose, rigid tube, or fitting
(means shall be taken to eliminate the interface of elements in contact or to otherwise protect the
components).
Hydraulic and Pneumatic Pumps and Motors
Inspect for:
a. Loose bolts or fasteners.
b. Leaks at joints between sections.
c. Shaft seal leaks.
d. Unusual noises or vibration.
e. Loss of operating speed.
f. Excessive heating of the fluid.
g. Loss of pressure.
Wire Rope
a. A qualified inspector shall inspect wire ropes at least annually. More frequent intervals shall be
determined by a qualified person and shall be based on such factors as expected rope life as
determined by severity of environment, percentage of capacity lifts, frequency rates of operation,
and exposure to shock loads. The qualified inspector shall carefully note any deterioration, such as
described below, that results in appreciable loss of original strength and determine whether further
use of the rope constitutes an acceptable risk. This inspection shall include examination of the entire
rope length without detaching it from the drum.
Maximum allowable rope reductions. Rope diameter Maximum allowable reduction from
nominal diameter
1. Reduction of rope size below nominal diameter, whether due to loss of core
support, internal or external corrosion, or wear of outside wires .
2. The number and distribution or concentration of broken outside wires.
3. Worn outside wires.
4. Corroded or broken wires at end connections.
5. Corroded, cracked, bent, worn, or improperly applied end connections.
6. Kinking, crushing, cutting, or un stranding.
b. The qualified inspector shall take care when inspecting running rope where rapid deterioration
could occur, such as in the following:
1. Sections in contact with saddles, equalizer sheaves, or other sheaves where rope travel is limited.
2. Sections of the rope at or near terminal ends where corroded or broken wires may protrude.

Seminar on Safe Working with EOT & Mobile Crane

c. The qualified inspector shall take care when inspecting certain ropes such as the following:
1. Rotation-resistant ropes, because of their higher susceptibility to damage. The internal
deterioration of rotation resistant ropes may not be readily observable.
2. Boom hoist ropes, because of the difficulties of inspection and the important nature of these
ropes.
d. No precise rules can be given for determining the exact time to replace wire rope because many
factors are involved. Safety in this respect depends largely on the use of good judgment by an
appointed
person in evaluating remaining strength in a used rope, after allowance for deterioration disclosed
by inspection. Safety of rope operation depends on this remaining strength.
e. Removal criteria for wire rope replacement shall be as follows: 1. In running ropes, 6 randomly
distributed broken wires in one rope lay, or 3 broken wires in one strand in one rope lay.
2. In standing ropes, more than two broken wires in one lay in sections beyond end connections or
more than one broken wire at an end connection.
3. In rotation resistant ropes, two randomly distributed broken wires in six rope diameters or four
randomly
distributed broken wires in thirty rope diameters.
4. One outer wire broken at the point of contact with the core of the rope that has worked its way
out of the rope structure and protrudes or loops out from the rope structure; additional inspection
of this part of the rope is required.
5. Wear of one-third the original diameter of outside individual wires.
6. Kinking, crushing, bird caging, or any other damage resulting in distortion of the rope structure.
7. Evidence of heat damage from any cause.
8. Reduction from nominal diameter greater than the amounts listed in Table 9-2.
f. All rope that has been idle for a month or more due to shutdown or storage of a crane on which it
is installed shall be inspected before it is placed in service. This inspection shall be for all types of
deterioration and shall be performed by an appointed person whose approval shall be required
before further use of the rope. A written and dated report of the rope condition shall be filed.
g. In order to establish data as a basis for judging the proper time for replacement, a continuing
inspection record shall be maintained.
h. Replacement rope shall be the same size, grade, and construction as recommended by the crane
manufacturer, unless otherwise recommended by a rope or crane manufacturer due to actual
working condition requirements.
i. Never use discarded wire rope for slings.
LOAD HOOKS/LOAD BLOCKS
Load hooks/load blocks that have been changed out shall be inspected by a qualified inspector
before returning the crane to service. Inspection records shall be retained throughout the service life
of the hook or load block and shall be readily available.
MAINTENANCE
PREVENTIVE MAINTENANCE
a. A preventive maintenance program shall be established and based on the recommendation of the
crane manufacturer. If equipment maintenance procedures deviate from published manufacturer's
recommendations, the alternate procedures shall be approved in advance by the manufacturer or
another qualified person and be kept readily available. Dated maintenance records should be kept
where readily available to appointed personnel.
b. Replacement parts shall be at least equal to the original manufacturers specifications.
c. All moving parts of the crane for which lubrication is specified shall be regularly lubricated.
Lubricating systems should be checked for proper delivery of lubricant. Operators and maintenance
personnel shall follow the manufacturers recommendations as to the points and frequency of
lubrication, maintenance of lubricant levels, and types of lubricant to be used.

Seminar on Safe Working with EOT & Mobile Crane

9.4.2 MAINTENANCE PROCEDURES

a. Before starting adjustments or repairs on a crane, maintenance personnel shall take the following
precautions as applicable:
1. Place the crane where it will cause the least interference with other equipment or operations in
the area.
2. Lower the lower load block to the ground or otherwise secure it against dropping.
3. Lower the boom to the ground, if possible, or otherwise secure it against dropping.
4. Place all controls in the OFF position and secure all operating features from inadvertent motion
by brakes, pawls, or other means.
5. Ensure starting means are rendered inoperative.
6. Stop the power plant or disconnect it at the power takeoff.
7. Relieve hydraulic oil pressure from all hydraulic circuits before loosening or removing hydraulic
components.
b. Warning or out-of-order signs shall be placed on the crane controls. Signs or flags shall be
removed only by authorized personnel.
c. After adjustments and repairs have been made, the crane shall not be returned to service until all
guards have been reinstalled, trapped air has been removed from the hydraulic system, safety
devices are reactivated, and maintenance equipment is removed.
d. For locomotive cranes:
1. Employ blue flag protection on each side of the crane (except dead ends).
2. Place derails not less than 50 ft from the crane on each side (except dead ends).
3. Allow only authorized personnel to remove warning signs, flags, and derails.
WIRE-ROPE MAINTENANCE
Personnel using wire rope shall ensure proper care by doing the following:
a. Store rope to prevent damage or deterioration.
b. Unreel or uncoil rope as recommended by the rope manufacturer and with care to avoid kinking
or inducing a twist.
c. Before cutting a rope, use some method to prevent unlaying the strands. Heat-affected zones of
flame cut wire rope shall not be allowed to bear load.
d. During installation, avoid dragging the rope
in the dirt or around objects which will
scrape, nick, crush, or induce sharp bends in
it.
MAINTENANCE
e. Maintain rope in a well-lubricated condition to reduce internal friction and to prevent corrosion.
Ensure that lubricant applied as part of a maintenance program is compatible with the original
lubricant. Consult the rope manufacturer when in doubt. Lubricant applied shall be of the type that
does not hinder visual inspection. Those sections or rope that operate over sheaves or are otherwise
hidden during inspection and maintenance procedures require special attention when the rope is
lubricated.
f. When an operating rope shows greater wear at its ends than on the remainder, its life can be
extended (in cases where a reduced rope length is adequate) by cutting off the worn end, thus
shifting the wear to different areas of the rope.
OPERATIONS
a. The following shall apply to all personnel involved in mobile crane operation.
b. At the initial stage of the planning process, an appointed person shall classify each lift into one of
the DOE-specified lift categories (ordinary, critical, or preengineered production).
CONDUCT OF OPERATOR
a. Cranes shall only be operated by personnel qualified per Chapter 6 of this Standard for the type of
crane being operated..

Seminar on Safe Working with EOT & Mobile Crane

b. Do not engage in any practice that will divert your attention while operating the crane.
c. Keep the operating area free of water, snow, ice, oil, and debris that could cause your hands or
feet to slip from the controls.
d. Keep the operating cab windshields clean and free of anything that obstructs vision. Replace
broken windows.
e. Ensure proper functioning of tires, horn, lights, battery, controller, lift system (including loadengaging means, chains, hoist rope, and limit switches), brakes, and steering mechanisms. If at any
time a lifting device is found to be in need of repair, is defective, or is in any way unsafe, report it
immediately to the designated authority and take the unit out of service until it has been restored to
safe-operating condition or a determination has been made by the responsible manager that the
deficiency will not adversely affect the safe operation of the unit.
f. When two or more cranes are used to lift one load, one designated person shall be responsible for
the operation. That person shall analyze the operation and instruct all personnel involved in the
proper positioning, rigging of the load, and the movements to be made. That person shall also
determine the necessity to reduce crane ratings, position of load, boom location, ground support,
and speed of movement.
g. Determine that no one is working on the crane or is close to it before starting the engine or
beginning to operate the crane.
h. Barricade accessible areas within the swing radius of the rear of the rotating superstructure of the
crane to prevent anyone from being struck or crushed by the crane.
i. Do not hoist two or more separately rigged loads in one lift, even though the combined load is
within the cranes rated capacity.
j. When fueling the crane, stop the engine(s) and ensure that smoking or open flames are not
permitted within 25 ft of the fueling area.
k. Fire extinguishers shall be maintained in a serviceable condition.
l. Do not store gasolinee, acids, caustics, or cleaning solvents that emit toxic fumes in operating cabs.
Store fuel in safety cans in safe locations.
m. Ensure that alternate egress routes are not locked on mobile units with operating enclosures.
n. Position the crane on a solid and level footing. It may be necessary in certain situations to use
heavy timber mats to build a good working foundation.
o. When swinging the crane, watch out for centrifugal force. Swing the crane slowly to avoid an
outward swing of the load. Attach a tag-line to the load if necessary to control the swing.
p. Watch for boom kickback. Never operate with the boom at a higher angle than shown on the
capacity charts.
q. Use extreme caution when operating the crane near workers in elevated areas.
r. Use power lowering when lowering loads. When lowering heavy loads, keep the hoist brake as
reserve. Use a safety pawl on the boom-hoist drum when not lowering.
s. Avoid two-blocking, caused when the hook block makes contact with boom-point sheaves. A
continuing pull on the hoist lines can break the rope or pull the boom back over the cab on some
types of booms. On hydraulically telescoping booms, be sure to play out the hoist line when
extending and spool in the hoist line when retracting.
t. Lock carrier air brakes ON when operating, and check the pressure of the air brakes frequently.
u. Watch out for the carrier-cab on truckmounted units when swinging the boom. Keep boom high
enough to swing clear of cab.
v. In the absence of crane manufacturers instructions regarding maximum wind speeds for
operation, operations undertaken at wind speeds in excess of 25 mph should be evaluated by a
qualified person to determine if the size, shape and weight of the load can be safely lifted.
w. When a crane is to be operated at a fixed radius, the boom-hoist pawl or other positive locking
device shall be engaged.
x. On truck-mounted cranes, no loads shall be lifted over the front area, except as approved by the
crane manufacturer.

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10

y. Crane cabs, necessary clothing and personal belongings shall not interfere with access or
operations.
z. Tools, oil cans, waste, extra fuses, and other necessary articles shall be stored in the tool box, and
shall not be permitted to lie loose in or about the cab.
Traveling the Machine
When traveling the machine:
a. Secure the boom and book block.
b. Check bridges before crossing; make sure they will support the weight of the machine.
c. Check river depths before fording.
d. Check clearances under overpasses, overhead lines, or any overhead obstruction; when side
clearances are tight, install a barrier or post a lookout, and make certain there is sufficient clearance
for tail swing.
e. When traveling with a load, snub the load to prevent swaying if possible; never travel with nearcapacity loads.
f. Never travel a rubber-tired unit with a load over the side.
g. On soft surfaces, always move with the load behind; it helps to raise the leading end of the
crawlers, and makes traveling safer.
h. Always set swing brakes when the unit is idle or holding loads for a period of time, especially on
slopes; if swinging during travel is necessary, engage swing-jaw clutch before releasing brakes.
i. Never back up until it is determined that everyone is clear of the machine.
j. Position the boom in the direction of travel for long moves.
k. Block treads when moving uphill; be sure they are blocked to prevent downhill movement before
shifting steering clutches.
l. Lock the turntable before traveling on a highway. Use a house lock or swing brake, and lower
boom into the rack to prevent swing.
m. When loading machine on the trailer, always use a ramp; if a ramp is not available use blocking to
build one.
Making Adjustments or Repairs
a. When making adjustments or repairs:
1. Stop the machine.
2. Lower the boom or secure it against dropping.
3. Neutralize all controls.
4. Lock starter and remove ignition key to make the machine inoperative.
5. Display proper warning signs on controls of machine.
6. Keep hands, feet, and clothing away from gears, ropes, drums, and sheaves.
7. Never put hands on wire rope when climbing to the top of the cab.
8. Use a bar or stick to guide wire rope onto drums.
9. Keep hands well away from the fan drive while engine is running.
10. Safeguard the crane oiler; do not resume operation until a positive ALL CLEAR signal has been
given.
11. Replace all guards and shields before resuming operation.
b. Place blocking or other adequate supports under the boom before beginning boom disassembly
operations. Never stand under or on the boom during this work.
c. Before disconnecting oil lines, if machine has hydraulic controls, be sure to place boom on the
ground or in the boom rest; then move the pedals and control levers to equalize pressures within
the cylinders. Always release any air supercharge on the hydraulic reservoir and shut off the engine
(or declutch pumps) before disconnecting oil lines.
d. Do not reach into hydraulic-boom holes unless the sections are securely anchored together.
Ensuring Stability

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a. Know the rated capacity of the crane and the weight of the load. A safe lift depends on many
factors including boom length, boom angle, and load radius. Follow these requirements to avoid
buckling the boom or tipping:
1. Know the radius of the load; the radius is measured from center of rotation, not from the boom
foot pin.
2. Always operate within the rated capacity of the machine.
3. The gross capacity includes weight of hook, block, and any material-handling devices, (i.e., slings,
concrete bucket, magnet lifter, etc.); subtract the weight of all these to find the true weight (net
capacity) the crane can handle safely.
4. Ratings are based on operating the machine on firm, level ground; outriggers should be properly
extended and lowered before operation.
5. Avoid fast swings, hoists, or sudden braking; these can cause overloads.
6. Do not handle large, heavy loads in strong winds; the wind can catch the load and create an
unstable condition.
b. Test stability before lifting heavy loads. Check outrigger footing. Lift load slightly off the ground
and stop. Check the machine for movement ad check to be sure the brakes hold with the load
elevated.
c. Never use machine stability to determine capacity.
d. If there are any indications of tipping, the machine is already overloaded for that working radius.
e. Do not back crane away from the load while carrying a maximum load; this may cause the crane to
tip.
f. Always use outriggers when making lifts (with pick-and-carry units), and never lift a load forward
of the front outriggers, unless allowed on manufacturers load chart.
g. Lower outrigger jacks until the tires clear the ground, and level the unit to reach the machines full
capacity. Recheck and, if necessary, reset outriggers between heavy lifts.
h. Always fully extend outrigger beams unless otherwise specified on the manufacturers load charts
for the crane.
Further Safety Considerations
a Make only vertical lifts; never pull the load sideways.
b Keep speed slow in lifting and lowering loads.
c Swing carefully and slowly, and avoid boom or jib whipping; check counterbalance clearance.
d Do not let the load strike the boom or outriggers.
e Allow maximum clearance between the hook block and boom-point sheaves.
f Keep near-capacity loads as close to the ground as possible.
g Avoid hitting anything with the boom; an engineering analysis shall be made before putting the
crane back in service if this occurs.
OPERATING NEAR POWER LINES AND TRANSMITTER TOWERS
It is recognized that operating mobile cranes where they can become electrified from electric power
lines is an extremely hazardous practice. It is advisable to perform the work so there is no
possibility of the crane, load line, or load becoming a conductive path,
HOIST-LIMIT SWITCH
Check all limit switches, if supplied, without a load on the hook at the beginning of each work shift
or the first time the crane is used that shift. Inch each motion into its limit switch to ensure that twoblocking does not occur during the test. If a lift is in progress during a shift change, this
testing requirement is considered to have been.
MOVING THE LOAD
a. The appointed person directing the lift shall make certain that the load is well secured and
properly balanced in the sling or lifting device before it is lifted more than a few inches.
b. Before starting to hoist, note the following conditions:
1. Hoist rope shall not be kinked.
2. Multiple-part lines shall not be twisted around each other.

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HOIST. With forearm vertical, forefinger pointing up, move hand in small horizontal circles. LOWER.
With arm extended downward, forefinger pointing down, move hand in small horizontal circles.
RAISE BOOM. Extend arm, fingers closed, thumb pointing upward.
LOWER BOOM. Extend arm, fingers closed, thumb pointing downward.
Standard hand signals for controlling mobile crane operation. DOE-STD-1090- 2007
MOVE SLOWLY. Use one hand to give any motion signal and place other hand motionless above the
hand giving the motion signal.
RAISE THE BOOM AND LOWER THE LOAD. With arm extended, thumb pointing up, flex fingers in and
out as lone as load movement is desired. LOWER THE BOOM AND RAISE THE LOAD. With arm
extended, thumb pointing down, flex fingers in and out as long as load movement is desired.
SWING. Extend arm, point with finger in direction of swing of boom.
STOP. Extend arm, palm down; move arm back and forth horizontally.
EMERGENCY STOP. Both arms extended, palms down, move arms back and forth horizontally.
TRAVEL. Extend arm forward, hand open and slightly raised; make pushing motion in direction of
travel.
EXTEND BOOM. (Telescoping Booms). Hold both fists in front of body, thumbs pointing outward.
RETRACT BOOM (Telescoping Booms). Hold both fists in front of body, thumbs pointing toward each
other.
EXTEND BOOM (Telescoping Boom). One-hand signal. Hold one fist in front of chest, thumb tapping
chest.
RETRACT BOOM (Telescoping Boom). One hand signal. Hold one fist in front of chest, thumb pointing
outward and heel of fist tapping chest.
3. The hook shall be positioned above the center of gravity of the load in such a manner as to
minimize swinging when the load is lifted.
4. Following any slack-rope condition, it should be determined that the rope is properly seated on
the drum and in the sheaves.
5. All personnel including the qualified rigger shall be clear of the load.
c. During hoisting, take care to ensure that:
1. There is no sudden acceleration or deceleration of the moving load.
2. Load does not contact any obstructions. A dry run shall be conducted in areas where clearance
is limited.
d. Cranes shall not be used for side pulls, except when specifically authorized by a designated person
who has determined that the stability of the crane is not endangered and that various parts of the
crane will not be over stressed.
e. Avoid carrying loads over people.
f. No hoisting, lowering, swinging, or traveling shall be done while anyone is on the load hook.
g. Test the brakes each time a load approaching the rated capacity is handled by raising the load a
few inches and applying the brakes.
h. Do not lower the load below the point where less than two full wraps of rope remain on the hoist
drum.
i. Do not leave your position at the controls while the load is suspended, unless required to do so by
an approved emergency procedure.
j. If the load must remain suspended for any considerable length of time, the operator shall hold the
drum from rotating in the lowering direction by activating the positive controllable means of the
operators station.
k. Work on suspended loads is prohibited under normal conditions. When the responsible manager
decides that it is necessary to work on a suspended load, guidelines for ensuring safety of the work
shall be established through consultation with the appropriate safety organization.
Suspended loads that must be worked on shall be secured against unwanted movement.
l. Tag lines should be used as required to guide, snub, or otherwise control the load.

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BRIEF REPORT ON FATAL INCIDENT DUE TO MOBILE CRANE AT SARDA MINES

M Sateesha, Mechanical Engineer M/s Sarda Mines(P) Ltd.

--------------------------------------------------------------------------------------------------------Background:
To comply MoEF condition, tailings to be dumped in the form of cake for which filter press plant is
under progress where Fabrication & Erection jobs are going on. For lifting & shifting of MS plates,
angles etc. Hydra crane(Pick & Carry crane) are usually engaged to carry on the job with proper
supervision.
Brief Details of the Incident:
On Dt 22.01.2013 metal plates of 1.2mtr x 6 mtr x 6mm thick were being shifted from stockyard to
fabrication yard which is nearly 200mtr away. For this purpose a Hydra crane (Pick & Carry crane) of
12tonne was engaged. The wire ropes (2 nos) of 5tonne capacity were hooked to the plates. The
material (4 plates) was of approx. 1.5 tonne which was hooked to the Hydra at last position whose
capacity was 2 tonne. 2 no. of riggers were provided to arrange wire rope slings to put around the
material for proper lifting.
The above work was being done under the supervision of an experienced Asst Manager. After lifting
of plates he instructed the hydra operator to take the plates to the fabrication yard located at a
distance of around 200 mtrs from that place and the Riggers were asked to reach at the unloading
spot. After sending hydra, supervisor stayed at the same place in search of other desired sections of
steel.
During the process of transportation the plates were kept at 0.5mtr above the ground for smooth
transportation. Hydra was moving at a speed of 2 Km /hr. While Hydra was in motion the plates
started swinging slightly.
Riggers were moving ahead of Hydra on the road safety bund to guide the traffic on the way. To
control the swing of the plate one of the rigger came backward towards the moving hydra and
slipped from the bund and got himself injured with the hanging plates. By the time operator could
see it and had stopped the hydra, incident had taken place.
He got deep cut on his left thigh. After giving first aid he was shifted immediately to the dispensary
for necessary treatment. Doctors after primary treatment advised to shift to TATA hospital, Joda for
further treatment. In spite of their hard efforts and blood transfusion, Doctors were unable to save
the life of the victim and succumbed to his injuries.
Probable Causes:
During transport of plates the rigger attempted for adjustments while the plates were in
motion.
The plates should have been placed on the ground before any adjustment.
Attempts were made by the rigger to control the swing without informing the Hydra
operator or the concerned Supervisor.
At the time of shifting of plates, there was no supervisor in the vicinity
Preventive Measures:
The riggers/helpers engaged in shifting of loaded material shall remain at least 3 mtrs away
from the Mobile crane or the moving load.
Any adjustment of the load shall be done only in the presence of a competent supervisor.
No adjustment shall be done until the loads are placed on the ground.
SOP shall be properly understood and followed by the gang/team engaged in the shifting
operation

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Mobile Crane Safety

Somnath Choudhury, TIL

--------------------------------------------------------------------------------------------------------INTRODUCTION OF CRANE
A crane is a Tower or derrick equipped with cables and pulleys that is used to lift and
lower heavy materials.
Cranes are commonly used in the construction industry and in manufacturing heavy
equipment.
Cranes may either be controlled from an operator in a cab that travels with the crane,
by a pushbutton pendant control station, or by infrared or radio control.
Where a cab operator is employed, riggers on the ground will communicate with the
operator through a system of standardized hand-signals or, in larger installations,
radio systems; an experienced crew can position loads with great precision using
only these signals.

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DEFINITIONS
Crane Consists of a rotating structure for lifting and lowering horizontally on rubber tires or
crawler treads
Hoist - Used to lift and lower the load.
Boom An inclined spar, strut, or other long member supporting the hoisting tackle
Boom stops A device used to limit the angle of the boom at its highest position
Brake To slow or stop motion by friction or power
Block Sheaves or grooved pulleys in a frame with hook, eye and strap
Jib Extension attached to the boom point to provide added boom length for lifting specified
loads.

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Crane Inspection Guidelines

Pre-inspection
Crane Set up
Electrical Hazards
Load Charts
Safe operating precautions
Inspection Types
Starting the inspection
Specific inspection Items and References

PLACEMENT OF THE CRANE

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Planning before Start-Up

Level the crane and ensure support surface is firm and able to support the load
Contact power line owners and determine precautions. Know the location and
voltage of overhead power lines.
Know the basic crane capacities, limitations, and job site restrictions, such as the
location of power lines, unstable soil, or high winds.
Make other personnel aware of hoisting activities.
Barricade areas within swing radius.
Ensure proper maintenance and inspections.
Determine safe areas to store materials and place machinery.
Know the Weight of the Load
Refer to shipping ticket or other documentation
Ensure lift calculations are correct
Ensure load is within load chart rating for boom length and load radius of crane
Crane is rated by the maximum weight it will lift at a minimum radius with a minimum
boom length the further from its centre point, the less it will lift
Load Limiting Factors
Not level (Uneven) ground
Wind speed
Side loads
On its wheels
Lifting over the side
Use of extensions, jibs and other attachments
Limits of wire rope, slings and lifting devices
Mobile Cranes Lifting Principles
Centre of Gravity
Stability
Structural Integrity
Load Example 30 Ton crane
Will lift 27 Ton at 3m from the centre pin of the crane
Based on level surface, no wind, and outriggers fully extended
At 7.6m from the centre pin with an 80 foot boom, the capacity is only 6.7 Ton
At 22.5m from the centre pin, the capacity is only 2 Ton

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Major Causes of Crane Accident:

Contact with Elect. power lines
Overturns
Rope Falls
Mechanical failures
How Do Accidents Occur?
Instability unsecured load, load capacity exceeded, or ground not level or too soft
Lack of communication - the point of operation is a distance from the crane
operator or not in full view of the operator
Lack of training
Inadequate maintenance or inspection
Configuration Setup Procedure
After switching on the supply voltage the unit will complete a system check routine for 1 sec,
where all lights & the buzzer are activated. After successful check the display will show

The displayed number is the valid program / software of the system.

The display automatically switches over to the crane configuration setup. This allows the
operator to select the existing crane configuration
Select Parts of line: Use the pushbuttons, Down / Angle Length (7) or UP / TARE (9) to
select the number of parts of line.

Confirm displayed selection with the pushbutton Program / Buzzer (8)

The normal operating display OR the minimum angle pre-set selection mode will be
displayed at this time
If the displayed values are incorrect or the setup is changed since the crane was powered
off, press the pushbutton Program / Buzzer (8) to restart the Crane Configuration setup
procedure

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Crane Hazards:

Improper load rating

Excessive speed
Improper hand signal
Inadequate inspection and maintenance
Unguarded parts
Unguarded swing area

Dont

Working too close to power lines

Improper exhaust system
Shattered windows
No steps/guardrails walkways
No boom angle indicator
Not using outriggers

Competent Person:
The competent person must inspect all machinery and equipment prior to each use, and
during use, to make sure it is in safe operating condition.
If it needs fixing, take it out of service and dont use it until it is fixed.
Load Capacity - Speed Warnings
Make sure the crane operator can see the:
Rated Load Capacities
Operating Speeds
Special Hazard Warning or Instructions
POWER LINES
Stay clear from the Power lines at least 20 feet.
Guard Moving Parts:
Guard moving parts such as gears or chain
Swing Area:
Stay out of the swing aria of the crane and Make sure there are barriers or guards showing
swing radius
Operator Visibility:
The broken windows or other obstructions should not prevent the operators visibility
Cabin Ladders:
Use ladder for go to the upper portion of the cab
Guardrails:
Runways and steps need to have guardrails handholds and slip resistant surfaces
Suspended Load:
Do not stand under the suspended load
Supporting Surface:
Crane must be stabilized on a firm & level surface
Sheaves:
The grooves must be smooth and free from pitting surface which may lead rope damage
Rigging Equipment Slings:
Types of slings include alloy steel chain, wire rope, metal mesh, natural or synthetic fibre
rope, and synthetic web.

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Annual Inspections:
Inspection of the hoisting machinery must be made by a competent person
The employer must maintain a record of these inspections
What to Inspect:
Correct air pressure and no leaks
Tires properly inflated
Clearance for tail swing
Wire rope wear
Physical damage to crane
Loose or missing hardware, nuts, or bolts
Fluid leaks
Damaged wire rope:

Damaged wire rope must be taken out of service

Tire Inspections:
Conduct regular inspections of tires for excessive wear or damage.
Summary on crane safety:
An unstable load, lack of communication, lack of training, and inadequate
maintenance or inspection is major contributors to crane accidents.
Safety (LMI) system must be operated & maintained regularly to prevent major
accidents.
Contact with high tension power lines causes many accidents. Keep 20 distance
from power lines.
A competent person must operate & inspect the crane regularly to insure it is in
proper condition.
Must use proper Helmet, Safety shoes, Gloves while operation or maintenance the
crane.
Planning and Training reduces the accident.

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SAFE WORKING WITH MOBILE CRANES

V K Suman AGM (Mech) & K S Chauhan AGM (Mech)

SAIL, RMD, Bolani Ores Mines

--------------------------------------------------------------------------------------------------------Mobile cranes are used in mines most frequently for hoisting and placing spare parts during the
assembly and maintenance of large mining machines. Another use is of pick and carry of light weight
spares from one location to the other. For the above mentioned jobs as per requirement either truck
mounted or crawler cranes are used.

The lifting ability of a crane depends primarily on balance, rather than engine power. Cranes
are more efficient than other machines for most hoisting work because:
(1) They do not carry the dead weight,
(2) Slower and smoother lifting can be achieved by increasing the number of lines, and
(3) The operator has a better view of the hook and the load.
A crane can lift maximum loads only if the boom is held high enough to keep the load close to the
crane. A crane can handle lesser loads with greater safety and convenience if the loads are close
enough so that there is no question about stability. It is therefore customary to operate cranes with
their booms held high.

Hazards associated with the mobile crane operations can be categorised as:

Hazards during maintenance/pre-operation stages ;

o Operators and maintenance crews are subjected to slipping and falling while
mounting and dismounting, cleaning windows, inspecting the machine or during
refuelling/maintenance time.
Hazards during operation of cranes
Tipping of the crane
Falling or dropped loads
Boom collapse
Collision with obstacles at ground level or overhead.
Touching overhead power-lines

Use of the mobile cranes is necessary for moving large objects efficiently and for reducing the
manual handling operations. Every year, we come across with several instances of mishaps due to
lifting accidents resulting into injuries, loss of work time and property. It becomes imperative to
ensure proper safety measures, to reduce the lifting accident instances. For safe working with
cranes, a complete approach is required, where one should address all factors; i.e. People,
Machinery, Loads, Methods and finally the work environment.

People:
People related to the safe lifting operation include a Crane operator and
Ground crew including Work supervisor, Signaller, Slingers (riggers) and other

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people working in the nearby area. The safe operation of a crane requires careful
selection and training of the crane operator and ground crew.

Mobile crane operators have a heavy responsibility for the safety of persons and equipment. A
ground person (rigger) or ground crew is usually present, and can be injured if the operator makes
mistakes. The loads that are handled are expensive and fragile. Cranes often operate close to other
machines. The job demands top skills, good judgement, and thorough training. A crane operator
must have thorough knowledge of his equipment, its operating characteristics, its limitations, and
the hazards of improper usage. He must be aware of safe procedures for operating the crane and
handling loads. Only trained and qualified persons should be permitted to operate cranes.

Ground crew during a lifting operation include:

Work supervisor: responsible for the regular inspection, operation and
maintenance of the lifting appliances. The person should have proper
training and detailed knowledge about the equipment in use and relevant
practical experience about the lifting operation a nd various hazards
during operation.
Slingers: responsible for attaching and detaching the load from the crane. He shall have

knowledge and training on general lifting operation, competence of selecting the

appropriate lifting gears like Chains, slings, ropes, or tongs etc. to fasten the load for lifting
as per the load requirements. These people requires to communicate with signallers and the
operators as they are prone to be caught in the rigging if the crane operator begins hoisting
while they are still making adjustments. Serious hazards like overloading, dropping or
slipping of the load are caused by improper hitching or slinging.
Signaller: responsible for relaying the signal from the slingers to the crane operator.
Standardized signalling between the ground person and crane operator is very important to
safe operation. Signaller should be well conversant with the standard signals, trained about
the general safe lifting operation and be able to direct the movement of the cranes and
loads. Serious hazards like Overturning of the crane by abrupt swinging, collision with
obstacles and booms touching the power-lines etc. are caused due to improper signalling.

General safety precaution to be adhered is to attach proper taglines to the loads that require
steadying or guidance while suspended. Hitches and slings must be suitable for the particular
material handled. Everyone, including the ground crew, must stay clear of suspended loads. No one
is permitted to ride on loads or hoisting hooks except in certain unusual situations where this
method eliminates a greater hazard.

Machinery
It includes the mobile crane and the lifting gears. The basic points of consideration are; Selection of
the machinery and its operating/utilisation procedures.
Cranes: Proper selection of the crane is the first point of consideration for the safety of lifting jobs.
Safe working load for operating the crane shall be specified according to test and examination
certificates and such loads must not be exceeded during the lifting operation. Following points shall
be considered:

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 Weights and dimensions of loads

Height of lift and distances/areas of movement of loads
Number and frequency of lifts.
Period of time for the lifting operations
Ground conditions
Other factors.
During operating the crane following points shall be considered;
Crane shall be operated on a firm level ground that adequately supports the weight of the
crane and loads.
Before lifting, fully extend outriggers and ensure their stability on the ground.
The weight of the load shall not exceed the safe working load
Never abruptly swing or stop the crane.
Loads shall not be dragged on the ground.
Move the load at a safe speed - use low speeds within several meters of the loads
destination.
Adjust the boom length to ensure the crane is operating within the extent of the safe
operation radius.
When moving uphill or downhill, the boom angle shall be adjusted to the safe working
condition.
Lifting tools and tackles: function is to tie the objects tightly before lifting them. If a wrong
choice is made about the lifting tools and tackles, lifting may fail and result into an accident.
Generally used lifting tools and tackles are;
Wire rope slings, Wire rope slings with cable clips or Chains
Shackles,
Eye-bolts
Hooks and
Slings, Links and swivels
Spreader beams etc.
All lifting tools and tackles shall be tested by qualified examiners and suitably marked with a safe
working Load (SWL).

Load
As the cranes are used for lifting the loads, for safe lifting it is required to remain very clear about
the following points;
Know the weight and shape of the load.
Pay attention to the loads centre of gravity- ensure that it is kept directly under the main
hook.
While lifting large or heavy loads, wind and operator visibility must be considered.
Corner pads shall be used for loads with sharp edges.
Loose loads shall be packed or placed in suitable containers before lifting. The containers
must be structurally sound and four slings must be used to avoid inclining.

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Methods
Once the loads, machinery and people are finalised, before taking up the job, job methodology, i.e.
the way job has to be carried out needs to be finalised. Points to be addressed in the brain-storming
are;
Plan a suitable lifting route, to avoid collision with any persons, objects or overhead power
lines.
Do not drag the loads.
Move the loads as near to the ground as possible
Stop people from standing in the lifting area.
Do not ride on a load that is being lifted.
A minimum of 2 distance must be maintained from any of the barrier or building.
When operators visibility is blocked, the signaller shall render assistance.
Lift the load at a low speed so that the sling tightens slowly and maintains a balanced
position.

Environment
Safe working of a crane and lifting of the material is directly related to the environment in which
work has to be carried out. Points of attention are:
It is advisable to avoid the rainy seasons, as there is possibility of having wet and slippery
ground, loose soil etc. As it may cause danger to the cranes stability, lifting work must be
stopped.
In case of thunderstorms, Lifting operation should be stopped.
While working in strong wind condition, decrease the SWL by a suitable factor or stop lifting.
In case of loose soil situation, Use large size wooden planks below the outriggers to keep the
crane load distributed.
In case of Sloppy terrain, adjust outriggers to keep the crane horizontal.
In case of working near Overhead lines, the safety margin of the jibs shall be kept as
minimum 6 meters or the distance as suggested by the electrical department.
Once above factors have been taken into account and the lifting operation is under taken then
following tables has to be considered for safety of during operation;

For Starting the crane and performing the pre-operation checks

POTENTIAL ACCIDENTS OR HAZRDS
A) Hitting or running over persons or objects in
area striking interior of cab if crane moves
suddenly.

B) Engine or auxiliary equipment malfunction.

RECOMMENDED SAFE JOB , PROCEDURES

A) Check machine for warning tags. Check
controls to be sure they are properly positioned.
Warn any members of nearby work crews that
you are starting your machine by sounding start
up signal. Check backup alarm (if applicable)
after start-up.
B) Let engine run until it reaches normal
operating temperature. Check all gauges,
indicators and warning lights again for normal
readings.

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C) Loss of control, improper operation.

D) Electrocution.
E) Thrown against cab interior or thrown out of
the machine

C) Test all controls and check that operations of

different functions are in order.
D) Be cautious of overhead power lines at all
times. Pay particular attention to clearance.
E) When driving truck mounted cranes, wear
seat belts.

During general operation stage

POTENTIAL ACCIDENTS OR HAZARDS
A) Tipping of crane due to Overloading

B) Tipping of crane due to stability

C) Tipping of crane due to jerky operation

D) Tipping of crane during bad weather
conditions.
E) Collision with obstacles; Crushed against a
stationary object
F) Collision with obstacles; Striking nearby
personnel or equipment
G) Electrocution, electric shock, fires.

RECOMMENDED SAFE JOB , PROCEDURES

A) Know the rated capacity of your crane for
various boom angles/ load centre. Safe ratings
are based on operating the machine on firm,
level ground
B) Check stability before lifting loads. Ensure the
outriggers are firmly positioned on solid
surfaces, crane is level, brakes are set, and load
is properly rigged. Lift load slightly off the ground
and confirm stability before hoisting further.
C) Do not operate crane too fast. Avoid fast
swings, hoists or sudden breaking
D) Lift only the proper types of materials. Do not
handle large heavy loads in strong winds, as the
wind could create an unstable condition
E) Do not allow anyone to ride the load or load
hook
F) Make a "dry run" in tight areas to help
determine the safest way to operate under
existing conditions.
G) Keep boom away from overhead lines. NEVER
ALLOW ANY PORTION OF THE MACHINE OR
LOAD TO PASS WITHIN 10 FEET OF AN
ENERGIZED HIGH VOLTAGE POWER LINE.
Consider every overhead line energized until the
power company states otherwise. If you do hit a
power line, remember:
1) Stay inside cab, if possible, until line is cleared
or power, is shut off.
2) Warn all persons in the area to keep clear of
the crane and the suspended load.
3) If you must leave the cab, such as in the event
of a fire, be sure to jump clear of the machine.
Do not contact any part of the machine or the
load.

For lifting transporting, and lowering material.

POTENTIAL ACCIDENTS OR HAZRDS
A) Catching ground personnel in pinch points,
dropping load, striking personnel or
obstructions.

RECOMMENDED SAFE JOB , PROCEDURES

A) Be certain that proper signal procedures are
established between ground crew and crane
operator. Crane operator should communicate

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B) Caught in pinch point, struck by dropped or

swinging load.

C) Boom failure or damage.

D) Overloading, overturning, losing control of
load, machine damage
E) Additional strain on rigging, rigging coming off
hook, hazards in hooking and unhooking loads.
F) Wire rope or load attachment failure.
G) Overturning from unbalanced load, loss of
brakes.
H) Overturning from excessive load for boom
angle, loss of brakes.

I) Overturning from unbalanced load.

J) Striking equipment or people with boom.

K) Tipping of crane.

with only one signal person; however, crane

operator should observe any stop or emergency
signal.
B) Ground personnel must ensure proper rigging,
stay out of pinch points, and stay clear of hoisted
loads. Tag lines permit steadying or guiding a
load from a safe distance.
C) Make sure the hoist line is vertical. Do not
make side loadings.
D) Avoid sudden starts and stops. Keep speeds
low when lifting and lowering loads.
E) Do not hoist two or more separately rigged
loads in one lift, even though the combined load
is within the crane's capacity.
F) Allow maximum clearance between hook and
head sheaves.
G) Use the shortest boom possible. Keep nearcapacity loads as close to the ground as possible.
H) Test stability before fully lifting load by:
1 ) lifting load slightly off the ground
2) Checking the machine for movement, and
checking to be sure the brakes hold with the load
elevated.
I) Be aware of centrifugal force when swinging.
Swing crane slowly to avoid outward swings of
load. If necessary, attach tag line to the load to
control the swing.
J) Always control load. To prevent excess motion
during travel, use taglines to guide or snub the
load. Never carry suspended loads over
personnel.
K) Always use outriggers to make any lifts,
except light loads with pick-and-carry units.
Lower outrigger jacks to completely remove all
machine weight from tyres and level unit to
safely reach the full capacity of the machine.
Recheck and, if necessary, reset outriggers
between heavy lifts.

In brief, working with mobile crane is a team work, where the entire team must work cohesively to
avoid any instance of unsafe acts.

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Code of Practice for inspection & maintenance of mobile and EOT crane
Narayan Sharma,Head(Processing) Tata Steel Noamundi
-------------------------------------------------------------------------------------------------------------------------Purpose: To provide guidelines for inspection and operation of cranes in order to improve safety.
Type of cranes used in Mining/ construction:
1. Mobile cranes
2. EOT cranes (ELECTRICAL OVERHEAD TRAVELLING)
WHAT IS ITS CAPACITY?
ITS SWL- SAFE WORKING LOAD e.g. 5T, 2T, 32T, etc.
It is tested annually by competent person.
It is compulsory by law.
Service Condition:
Normal Service: Involves operations of the crane with randomly distributed load within the
rated load limit or uniform loads of less than 65% or rated load limit for no more than 25%
of the time for a normal work shift.
Heavy Service: Involves operation of the crane within the rated load limit that exceeds
normal service.
Severe Service: Involves operation of the crane in normal or heavy service with abnormal
operating conditions.
Inspection Types:
FREQUENT (Shift/ Daily / Weekly ): Frequent inspections are visual inspections and examinations by
the operator or other designated personnel.
Inspection intervals are:
PERIODIC (Monthly/ Semi/ Yearly): Periodic inspections are visual and audio inspections and
examinations by designated personnel making records of external conditions to provide the basis
for continuing evaluation.
Checking of Cracks and Repairing
Check cracks in the structure and in all welds.
A crack in a weld will always start on the end and work itself along the entire weld until it
fails completely.
Many times a crack in the paint will be a clue to a weld that is failing.
Early noticed crack can be easily repaired by ground out and re-weld.
Before welding on any part of the crane, make sure you have a certified welder and if it is on
a structural part of the crane you should get the manufactures procedure.
Also, try to determine why it cracked in the first place. Is the crane being overloaded or used
improperly?

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Checking of Fasteners
Check all fasteners for loose, stretched, missing, or broken fasteners.
A good clue is checking for cracked paint around the fastener that shows there has been
movement.
Sometimes a build up of dirt or grease can give early indication
Using a torque wrench to check for tightness may give false indication. Corrosion could give
you a false reading.
Replace a loose or stretched bolt rather than tighten it. It probably has been damaged.
Be sure to replace the bolt with a grade 8 or better.
If there are other bolts near by that show signs of looseness, then replace them all.
Checking of Ropes
Reduction of rope diameter below nominal diameter due to loss of core support, internal or
external corrosion, or wear of outside wires. A number of broken outside wires and the
degree of distribution or concentration of such broken wires.
Worn outside wires.
Corroded or broken wires at end connections.
Corroded, cracked, bent, worn, or improperly applied end connections.
Severe kinking, crushing, cutting, or un-stranding.
Tyre Inspection
Tyre Pressures :- Pressures should be checked weekly when the tyres are cold.
Tyre valves should be checked to ensure that they are not leaking. High pressure valve caps
should always be replaced.
Any tyre found to be severely under inflated or deflated must be removed from the rim and
checked out by an authorised dealer.
The tread and side walls should be checked for cuts;
All foreign objects caught in tread pattern should be removed
Tread depths should be measured as part of a routine inspection program. The minimum
legal tread depth for a wheeled mobile crane is 1mm. Any crane tyre found to be at or below
this limit must be replaced or re-grooved in accordance with the manufacturers
requirements.
Checking of Hooks

Hooks with threads and nuts need to have threads inspected periodically.
Hooks can only be repaired per manufacturers procedures.
Wear in excess of 5% in the neck of the hook and 10% in other areas including the bow of
the hook is cause for removal.
An increase in the hook throat opening of more than 15% is cause for removal.
Any twist in the hook of more than 10% is cause for removal.
The hook safety latch should be present and function properly.

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SAFE OPERATION Dos

Read and understand the operators manual
Follow all placards, warning labels and signs on machine. All warning labels on the crane
including crane operation instructions must be on the crane and legible.
The safe-working-load of the crane should be easily visible to the operator. The safe working
load would be the maximum load of the weakest link on the crane. For example: If the
maximum SWL of the hoist was 5 tons, then the SWL, but the beam that it was hung under
was good for 7 tons, the SWL of the crane could not exceed 5 tons and if stenciled on the
beam, it should reflect the 5 ton rating.
Keep unnecessary items out of the cab
Enter and exit cab only through approved access ways
Use both hands to climb access ladder
Complete the pre-shift inspection checklist before operation
Know the location of emergency shutoff switches
Know emergency evacuation routes
Place all controls in the OFF position before turning the main switch ON
Maintain a portable fire extinguisher in the cab
If a power failure occurs, place all controls in the OFF position
Park the cab in an approved, designated position
Start lifts slowly and avoid shock loading
Suspend and transport loads at a level that allows the operator a clear view
Use a loud signal, such as a whistle, horn or bell or verbal warning to alert employees of
crane movement
When lifting near or at capacity, test the brakes after the load is raised a few inches.
Always place the hook directly over the center of gravity or the designated lifting point
Before hoisting the load, check for loose parts that might shift or fall
SAFE OPERATION Donts
Never hoist a load over the heads of employees
Never use limit switches or end stops as operating controls
Avoid running the crane into the end stops or limit switches
Never walk backward when guiding a load
Never hoist two or more separately rigged loads on a single hook even if the combined
weight is within the capacity of the crane
Never wrap the hoist line around the load
Avoid bumping crane and carriage stop blocks
Never use taglines to swing the load
Never drag slings, cables or chains across the floor
Never climb or jump from one crane to another
Never walk along runway tracks
Never move the cab without a signal from the designated signal giver
Avoid bumping crane and carriage stop blocks
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Safety during maintenance

Before adjustments and repairs are started on a crane the following precautions shall be taken:
The emergency shut off musts be visible and accessible.
The crane to be repaired shall be run to a location where it will cause the least interference
with other cranes and operations in the area.
All controllers shall be at the off position.
The main or emergency switch shall be open and locked in the open position.
Warning or "out of order" signs shall be placed on the crane, also on the floor beneath or on
the hook where visible from the floor.
Where other cranes are in operation on the same runway, rail stops or other suitable means
shall be provided to prevent interference with the idle crane.
After adjustments and repairs have been made the crane shall not be operated until all
guards have been reinstalled, safety devices reactivated and maintenance equipment
removed.

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SAFETY PRECAUTIONS WITH EOT CRANES

by K.L. Janghel, Bikash Kumar & Rajendra Singh of Rungta Group
-------------------------------------------------------------------------------------------------------------------------------------INTRODUCTION TO EOT CRANE
E (Electrical) O (Overhead) T (Travelling) Crane: It is also known as OVERHEAD CRANE. It is widely
used in workshop, plants and construction yards.
Advantage: It does not occupy any space on the floor as it moves overhead.

Details of EOT Crane:

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MAJOR ASPECTS OF SAFETY:

a) Electrical
b) Mechanical
c) Operational
d) Maintenance
ELECTRICAL SAFETY
As the electrical energy supply is from external source, it should be provided with instant cut
off switch in one operation (i.e. emergency switch). ( IER 1956, Rule 34 & 37)
As it runs on rail on both sides, the rails must be electrically continuous and earthed properly
with earth leakage relay provided in the control circuit(IER 1956, Rule 37)
Electrical bus-bar is a bare conductor of electrical supply. So, it must be inaccessible. (IER
1956, Rule 34)
On the structure along the bus-bar, the sign of electrical danger mentioned with the supply
voltage must be displayed at the interval of 10mtrs. (IER 1956). The board should have also a
red light indicator placed conspicuously to indicate that the bus-bar is in live condition.
The festoon cable arrangement for traversing of hoist, as it is having voltage more than
100V, has to be DGMS approved. (DGMS Circular No.Legis.No.1/1993)
No festoon cable arrangement should be provided to replace bus-bar system for longitudinal
travelling.
The control panel voltage (in operators cabin and pendent switch etc.) should not exceed
110V (IER 1956)
The supply voltage to EOT Crane, in any case, should not exceed 600V, 3 phase, 60Hz (US
Standard). In Indian standard it may be not exceeding 440V, 3 phase, 50Hz.
Every EOT must be provided with limit switches for restricting the movement of following
operations within specified range :
Longitudinal movement on rails
Transverse movement of hoist
Vertical movement of hoist
The individual motors of the crane must be provided with
Individual MCBs.
Overload relay.
Under voltage relay.
When the electrical supply to the crane is ON, an indicator light should glow at local panel.
Motor brake must be designed in such a way that when the power is OFF, the brake gets
applied automatically on the motor.
Each hoisting unit shall be provided with two means of braking. One with electrical actuation
and another with mechanical actuation.
The EOT crane must be provided with an Audio-Visual signal system to alert the
surroundings while operating.
The work place of EOT cranes must be provided with sufficient illumination as per DGMS
Circular.

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MECHANICAL SAFETY
EOT crane must be installed on perfectly leveled and aligned rails mounted on sufficiently
strong structure (with appropriate factor of safety).
All the parts i.e. shackle, pins, slings (steel wire rope), chain links and rope capel (for forming
rings) must be provided as per specification of DGMS Circular No. Tech. 1/2001)
The end carriages of the crane must have rubber/spring buffers to minimize the impact due
to collision with end stoppers in case of failure of limit switches.
The crane hook must be provided with spring loaded safety latch and as per DGMS
specification
The manufacturer must ensure that the factor of safety associated with the design of the
crane must be extra 25% of the rated capacity of the crane.
The crane gantry should have walkways with hand railings and toe guards.
The walkways should have full length chequered plates floors properly welded.

OPERATIONAL SAFETY
The electrical supply to the crane must be switched ON only after written instruction of the
shift-in-charge given to the control room and it must be well communicated to the operator.
The crane must be operated only by a well-trained and authorized Operator (competent
person) appointed by the Mines Manager.
The Operator along with Rigger and electrician should maintain a check list for the following
points before operating the crane on daily basis.
Brakes (LT/CT/Hoist).
Gear box oil level
Rope condition
Hook and latches
Limit Switches
Bus-bar supply contacts
The slinging and lifting of loads should only be done by a well-trained rigger and skilled
associates who are authorized as the competent persons by the Mines Manager.
Only pre-determined load to be lifted by the EOT crane which must be always less than the
specified rated capacity of the crane.
The additional hooking tools (slings, ropes, shackles, chains etc.) must be having the known
capacity of 1.5 times of the pre-determined load.
The signaling for lifting and movement must only be given by a single person (i.e. trained
rigger) and the rigger must follow the specified signal codes well understood by the
operator. Preferably rigger must use a whistle for better audibility of the signal.
The operator must take care, while moving the load in lifted condition that the swing range
of the load should be negligible and should be moved in free zone.
The persons involved in operation and signaling of EOT crane should have the proper PPEs
being used by them such as safety shoes, helmet, hand gloves, florescent jackets etc. They
should not also use any loose cloth wearing. (MMR 1961, Reg.174)
The riggers and the workers on the shop floor should stay at safe distance from the swinging
range of the load.
The crane hook should have self-retaining safety latch in locking position before lifting load.

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 The load must be always tied and lifted in vertical position, and not in slanting rope position.
The operators and the riggers must be checked medically for their eye sights and audibility
every year.
The operator and rigger must not be under the influence of intoxicating material and must
be mentally attentive.
If the work continues from one shift to the other shift, then there shall be a register
maintained in the control room for handing over and taking over of the job with particular
reference to the power supply to the crane.
MAINTENANCE SAFETY
The competent person appointed by the Mines Manager should inspect thoroughly the EOT
crane once in a week and shall maintain the record of the observations in a bound paged
book kept for the purpose. (MMR 1961, Reg.176)
The report of such observation must be also given to the appointed engineer in-charge who,
in turn, should ensure that the defects in the crane are timely eliminated.
The following weekly checking and maintenance must be made on the crane trough a check
list.
The fasteners of the girders and rails
The gear box couplings
The welding of structures and end stoppers
Oil leakages
Rope drum
The condition of ropes and pulley blocks including lubrication.
The tribological conditions of the following items must be checked on monthly basis and the
report must be maintained in a bound paged book kept for the purpose.
Ropes
Bearings
Rails
Wheels
Shafts
Coupling and brakes
Rope drums
UV/ultrasonic/radiography test must be made yearly once for checking micro cracks
developed on hook, wheels, rails, crane and gantry girders and report must be timely
attended to.
All the parts and components of the EOT crane should have individually maintained history
sheet for its periodical replacement which will suffice the need of ascertaining the frequency
of future replacement required.
The structures on which EOT crane is mounted should be checked for its stability in every
five years as per DGMS Circular.

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