Crane & Lifting Safety

Major Causes of Crane Accidents

• Contact with power
lines

• Overturns

• Falls
• Mechanical failures
2
 How Do Accidents Occur?
• Lack of communication - the
point of operation is far
distance from the crane
operator or not in full view of
the operator

• Lack of training

• Instability – unsecured load,

load capacity exceeded, or
ground not level or too soft

• Inadequate maintenance or
inspection
3
 Crane Hazards
• Improper load rating • Working too close to
power lines
• Excessive speeds
• Safety equipment not
• No proper hand functioning properly
signals
• Shattered windows
• Inadequate
inspection and • No steps/guardrails
maintenance walkways
• Unguarded parts • No / Damaged boom
angle indicator
• Unguarded swing
radius • Not using / improper
outriggers pad
4
 Crane Hazards

Defective or damaged sheaves Damaged windows / poor visibility

Poor out rigger pad/unstable ground

Malfunctioning or missing boom angle indicator

5
 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 unload the materials or actual
place of erection.
6
 Competent Person
Is a person capable of
assessing and planning a lift,
selecting, inspecting, installing
the lifting equipment and
accessories, and completing
the necessary documentation.

He should have the necessary

practical and theoretical
knowledge and experience of
the equipment to be used to
enable him to detect defects,
weaknesses or anomalies that Broken
might jeopardise safe lifting Track
operations.
7
 Crane and its Operator
•All crane must be certified by the 3 rd
Party in
annual basis
•Operators must hold a current valid certificate to
operate the assigned equipment
•Crane operator shall be tested for competency by
client or Government representative
•Crane operator manual in English must be made
available in operators cabin
•All cranes must be fitted with anti two block
device

8
 Crane and its Operator
All operators must be trained and conversant with the
following;
1. The safe operation of the machine
2. Location and operation of all safety back up systems
3. Reading and understanding of the load chart
4. Capabilities of the machine in all unusual circumstances
5. Any peculiarities pertaining to the machine
6. No operator will be permitted to operate a machine for
which he is not trained (Except he is giving adequate
training on the machine)
7. Crane key should not be left by the operator whenever he
leave the crane cabin
8. Operator should not leave the crane with the still load
hanging or not yet fixed
9
 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
 Others as per Crane Check
List

10
 Damaged Wire Rope

Crushed Rope
Broken Strands

Damaged wire rope must be taken out of service

11
 Damaged Web Sling

Damaged web sling must be taken out of service

12
 Load Capacity-Speed-Warnings

 Crane manual should

always available in
Operators booth
 Make sure the crane
operator can see the:
– Rated Load Capacities
– Operating Speeds
– Special Hazard
Warning or Instruction
Load Rating Chart

13
 Load Moment Indicator
 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 and
minimum boom length – the
further from its centerpoint,
the less it will lift
14
 Load Limiting Factors
 Not level
 Wind
 Side loads
 On its wheels
 Lifting over the side
 Use of extensions, jibs and
other attachments
 Limits of wire rope, slings
and lifting devices

15
 Cranes Lifting Principles

 Center of Gravity
 Leverage
 Stability
 Structural
Integrity

16
 Load Example – 30 ton crane
 Will lift 30tons at 3m from the center pin of the
crane
 Based on level surface, no wind, and outriggers
fully extended
 At 7.5m from the center pin with a 25m boom
length, the capacity is only 6.8tons
 At 22.5m from the center pin, the capacity is
only 2tons

17
 Improper Slinging/computation of load

Improper Slinging / computation of load’s weight

or speeds can result in the tipping/tumbling of the crane
18
 Improper Slinging/computation of load

Improper Slinging / computation of load’s weight

or speeds can result in the tipping/tumbling of the crane
19
 Rigging
 No person will be employed as a rigger until successful
completion of the riggers training course
 Only persons qualified as riggers will directly supervise
or be engaged in rigging work
 Each rigger will be issued with a badge for identification
as a qualified rigger
 A rigger must act in a manner that does not endanger
himself or others at work
 A lifting plan must be in place for lift of 40 tons and
above, and all special and difficult lifts (high, long to
reach or two crane lifts)

20
 Lifting Plan
Lifting plan must include as a minimum;
 Position of item to be lifted and lifting equipment (Pick up and
set down)
 Weight and configuration of item to be lifted
 Radius of lift
 Calculated capacity of lifting equipment at all stages (Load chart
attached)
 Details of lifting equipment (shackles, lifting beams etc)
 Lifting restrictions
 Ground loads

21
 Rigging Requirements
 All sling or steel wire shall be
kept in good condition
 Damage wire rope or any lifting
gears must be discarded
immediately
 All rigging equipment must have
a valid test certificate
 All rigging gear must be
inspected and records of
inspections kept (Competent
person and color code)
22
 Quarterly Color Coding

JANUARY JULY
APRIL
AUGUST OCTOBER
FEBRUARY MAY
MARCH SEPTEMBER NOVEMBER
JUNE
DECEMBER

INSPECTION AND COLOR CODING SHALL BE

CONDUCTED BY RIGGING COMPETENT PERSON

23
 Hand Signal

An illustration of the
signals must be
posted at the job site.
This standard signal
shall be used by the
rigger and must be
clearly understood by
the crane operator

24
 Barricade Affected Area

Stay out of the swing radius of the crane

Make sure there are barrier guards showing swing radius
25
 Rigging and Slinging
Provide stable
footings for
outriggers

26
 Rigging and Slinging
Use “Tag Lines” on
ALL lifts

27
 Rigging and Slinging
Use “Choker Hitch”
on loose material

28
 Rigging and Slinging
Use “Dunnage” and
“Wedges” for stacking

29
 Rigging and Slinging

30
 Rigging and Slinging

31
 Rigging and Slinging
Secure the block to the
anchor point on the crane

Sheaves will
be damaged

32
 Rigging and Slinging
Sling angle must
be <90

Max.90
90O
MAX

33
 Rigging and Slinging
ALL hooks must have
safety latches

34
 Rigging and Slinging
Use softener to
protect the slings

35
 Rigging and Slinging

Use softeners on the load NOT to

the sling (otherwise damage
cannot be seen)

36
 Rigging and Slinging

Do NOT overcrowd a
hook – use a shackle

37
 Rigging and Slinging

Do NOT overcrowd a hook –

use a shackle
38
 Rigging and Slinging

Never stand under a load

39
 Rigging and Slinging
Demarcate
affected
lifting areas

40
 Rigging and Slinging

Ensure hook is above

load centre before lifting
41
 Rigging and Slinging
For container lifts, use
“Shackles” or “Container
slings”

42
 Rigging and Slinging
Required personnel
during Crane lifting:
-Crane Operator
-Rigger / Slinger
-Rigger /Signal man

43
 Rigging and Slinging

44
 Rigging and Slinging

IF IT TAKES MORE THAN

ONE MAN,
SOMETHING’S WRONG ! !

45
 Battening Down
It is sometimes imagined that
slings in choke hitch can be
made more secure by striking
the eye of a sling in an attempt
to force the bight into closer
contact with the load.
This dangerous
malpractice is often called
“battening down”.
The bight should be
allowed to assume its natural
angle which will be about 120° NATURAL ANGLE 120º

46
 Man Basket Operation
Permit must be obtained prior to any
Man Basket Operation and the
following conditions must be met;
•Only approved Man basket is to be
used for lifting personnel by a crane
•Crane must have positive drive up
and down
•Crane must be equipped with a
functional anti two block device
•Crane must not operate outside of a
radius that reduces the cranes
capacity by more than 50%
•All shackle pins must be well secured
•Additional sling must attach to the
headache ball as a lifeline
47
 Man Basket Operation
•The man-cage must not be
used to lift personnel and
material at the same time
•Only two persons are to be
lifted in the Man basket
•All personnel must wear full
body harness
•All signal must be given by a
qualified rigger identified by a
jacket
48
 Man Basket Operation
• Man-basket permit will be
valid only for one operation
• A trial lift will be first
conducted prior to actual man
basket operation
• Once basket is lifted
personnel are not allowed to
climb in or out of it

49
 Summary

An unstable load,
lack of
communication, lack
of training, and
inadequate
maintenance or
inspection are major
contributors to crane
accidents.

50
 Summary

• Operators or others working in the area can be victims

to “struck by" and "caught in" injuries.
• Contact with power lines causes many accidents.
• A competent person must inspect a crane regularly to
insure it is in proper order.
• Planning and training reduces accidents.

LIFT SAFELY AND LIVE HAPPY

51