Title: Mobile Cranes Operator Safety Training and Policy / Review Date: 12-15-2008
Mobile Cranes
- Policy:
1.1. Only designated personnel will be permitted to operate company cranes.
1.2. All new or used cranes shall be inspected prior to initial use.
1.3. The documentation shall include the date of the inspection, the signature of the person that is doing the inspection, and the identification of the equipment. This documentation shall be kept at the District/Area/Subsidiary/Project office on file. All controls for excessive wear and contamination.
1.4. Operator’s must meet the physical qualifications, pass a physical, a written examination, understand and be able to use a load chart as well as calculate loads for the crane type. Referenced ASME B30.5 5-3.1(a).
- Daily or Before Use Inspections:
2.1. Shall include the following and do not need to be documented.
2.2. All controls for adjustment and proper operation.
2.3. Any fluid or air leaks should be identified and repaired.
- Monthly inspections must be conducted and these inspections must be documented. A monthly inspection shall include the following:
3.1. All controls for excessive wear and contamination.
3.2. All safety devices for proper operation.
3.3. Crane hooks that are deformed or cracked. Cranes will be taken out of service if a hook has:
3.3.1. Cracks in the hook.
3.3.2. A hook with a throat opening greater than 15% of normal.
3.3.3. A hook with more than 10 degrees of twist.
- Item that must be taken out of service if:
4.1. Wire Rope
4.1.1. It has reeving that is in accordance with the manufacturer’s recommendations.
4.1.2. The diameter of the rope to determine wear and insure that the rope will handle the specified load.
4.1.3. A check for broken wires that may reduce the load capacity of the rope.
4.1.4. A check for severe kinking, crushing, cutting or un-stranding of the rope.
4.2. Electrical equipment for deterioration, dirt, moisture and proper operation.
4.3. Deformed, cracked or corroded members of the crane structure.
4.4. Loose bolts or rivets.
4.5. Cracked or worn sheaves or drums.
4.6. Worn, cracked or distorted parts such as pins, bearings, shafts, gears and locking devices.
4.7. Proper operation of brake and clutch systems.
4.8. Excessive wear on brake and clutch parts.
4.9. Load, boom angle and other indicators that are over full range for calibration and proper operation.
4.10. Crane power plants for proper operation.
4.11. Excessive wear on sprockets and chains.
4.12. Travel steering, breaking and locking devices for proper operation.
4.13. Excessively worn or damaged tires or tracks
- Operational Tests
5.1. Test shall be conducted daily or before use and shall include the following:
5.1.1. Load hoisting and lowering mechanisms.
5.1.2. Boom hoisting and lowering mechanisms.
5.1.3. Travel mechanisms.
5.1.4. Safety devices.
5.2. Documentation of the manufacturer certified crane tests shall be made available for inspection.
5.3. A thorough annual inspection of the hoisting machinery shall be made by a competent person, or by a government or private agency recognized by the U.S. Department of Labor. The employer shall maintain a record of results of inspection for each hoisting machine and piece of equipment. Referenced 1926.550(a)(6).
- Maintenance Procedures:
6.1 Before maintenance or repairs are started warning signs must be placed in a conspicuous place informing workers the crane is out of service.
6.1.1. A “Do No Operate” tag must be placed in clear view on the main cab access door, Ignition key slot, or steering wheel or operation controls anytime service work can be preformed.
6.2. All guards shall be reinstalled.
6.3. Safety devices shall be activated.
6.4. All tools and service equipment shall be removed from the crane.
6.5. Maximum load ratings for stability determination.
6.5.1. The following load ratings shall not be exceeded:
6.5.1.1. Crawler crane without outriggers 75%
6.5.1.2. Crawler crane with outriggers 85%
6.5.1.3. Truck and wheel mount cranes with outriggers 85%
6.5.2. These ratings will be established by taking a percentage of the load that will produce a tipping condition with the boom in the least stable direction.
6.6. A load-rating chart that is legible shall be securely mounted to the crane cab in a location that is visible to the operator.
6.7. Modifications or additions, which affect the safe operation of equipment, may only be made with the manufacturer’s written approval. Referenced 1926.550(a)(16)
7. Handling the load.
7.2. No crane shall be loaded beyond its rated capacity except for tests performed by a competent manufacturer representative.
7.3. The hoist rope shall not be used as a sling.
7.4. The crane shall be level and blocked before the load is lifted
7.5. The load shall be secured and balanced before the load is lifted more than a few inches.
7.6. Before lifting the load the should be noted:
7.6.1. The hoist rope is not kinked.
7.6.2. Multiple part lines are not twisted.
7.7. While lifting the load, insure that:
7.7.1. There is no sudden acceleration or deceleration.
7.7.2. The load does not contact any obstructions.
7.7.3. The load is not putting undo stress on the crane from side loading.
7.7.4. The load shall not be moved while anyone is on the hook or on the load.
7.7.5. Loads shall not be carried over personnel.
7.7.6. Loads shall not be lifted over the front area of truck-mounted cranes except as noted by the manufacturer.
7.7.7. Cranes shall not be operated without counterweight as specified by the manufacturer. Truck Cranes can be operated for light loads without full counterweight if special care is exercised.
7.7.8. Cabs shall be free of unnecessary clothing and personnel belongings. Tools, oil cans and other necessary articles shall be stored in the toolbox and not permitted to lie loose in the cab.
7.7.9. Machines shall not be left running while being fueled. All portable cans used for fueling shall be UL listed containers that are equipped with an automatic closing cap and a flame arrester.
7.7.10. All cranes shall be equipped with a fire extinguisher and all operating and maintenance personnel shall be familiar with the operation of the fire extinguisher.
7.7.11. Hand signals to crane operators shall be those prescribed by the applicable ANSI standard for the type of crane in use. An illustration of the signals shall be posted on the job site. Referenced 1926.550(a)(4).
7.7.12. All crawler and truck cranes in use shall meet the applicable requirements for design, inspection, construction, testing, maintenance, and operation as prescribed by ANSI B30.5-1968. Elkhorn Construction Inc. shall prepare a certification record which includes the date the crane items were inspected, the signature of the person who inspected the crane items, and a serial number, or identifier number for the crane inspected. Referenced 1926.550(b)(2).
7.8. The following distance must be maintained when operating a crane near a energized power line:
7.8.1. 10 ft. clearance for lines 50 kv or less.
7.8.2. An additional 0.4 in. for each 1 kv over 50 kv.
7.8.3. In transit boom clearance shall be 4 ft. at a minimum.
7.8.4. Before starting work near power lines, the owner of the system must be notified.
7.8.5. Any overhead power lines must be considered live until the owner of the system indicates that it is not an energized line.
8. Reference: OSHA 1910.180
Written & Performance Test For Mobile Crane Operators
Employee:______Date:______Time:______oam opm.
True or False (Must get a minimum of 12 questions correct)
o o 1. It is not always necessary to take the time to extend and place outriggers.
o o 2. An Anti-Two-Block device is not really needed for the crane to work properly.
o o 3. The outriggers can compensate for setting up on uneven ground provided the crane is setting level for the lift.
o o 4. Wire Rope that shows wear and a few breaks must be replaced before making a lift.
o o 5. An Operator must fully understand the specific charts and warning placards/stickers placed on the crane before operating the crane.
o o 6. It is ok to run the wire rope on any drum out as far as you want as long as there is at least one rap of rope left on the drum.
o o 7. If you find something wrong with a crane during the Daily Inspection you should document it on the Daily Inspection Report and then report the problem to your supervisor immediately.
o o 8. Operators shall read and understand the operator’s manual because it contains information the Operator needs to operate the crane safely.
o o 9. All cranes are built with counter weights to withstand and counteract wind conditions so they are not a consideration in moving loads and parking the crane.
o o 10. Common hazards on the construction site include, pedestrians, overhead power lines and uneven grade and changing surface conditions.
o o 11. As long as you are at least a couple of feet from overhead power line you will be ok.
o o 12. When picking a load you should use spotters that have visual contact with the load and use approved hand signals.
o o 13. A small light load can be moved quickly to it’s new position.
o o 14. Tag lines are always required when lifting any load.
o o 15. It is ok for you or a fellow worker to get under a raised load, to make adjustments, make sure there are no problems or to measure it to see if it will fit the storage area.
Mobile Crane Operator’s Written Test Key
True or False (Must get a minimum of 12 questions correct)
o ý 1. It is not always necessary to take the time to extend and place outriggers.
o ý 2. An Anti-Two-Block device is not really needed for the crane to work properly.
ý o 3. The outriggers can compensate for setting up on uneven ground provided the crane is setting level for the lift.
ý o 4. Wire Rope that shows wear and a few breaks must be replaced before making a lift.
ý o 5. An Operator must fully understand the specific charts and warning placards/stickers placed on the crane before operating the crane.
o ý 6. It is ok to run the wire rope on any drum out as far as you want as long as there is at least one rap of rope left on the drum.
ý o 7. If you find something wrong with a crane during the Daily Inspection you should document it on the Daily Inspection Report and then report the problem to your supervisor immediately.
ý o 8. Operators shall read and understand the operator’s manual because it contains information the Operator needs to operate the crane safely.
o ý 9. All cranes are built with counter weights to withstand and counteract wind conditions so they are not a consideration in moving loads and parking the crane.
ý o 10. Common hazards on the construction site include, pedestrians, overhead power lines and uneven grade and changing surface conditions.
o ý 11. As long as you are at least a couple of feet from overhead power line you will be ok.
ý o 12. When picking a load you should use spotters that have visual contact with the load and use approved hand signals.
o ý 13. A small light load can be moved quickly to it’s new position.
ý o 14. Tag lines are always required when lifting any load.
o ý 15. It is ok for you or a fellow worker to get under a raised load, to make adjustments, make sure there are no problems or to measure it to see if it will fit the storage area.
Mobile Crane Operators Performance Checklist
1 o Completed training and written testing.
2 o Operator has the Physical capabilities and/or Physician Releases (as required).
3 o The knowledge and understanding of the specific Crane Operation’s Manual.
4 o Perform and Document a Daily Inspection on the Daily Inspection Report (3E-0095).
5 o Knows how to determine safe load capacities at boom various angles. (Load Charts...etc.)
6 o The knowledge of the crane’s capabilities and capacity.
7 o The ability to read and understand gauges.
8 o The ability to recognize mechanical discrepancies and problems of crane.
9 o The knowledge of Safe Operating Practices and Elkhorn’s Procedures (3E-0000).
10 o The knowledge of electrical service conductors, safety requirements.
11 o Hands-on demonstration of ability to perform all functions of the crane.
12 o Shows familiarity with the crane controls and refueling procedures.
13 o Gave proper signals and or communication when turning.
14 o Slowed down at intersections.
15 o Sounded horn at intersections.
16 o Obeyed signs.
17 o Kept a clear view of direction of travel.
18 o Turned corners correctly — was aware of rear end swing.
19 o Yielded to pedestrians and or fellow workers.
20 o Drove under control and within proper traffic lanes.
21 o Planned load property.( Load Lift Permit/ checklist as required)
22 o Outriggers extended and placed properly.
23 o Outrigger Pads utilized.
24 o Only lifted properly rigged loads (Tag Lines).
25 o Understood and responded to proper hand signal
26 o Approached load property.
27 o Lifted load property.
28 o Maneuvered/Swung load smoothly/slowly. (Utilized Spotter)
29 o Lowered load smoothly/slowly.
30 o Stops smoothly/completely.
31 o Load balanced property.
32 o Did place loads within marked area.
33 o Did place controls in locked position, set brake, turned power off.
34 o Followed proper instructions for maintenance.
o Pass o Fail Evaluator______
Employee Name: ______Date:______
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