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1 OVERHEAD CRANE OPERATOR SAFETY TRAINING OVERHEAD CRANE OPERATOR SAFETY TRAINING

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Page 1: Overhead Crane Safety Training - oshacampus.com · 1 overhead crane operator safety training overhead crane operator safety training

1

OVERHEAD CRANEOPERATOR

SAFETY TRAINING

OVERHEAD CRANEOPERATOR

SAFETY TRAINING

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TYPES OF OVERHEAD CRANESTYPES OF OVERHEAD CRANESTYPES OF OVERHEAD CRANES

Floor Mounted Jib

Bridge Crane

Wall Mounted JibMonorail Crane

Here is an assortment of overhead cranes.

Take pictures of the different types you may have at your facility and put them on this page. You may also replace other pictures and drawings in this presentation. To do so:

1. Download a picture from a digital camera or scan a picture onto your computer.

2. Click on the “insert’ button on the toolbar above and select picture>from file and then go to where the picture is stored on your computer. Click on that file and it is inserted on the current slide.

3. You may crop it, downsize it, add borders and lighter or darken it. It’s easy and adds immensely to the presentation.

4. You may also create a hyperlink from a smaller picture to a picture that takes up the whole slide to see the details better. To do this, a) right click on the picture, left click on ‘action settings’, select ‘hyperlinks, and then scroll down to the slide where the full size picture is. A good place for it is at the end of the slide show. Be sure to create a hyperlink back the the original slide to ease in navigating back and forth between slides.

5. Many of the pictures in this presentation have hyperlinks to a full size picture at the end of the presentation. Once you have created a hyperlink, it will stay with that slide no matter what order you put the slides in.

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OVERHEAD CRANE REGULATIONSOVERHEAD CRANE REGULATIONS

• 29 CFR 1910.179 Overhead cranes and gantries

• 29 CFR 1926.554 Overhead hoists

• ASME B30.2 Overhead and gantry cranes (Top running bridge, single or multiple girder, toprunning trolley hoist)

• ASME B30.11 Monorails and underhung cranes

• ASME B30.16 Overhead hoists (underhung)

• ASME B30.17 Overhead and gantry cranes (Toprunning bridge, single girder, underhung hoist)

These are the main standards concerning overhead cranes but certainly not all of them. Many States have additional standards as do some industries such as Maritime, Mining, Offshore oil platforms, etc.

We have included only the two OSHA standards and the B30.16. This is because the are almost identical when it comes to operation and inspections.

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TYPES OF INSPECTIONTYPES OF INSPECTION

FREQUENT: Frequent inspections are visual inspections andexaminations by the operator or other designated personnel. Records are not required. Inspection intervals are:

• Daily to monthly

PERIODIC: Periodic inspections are visual and audio inspections andexaminations by designated personnel making records of externalconditions to provide the basis for continuing evaluation.

• 1 to 12 month intervals

29 CFR-1910.179(j)(1)(ii)

Inspection procedure for cranes in regular service is divided into two general classifications based upon the intervals at which inspection should be performed. The intervals in turn are dependent upon the nature of the critical components of the crane and the degree of their exposure to wear, deterioration, or malfunction. The two general classifications are herein designated as "frequent" and "periodic" with respective intervals between inspections as defined below:1910.179(j)(1)(ii)(a)

Frequent inspection - Daily to monthly intervals.1910.179(j)(1)(ii)(b)

Periodic inspection - 1 to 12-month intervals.

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DEFINITIONS OF SERVICEDEFINITIONS OF SERVICE

Normal Service: Involves operations of the crane with randomlydistributed load within the rated load limit or uniform loads ofless than 65% or rated load limit for no more than 25% of the timefor a normal work shift.

Heavy Service: Involves operation of the crane within the rated loadlimit that exceeds normal service.

Severe Service: Involves operation of the crane in normal or heavyservice with abnormal operating conditions.

1. Some cranes are used more than others. 2. The frequency of service is a key factor in determining how often the crane

should be inspected and serviced. 3. Even cranes that are not used need to be inspected, lubricated and maintained.

Especially cranes that are out in the weather all year or in corrosive environments.

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MONTH ___________________Date Completed:_______ Inspected by: ___________INSPECTION AREA INSPECTION RESULTS

Sat. Unsat. N/A CommentsSupporting Structure

WeldsBolts

BridgeRails & AlignmentTrucks & WheelsMotor & Drive TrainBrakesStops & Limit Controls

TrolleyWheelsMotor & Drive TrainBrakesStops & Limit ControlsRails & Alignment

HoistWire Rope ConditionRope ReevingChain ConditionBrakes & RatchetsEqualizer SheavesHoist Limit ControlFunctional Operation

ElectricalControl MarkingsControl FunctionsWarning AlarmsPower DisconnectControl PendantsFestoons

Load BlockSheavesPinsSwivelHook

INSPECTION CHECK LISTINSPECTION CHECK LIST

1. This is a sample of the inspection booklet found on your CD. You can print one out for every crane. There are two versions, this one, and one that has check boxes at the bottom of the page for the operator to initial that he has performed a pre-shift inspection.

2. This is a good time to go out to one of the cranes in your facility and do an inspection of it.

3. Pre-shift inspections do not have to be lengthy. You are basically looking for obvious things that might be wrong with the crane.

4. Monthly or yearly inspections, of course, should be thorough and performed by a competent individual.

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SUPPORTING STRUCTURESUPPORTING STRUCTURE

Note The AccumulationOf Dirt And/or Paint

CHECKING FOR TIGHTNESS

Cracks In Paint Or Dirt Build-upOften Is Caused By Loose Bolts.

1. Check all fasteners for loose, stretched, missing, or broken fasteners.2. A good clue is checking for cracked paint around the fastener that shows there

has been movement.3. Sometimes a build up of dirt or grease can do the same thing.4. Using a torque wrench to check for tightness does not always work.

Corrosion could give you a false reading.5. Replace a loose or stretched bolt rather than tighten it. It probably has been

damaged.6. Be sure to replace the bolt with a grade 8 or better.7. If there are other bolts near by that show signs of looseness, then replace them

all.

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Inspect Welds For Cracks

CRACKED WELDSCRACKED WELDS

1. Check cracks in the structure and in all welds.2. A crack in a weld will always start on the end and work itself along the entire

weld until it fails completely.3. Many times a crack in the paint will be a clue to a weld that is failing.4. If caught early, the crack many times can be ground out and re-weld.5. 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.

6. Also, try to determine why it cracked in the first place. Is the crane being overloaded or used improperly.

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BRIDGE SYSTEMBRIDGE SYSTEM

SupportSystem

BridgeRails

SpanStructure

BridgeTrucks

Bridge Drive

Power Panel

1. Climbing up a and checking the bridge system is normally not part of the daily inspection. Use these slides to familiarize the student with the components of the bridge crane and how they work together to make a successful lift.

2. Many of these components can be inspected from the ground as the crane is being operated. If something seems wrong, then a closer look would be warranted.

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BRIDGE TRUCK DRIVEBRIDGE TRUCK DRIVE

DriveMotor

MotorBrake

FinalDriveShaft

DriveWheels

1. Climbing up a and checking the bridge system is normally not part of the daily inspection. Use these slides to familiarize the student with the components of the bridge crane and how they work together to make a successful lift.

2. Many of these components can be inspected from the ground as the crane is being operated. If something seems wrong, then a closer look would be warranted.

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DRIVE COUPLINGSDRIVE COUPLINGS

Check Couplings for:• Loose bolts• Loose or missing keys• Cracks

1. Climbing up a and checking the bridge system is normally not part of the daily inspection. Use these slides to familiarize the student with the components of the bridge crane and how they work together to make a successful lift.

2. Many of these components can be inspected from the ground as the crane is being operated. If something seems wrong, then a closer look would be warranted.

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DRIVE MOTOR BRAKEDRIVE MOTOR BRAKE

BrakeSolenoid

BrakeDrum

BrakeShoes

1. Climbing up a and checking the bridge system is normally not part of the daily inspection. Use these slides to familiarize the student with the components of the bridge crane and how they work together to make a successful lift.

2. Many of these components can be inspected from the ground as the crane is being operated. If something seems wrong, then a closer look would be warranted.

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WHEELTREADWEAR AT AN

ANGLE

WHEEL FLANGEWEAR

WHEEL ALIGNMENT FOR BRIDGE CRANEWHEEL ALIGNMENT FOR BRIDGE CRANE

HEAVY WEAR

1. Climbing up a and checking the bridge system is normally not part of the daily inspection. Use these slides to familiarize the student with the components of the bridge crane and how they work together to make a successful lift.

2. Many of these components can be inspected from the ground as the crane is being operated. If something seems wrong, then a closer look would be warranted.

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TROLLEY SYSTEMTROLLEY SYSTEM

Hoist Machinerymounted on trolleyTrolley Trucks

1. Climbing up a and checking the bridge system is normally not part of the daily inspection. Use these slides to familiarize the student with the components of the bridge crane and how they work together to make a successful lift.

2. Many of these components can be inspected from the ground as the crane is being operated. If something seems wrong, then a closer look would be warranted.

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MONORAIL CRANE TROLLEYMONORAIL CRANE TROLLEY

TROLLEY WHEELSFUNCTION SMOOTHLY

TROLLEY WHEELSCENTERED ON

BEAM

WHEELS INGOOD CONTACT

WITH BEAM FLANGE

1. Climbing up a and checking the monorail system is normally not part of the daily inspection. Use these slides to familiarize the student with the components of the bridge crane and how they work together to make a successful lift.

2. Many of these components can be inspected from the ground as the crane is being operated. If something seems wrong, then a closer look would be warranted.

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WIRESTRAND

WIRE ROPE

WIRE ROPE CONSTRUCTIONWIRE ROPE CONSTRUCTION

PROPER WAY TO MEASUREWIRE ROPE DIAMETER

Wire Rope Replacement

Broken Wires: 6 randomly distributedbroken wires in one lay, or three brokenwires in one strand in one lay.

Loss in Diameter: Reduction from nominal diameter of:1/64” for dia. up to & including 5/16”1/32” for dia. 3/8” to & including 1/2”3/64” for dia. 9/16” to & including 3/4”

1. Wire rope comes in various sizes and construction. The most common is the right regular lay wire rope of the 6X19 class.2. The strands of a wire rope are made up of several wires twisted together.3. Several strands are twisted together to form the wire rope.4. Common wire rope will have either a fiber core or an independent wire rope core or IWRC. For lifting purposes, IWRC is recommended because it resist crushing.5. The designation, 6X19, refers to the basic construction. The ‘6’ stands for the number of strands, not counting the core, that are used in the rope. The ‘19’ refers to the number of wire in each strand.6. When measuring the diameter of wire rope, make sure to measure across the stands and not the flat area between the strands.

29 CFR 1910.176(h)(2)(i)

In using hoisting ropes, the crane manufacturer's recommendation shall be followed. The rated load divided by the number of parts of rope shall not exceed 20 percent of the nominal breaking strength of the rope. (or a 5:1 safety ratio)

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ABRASION RESISTANCEIncreases with larger wires

Decreases with smaller wires

FATIGUE RESISTANCEDecreases with fewer wiresIncreases with more wires

WIRE ROPEWIRE ROPE

STANDARDS FOR SHEAVE& DRUM RATIOS

D = Diameter of drum or sheaved = Diameter of wire ropeRatio = D / d

ASNE/B30.5 “MOBILE CRANES”Minimum Ratios

Drum SheaveLoad Hoist 18 18Boom Hoist 15 15Load Block 16

1. Point out the trade-offs between abrasion and fatigue resistance.2. Show how sheave size and wire rope diameter relate to each other and the effects they have on wire rope life.3. Review how sheaves are dimensioned.

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WIRE ROPE INSPECTIONWIRE ROPE INSPECTION

Crossed lines on drum

Heavy loads over small sheaves

Accentuated with heavy loads

Improper socketing, kinks

Sudden tension release

Repeated bending, normal loads

KINKED WIRE ROPE

STRAND KNICKING

FATIGUE FAILURE

HIGH STRAND

BIRDCAGE

FATIGUE BREAKS

29 CFR – 1910.179(m)(1) Running ropes. A thorough inspection of all ropes shall be made at least once a month and a certification record which includes the date of inspection, the signature of the person who performed the inspection and an identifier for the ropes which were inspected shall be kept on file where readily available to appointed personnel. Any deterioration, resulting in appreciable loss of original strength, shall be carefully observed and determination made as to whether further use of the rope would constitute a safety hazard. Some of the conditions that could result in an appreciable loss of strength are the following:(i) Reduction of rope diameter below nominal diameter due to loss of core support, internal or external corrosion, or wear of outside wires.(ii) A number of broken outside wires and the degree of distribution or concentration of such broken wires.(iii) Worn outside wires.(iv) Corroded or broken wires at end connections.(v) Corroded, cracked, bent, worn, or improperly applied end connections.(vi) Severe kinking, crushing, cutting, or unstranding.

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DRUM INSPECTIONDRUM INSPECTION

1. Check to make sure the wire rope is spooled properly on the drum.2. On lagged drums, make sure the rope hasn’t jumped a groove which could

damage the rope.3. Check to make sure the dead end is secured properly.4. Never hoist down to the point that there would be less than 2 wraps left on the

drum.5. Check oil often.

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HOIST MACHINERYHOIST MACHINERY

CHECK DRUM GROOVES FOR

WEAR

HOISTDRIVE

TROLLEYTRUCK

1. Check to make sure the wire rope is spooled properly on the drum.2. On lagged drums, make sure the rope hasn’t jumped a groove which could

damage the rope.3. Check to make sure the dead end is secured properly.4. Never hoist down to the point that there would be less than 2 wraps left on the

drum.5. Check oil often.

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HOIST MACHINERYHOIST MACHINERY

SINGLE REEVED DRUM DOUBLE REEVED DRUM

VERIFYFUNCTIONINGLIMIT SWITCH

CHECKRUNNINGSHEAVE

FOR WEAR

CHECKEQUALIZING

SHEAVEFOR WEAR

CHECKCLEVISWEAR

1. Check running and equalizing sheaves for wear and free movement.2. Check the limit switch to make sure it stops the hook or load if two-blocked.3. Check the oil often, especially if you detect any leakage.

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WORN GROVES PROPER SIZE GROVE

CHECK FLANGES FORCHIPS, CRACKS, WEAR

CHECK BEARINGS FORWOBBLE, GREASE, EASEOF ROTATION

MEASURE GROOVE

INSPECTING SHEAVESINSPECTING SHEAVES

CHECK GROOVE WEAR

150ºCONTACT

1. Check for bearing wear and lubrication.2. Check the flanges and treads.3. Show how to use a sheave gauge.4. Sheaves can only be repaired per manufacture’s procedures.

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CHAIN HOISTCHAIN HOIST

Bent Links Stretched Links Worn Links

ChainGuide

PocketWheel

The chain hoist should be checked for the following:

1. Bent links (Usually a sign that it has been used to wrap around a load and bent on sharp corners)

2. Stretched links. The links will be sucked in slightly on the sides. Also, measure 5 links and check that measurement during your annual inspection.

3. Chain should not be rusted or brown. If the crane is in a corrosive atmosphere, be sure to oil it often.

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HOOK INSPECTIONHOOK INSPECTION

Wear & Deformation

“Opening Up”

Wear & Cracks

Cracks & Twisting

[ Wear[ Deformation[ Cracks & Sharp Nicks[ Modifications[ Safety Latches[ Swivel Wear & Lubrication[ Hook Shackle Mousing

CHECK FOR:

1. Hooks with threads and nuts need to have threads inspected periodically.2. Hooks can only be repaired per manufacturer’s procedures.3. 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.4. An increase in the hook throat opening of more than 15% is cause for removal.5. Any twist in the hook of more than 10% is cause for removal.6. The hook safety latch should be present and function properly.

Accident 014504732 - Employee Killed When Struck By Loose Crane Hook At approximately 8:15 am on January 29, 1990, employee #1 was working on a

large steel panel weighing approximately 2,608 pounds and measuring 22 feet long and 6 feet wide. The panel was supported by an overhead crane chain and hook and was set on metal horses at an angle. The hook slipped off of the steel panel and struck employee #1 on the head, resulting in his death.

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HOOK INSPECTIONHOOK INSPECTION

10o

ThroatOpening

TwistedHook

15%10 percentMaximumAllowableWear

1. Hooks with threads and nuts need to have threads inspected periodically.2. Hooks can only be repaired per manufacturer’s procedures.3. 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.4. An increase in the hook throat opening of more than 15% is cause for removal.5. Any twist in the hook of more than 10% is cause for removal.6. The hook safety latch should be present and function properly.

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CRANE BLOCKCRANE BLOCK

SIDE PLATEBOLTS TIGHT

SHEAVE PIN& BEARING

TIGHT

SAFETYLATCH

FUNCTIONING

CHECK FOR DISTORTIONSOR WEAR

SHEAVE GROOVENOT WORN, SHEAVES

TURN FREELY

HOOK NUT TIGHT

& THEADS INSPECTED

PERIODICALLY

HOOK ROTATION &SWIVEL SMOOTH &

TIGHT

SHEAVE PINKEEPER IN PLACE

AND TIGHT

1. The sheaves and bearings need to be inspected as discussed earlier.2. The side plates and any additional weights attached to the their sides need to be

inspected for loose or missing bolts or other fasteners.3. The hook should rotate freely on the swivel bearing. Check for excessive

movement.4. The hook shank and nut should be separated periodically and the threads

inspected for corrosion and other damage. The lose of more than 20% of the treaded area due to corrosion is cause for removal.

5. The safety latch must be in place and functioning properly.

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ELECTRICAL CONDUCTORSELECTRICAL CONDUCTORS

Current Collectorsride on this surface

Check Conductors for:• Loose fasteners• Burned surfaces• Dirt and corrosion• Electrical connections

Always lock out the crane before working around the electrical conductors.

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CURRENT COLLECTORSCURRENT COLLECTORS

Current Collectors rideagainst conductors

Electrical Conductors

Check Collectors for:• Good spring tension• Collector surfaces are

not corroded or burned• Electrical connections• Ease of movement

Always lock out the crane before working around the electrical conductors.

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FESTOON SYSTEMSFESTOON SYSTEMS

CABLE TERMINATION

INSULATORSIN GOOD

CONDITION

PROPERCABLE

TENTION

FREE TROLLEYMOVEMENT

ELECTRICALCONNECTORS

TIGHT

STRAIN RELIEFADJUSTED FOR

CORRECTLENGTH

1. Festoons need to be checked for proper cable tension, free trolley movement and wire connections.

2. Also, make sure there are no pinch points during bridge or trolley movement.

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PENDANT AND CONTROLSPENDANT AND CONTROLS

ALL CONTROLFUNCTIONSCLEARLY LABELED

1. Many times the pendant controls get dropped or banged up during operation.2. Never use the pendant to pull the crane around.3. Use a strain relief chain or cable to protect the wires from pulling out.4. Make sure all controls are marked and legible.5. Check for buttons that are broken or stick.6. Always check the emergency stop button on the pendant.

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MAX. SWL 10,000 lbs

ACME5 TONACME

5 TON

MAX. SWL 10,000 lbs

Know the SWL of the crane and never exceed it

Follow all placards, warning labels and signs on machine

SAFE CRANE OPERATIONS SAFE CRANE OPERATIONS

1. The safe-working-load of the crane should be easily visible to the operator.2. 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 ½ tons, the SWL of the crane could not exceed 5 tons and if stenciled on the beam, it should reflect the 5 ton rating.

3. All warning labels on the crane including crane operation instructions must be on the crane and legible.

29 CFR 1910.179(b)(5) Rated load marking. The rated load of the crane shall be plainly marked on each side of the crane, and if the crane has more than one hoisting unit, each hoist shall have its rated load marked on it or its load block and this marking shall be clearly legible from the ground or floor.

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LOCK-OUT TAG-OUT LOCKLOCK--OUT TAGOUT TAG--OUT OUT

DANGER

DO NOTOPERATE

ALWAYS DE-ENERGIZE ELECTRICALSYSTEMS BEFORE INSPECTING ANDWORKING ON THEM.

Before adjustments and repairs are started on a crane the following precautions shall be taken:29 CFR - 1910.179(l)(2)(i)(a) 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.(b) All controllers shall be at the off position.(c) The main or emergency switch shall be open and locked in the open position.(d) 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.(e) 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.1910.179(l)(2)(ii) 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.

1. The emergency shut off musts be visible and accessible.

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SAFE CRANE OPERATIONS SAFE CRANE OPERATIONS

Acme Bridge CraneOperation andMaintenance

Manual

ACME CORPORATION

Read and understand the operators manual

The Operator and Maintenance Manual should be available and every person that operates the crane should have read the safe operations section.

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Determine the weight of the load from accurate sources

Acceptable methods of determining weight

You may find the weight from:

Data on manufacturing label plates.

Manufacturer documentation.

Blueprints or drawings.

Shipping receipts.

Weigh the item.

Bill of lading (be careful)

Stamped or written on the load

Approved calculations

Never use word of mouth to establish the weight of and item!

SAFE CRANE OPERATIONS SAFE CRANE OPERATIONS

1. Knowing the weight of the load is essential to safe overhead crane operations. With mobile cranes, picking up a load that is too heavy could cause the crane to tip. Not so with overhead cranes. Severe damage could result in trying to lift a load that exceeds the SWL.

2. There are many ways to learn the weight of a load. The most accurate is, of course, weighing it yourself.

3. If you do weigh an item, be sure to mark the weight somewhere on the load for the next guy that has to lift it.

4. There will be times when you just have to make an a guess. Using the best calculations that you can, come up with an estimate and then double it. It it is well within the capacity of the crane, go ahead and make the lift. If by doubling it, it is within 75% of the capacity of the crane, then you should weigh it.

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Cranes shall not be used for side pulls except when specifically authorized by a responsible person who has determined that the stability of the crane is not thereby endangered and that various parts of the crane will not be overstressed.

SAFE CRANE OPERATIONS SAFE CRANE OPERATIONS MAX. SWL 10,000 lbs MAX. SWL 10,000 lbs

ACME5 TON

5TON

29 CFR - 1910.179(n)(3)(iv)

Cranes shall not be used for side pulls except when specifically authorized by a responsible person who has determined that the stability of the crane is not thereby endangered and that various parts of the crane will not be overstressed.

1. Side pulling on a crane may cause the wire rope on the drum to cross and be susceptible to kinks and crushing.

2. It could also put stress on the trolley causing damage.

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MAX. SWL 10,000 lbs MAX. SWL 10,000 lbs ACME5 TON

5TON

Never hoist a load over the heads of employees

SAFE CRANE OPERATIONS SAFE CRANE OPERATIONS

29 CFR – 1910.179(n)(3)(vi)The employer shall require that the operator avoid carrying loads over people.

1. Never allow a rigger to stand under a load as it descends for the purpose of controlling it.

2. Use a tag line instead.

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MAX. SWL 10,000 lbs MAX. SWL 10,000 lbs ACME5 TON

5TON

SAFE CRANE OPERATIONS SAFE CRANE OPERATIONS

The employer shall insure that the operator does not leave his position at the controls while the load is suspended.

29 CFR – 1910.179(n)(3)(x)The employer shall insure that the operator does not leave his position at the

controls while the load is suspended.

1. Always put the load down and secure it before leaving the area.

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The operator shall test the brakes each time a load approaching the rated load is handled. The brakes shall be tested by raising the load a few inches and applying the brakes.

MAX. SWL 10,000 lbs

ACME5 TONACME

5 TON

MAX. SWL 10,000 lbs

SAFE CRANE OPERATIONS SAFE CRANE OPERATIONS

8,750 lbs

29 CFR - 1910.179(n)(3)(vii)

The operator shall test the brakes each time a load approaching the rated load is handled. The brakes shall be tested by raising the load a few inches and applying the brakes.

1. As brakes become worn, they may stop a smaller load, but not one at or near capacity.

2. It is good practice to load test your crane at least every 3-4 years.

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SAFE CRANE OPERATIONS SAFE CRANE OPERATIONS MAX. SWL 10,000 lbs MAX. SWL 10,000 lbs

ACME5 TON

5TON

The load shall not be lowered below the point where less than two full wraps of rope remain on the hoisting drum.

29 CFR - 1910.179(n)(3)(viii)

The load shall not be lowered below the point where less than two full wraps of rope remain on the hoisting drum.

1. You never want to run out of hoist line. Many cranes have automatic stops that can be set so this will not happen. Still it is good practice to check you line when lowering loads down close to the limit of your line.

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At the beginning of each operator's shift, the upper limit switch of each hoist shall be tried out under no load.

SAFE CRANE OPERATIONS SAFE CRANE OPERATIONS

29 CFR - 1910.179(n)(4)(i)

At the beginning of each operator's shift, the upper limit switch of each hoist shall be tried out under no load. Extreme care shall be exercised; the block shall be "inched" into the limit or run in at slow speed. If the switch does not operate properly, the appointed person shall be immediately notified.

1. The upper limit switch will keep the load or hook from being pulled into to hoist, possibly parting the line.

2. Never use the limit switch to operate lower your load.

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SAFE CRANE OPERATIONS SAFE CRANE OPERATIONS

• Read and understand the operators manual• Follow all placards, warning labels and signs on machine• Know the SWL of the crane and never exceed it• Determine the weight of the load from accurate sources• If an estimate of the load is near the max. capacity of the crane,

then use a dynamometer to measure the exact weight• Use a loud signal, such as a whistle, horn or bell or verbal

warning to alert employees of crane movement• Never hoist a load over the heads of employees• Never use limit switches or end stops as operating controls• Begin each shift by testing the upper limit switches• Avoid running the crane into the end stops or limit switches• Never walk backward when guiding a load

Summary of safe crane operations

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SAFE CRANE OPERATIONS SAFE CRANE OPERATIONS • 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• Never electrical load and/or hoist-limit switches or warning devices• Start lifts slowly and avoid shock loading • Always place the hook directly over the center of gravity or the designated lifting point• Use taglines to help maneuver the load• Never use taglines to swing the load• Before hoisting the load, check for loose parts that might shift or fall• On cranes with wire rope hoist lines, there should never be less than two wraps on lagged (grooved) drums and three wraps on unlagged• When lifting near or at capacity, test the brakes after the load is raised a few inches• Suspend and transport loads at a level that allows the operator a clear view• Never drag slings, cables or chains across the floor

Summary of safe crane operations

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SAFE CRANE OPERATIONS SAFE CRANE OPERATIONS Cab-operated overhead cranes:

• Enter and exit cab only through approved access ways• Never walk along runway tracks• Never climb or jump from one crane to another• Use both hands to climb access ladder• Keep unnecessary items out of the cab• 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• Never move the cab without a signal from the designated signal giver• Avoid bumping crane and carriage stop blocks• If a power failure occurs, place all controls in the OFF position• Park the cab in an approved, designated position

Summary of safe crane operations

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HAND SIGNALSHAND SIGNALS

Multiple Trolleys Bridge Direction Trolley Direction Move Slowly

Emergency StopStopRaise LoadLower Load

1. Hand signal charts should be posted in the work area.2. Always have one person designated as the signal giver.3. Use clear precise motions.4. Review each hand signal and any other hand signals you might be using5. Anyone can give the emergency stop signal.

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WIRE ROPE SLING INSPECTIONWIRE ROPE SLING INSPECTION

1. Wire rope slings are to be inspected on a regular basis and a record kept of these inspections. Refer to the inspection card for inspection criteria.2. As of July 2000 wire rope slings are to have a tag which indicates the lifting capacities of the sling for vertical, choker, and basket hitches.

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COMMON CAUSE FOR REMOVALCOMMON CAUSE FOR REMOVAL

Severe wear, abrasion or scraping

Kinking

1. Kinking in the eyes and other parts of the wire rope sling is nearly always the result of it going around a pin or pick point that is of a less diameter than the rope itself.

2. Using slings with thimbles in the eye will prevent this.3. It is not recommended using a wire rope sling in a tight choker.

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FLEMISH EYEFLEMISH EYE

Separate rope into 2 part,3 adjacent strands and 3adjacent strands and core.These 2 parts are re-laidback in opposite directionsto form an eye and the endsare secured with a pressedsteel sleeve.

1. The Flemish eye is also know as a “Molly Hogan” or a “Farmers” eye.2. The strength of the eye is in the wrap and not the steel sleeve.3. They may be used with a thimble also.

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PRESSED STEEL SLEEVE

TURNBACK EYETURNBACK EYE

1. Turnback eyes are made by bring the rope back onto itself and crushing a steel sleeve around it.

2. The strength of the eye is in the sleeve and if not done properly may pull out.3. Turnback eyes are not recommended for lifting.

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TYPES OF TERMINATIONSTYPES OF TERMINATIONS

1. Wedge sockets are very handy if you are changing blocks or hooks often.2. Slings should not be used that have eyes made with wire rope clips.3. Eyes made with wire rope clips may be used to terminate the dead end of the

hoist line.

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CHAIN SLING INSPECTIONCHAIN SLING INSPECTION

1. Chain slings are to be inspected on a regular basis and a record kept of these inspections. Refer to the inspection card for inspection criteria.2. Chain slings are often used to hold steel while it is being welded. Always check to make sure no heat damage has occurred. Heat damage can be detected by discolored metal.

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SYNTHETIC SLING INSPECTIONSYNTHETIC SLING INSPECTION

1. This slide and the next two show the different types of sling damage that can occur. Refer to the inspection record of additional inspection criteria.

2. Synthetic slings are required to be inspected on a regular basis and a record kept of such inspections.

3. Never tie a knot in a flat sling to shorten it.4. Never use synthetic slings around high heat sources or hot work.5. When taking a sling out of service, cut the eyes in it or destroy it. If you don’t it

may find its way back into service.

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SYNTHETIC SLING INSPECTIONSYNTHETIC SLING INSPECTION

1. The manufacturer’s tag should be on the sling and contain the SWL.2. This tag must also be legible.3. Nylon slings are also susceptible to damage through ultra-violet light. Always

keep your slings out of the sun when not in use.4. Wet nylon slings can be used but lose 15% of their strength.

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SHACKLESSHACKLES

DEFORMATION BOLT SUBSTITUTION WEAR

1. Shackles must be load rated and have the WLL written on them along with the manufacturer and country where they were made.

2. Only shackles of the screw pin or bolt type may be used for lifting.3. If a shackle is used as a permanent part of the hoist line, then it must be

moused closed or use the bolt type with a cotter pin.4. Shackle that only use a cotter pin to keep the pin in are not legal for lifting.

When inspecting them, look for:• Wear• Deformation• Pin or bolt substitution• Non-rated shackles• Worn threads on the pin

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SHACKLESSHACKLES

IN-LINE45 DEGREES

90 DEGREES

LOAD

Side Loading Reduction ChartFor Screw Pin & Bolt Type Shackles Only†

0° In-Line45° from In-Line90° from In-Line

100% of Rated Working Load Limit70% of Rated Working Load Limit50% of Rated Working Load Limit

Angle of Side Load Adjusted Working Load Limit

† DO NOT SIDE LOAD ROUND PIN SHACKLES

1. The working load limit, WLL, shown on the shackle is for vertical loads.2. Round pin shackles are ones which do not have a nut on the end of the pin and should not be used for lifting..

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EYE BOLTSEYE BOLTS

DO NOT REEVE SLINGS ONE EYE BOLT TO ANOTHER. LOAD ON BOLT IS ALTERED.

WRONG!

CAUTION!

STRUCTURE MAY BUCKLE FROMCOMPRESSION FORCES.

DIRECTION OF PULL ADJUSTED WORKING LOAD

In-Line

45 Degrees

60 Degrees

Full Rated Working Load

30% of Rated Working Load

60% of Rated Working Load

1. The rated capacity of a eye bolt drops significantly when pulled other than vertically.2. Emphasize the dramatic drop to the students.3. Threading a sling through the eye bolts increases the stress on the eye bolts by two and should never be done.

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BELOW-THE-HOOK LIFTING DEVICESBELOW-THE-HOOK LIFTING DEVICES

BALANCED“C” HOOK

BALANCED PALLET FORK

TELESCOPICCOIL GRAB

COILLIFTINGHOOK

1. These are a few of the types of below-the-hook lifting devices. There are many more.

2. Be careful of home-made lifting devices.3. Any lifting device must be load rated and have a manufacturer’s nomenclature

plate on it indicating its weight and SWL.4. Add pictures of the different types of lifting devices you have at your facility,

including: spreader and lifting beams, plate clamps, barrel clamps or hooks.

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SLING ANGLESSLING ANGLES

Tension in slings

Compression in load

Sling Angle

Stresses in the slings and the load increase as the sling angle decreases

1. When slings are brought together and form a hitch arrange as shown above the stresses in the slings increase and a compression force on the load is created.2. As the sling angle decrease the stresses in the sling and on the load increase.

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1000 lbs10

00 lb

s1000 lbs

500

lbs

500

lbs

1000 lbs

575

lbs 575 lbs

1000 lbs

705 l

bs

705 lbs

1000 lbs

1000 lbs 1000 lbs

1000 lbs

5735 lbs5735 lbs

SLING ANGLESSLING ANGLES

60°

45° 30°

1. Review each of the different sling angle configurations and point out the increase in the stresses.2. Sling angles of 60 degrees are the best to use because of the minimal increase of stress in the slings. When required to use smaller sling angles, slings need to be selected based on the increased stress and not on the weight of the load.3. When the sling angle is 30 degrees for a 1000 lbs load, the compression loads which are crushing the load will be 866 lbs. Depending on the structural strength of the load, it may be damaged.

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1000 lbs 1000 lbs 1000 lbs

500

lbs

500

lbs

A

Factor ofAngle “A”

Load in each slingleg = 500 x Load Angle Factor

H

L

A

Sling Angle Degree (A) Load Angle Factor = L/H9060504530

1.0001.1551.3051.4142.000

Load On Each Leg Of Sling = (Load / 2) X Load Angle Factor

SLING ANGLESSLING ANGLES

1. All that is need to calculate these stress is the weight of the object and a measuring tape.2. As shown in the slide above, the length of the sling is divided by the height of the sling connection to the top of the load.3. The answer is then multiplied by the portion of the load it is to support and this will be the stress in the sling.Example: If my sling was 8 feet long and the height ‘H’ was 4 feet, 8 divided by 4 equals 2. The portion of the weight the sling is to support is half of 1000 lbs or 500 lbs. 2 X 500 = 1000 lbs which is the stress in the sling.

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Acceptable methods of determining weight

You may find the weight from:

Data on manufacturing label plates.

Manufacturer documentation.

Blueprints or drawings.

Shipping receipts.

Weigh the item.

Bill of lading (be careful)

Stamped or written on the load

Approved calculations

Never use word of mouth to establish the weight of and item!

ESTIMATING WEIGHTSESTIMATING WEIGHTS

1. Knowing the weight of the load is critical to a safe lift.2. Not all information is reliable.3. The surest way to find the weight is to weigh the load.4. If the object is solid and made up primarily of one material then you

could calculate the weight.

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Calculating the weight

To find the weight of any item you need to know its volume and unit weight.

• Volume x Unit weight = Load weight

• Unit weight is the density of the material

• Unit weight is normally measured by pounds per cubic foot.

ESTIMATING WEIGHTSESTIMATING WEIGHTS

1. Anytime you calculate the weight it is really only an estimation. But it will get you in the “ball park”.

2. Always error on the safe side in your calculations.

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343634503053623030282550

524564

10075120105

TIMBERCedarCherryFir, seasonedFir, wetHemlockMapleOakPinePoplarSpruceWhite pineRailroad tiesLIQUIDSDieselGasolineWaterEARTHEarth, wetEarth, drySand and gravel, wetSand and gravel, dry

165535500560480710490460

16011014060155110130144150

80160

METALSAluminumBrassBronzeCopperIronLeadSteelTinMASONARYAshlar masonryBrick, softBrick, pressedClay tileRubble masonryConcrete, cinder, hayditeConcrete, slagConcrete, stoneConcrete, reinforcedMISC.AsphaltGlass

Here are some examples of common materials and their unit weight:

The unit weight is: pounds per cubic foot

ESTIMATING WEIGHTSESTIMATING WEIGHTS

1. It’s wise to have similar “cheat sheets” for materials that you handle frequently.2. Knowing the unit weight of different materials helps in weight estimation.3. Knowing the difference between steel (490 lbs), reinforced concrete (150 lbs),

and wood (25-65 lbs) is useful.

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If the material was cedar, then all we would have to do to determine it’s weight would be to multiply the unit weight of cedar x 64.

Unit weight x Volume = Weight

34 lbs. X 64 cubic ft. = 2,176 lbs.

CALCULATING VOLUMECALCULATING VOLUME

Volume of a cube

Length x Width x Height = Volume

8 ft x 4 ft x 2 ft = 64 cubic feet

8 ft long

4 ft wide

2 ft high

1. Cubes are easy to calculate.2. Finding the weight is as simple as multiplying the volume of the cube by the

unit weight of what it is made of.

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CALCULATING VOLUMECALCULATING VOLUME

Volume of a cylinder

Pi x Radius Squared x Length = Volume

π x Radius² x Length = Volume

3.14 x 1² ft x 10 ft = 31.4 cubic ft

If the material was reinforced concrete, then all we would have to do to determine it’s weight would be to multiply the unit weight of reinforced concrete x 31.4.

150 lbs. X 31.4 cubic ft. = 4,710 lbs.

2 ft wide

10 ft long

1. The volume of a cylinder is a little more difficult, but not rocket science. Having a scientific calculator and knowing how to use it is a good idea.

2. Again, just multiply the volume in cubic feet by the unit weight to find the weight of the load.

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Volume of pipe

Calculating the volume of pipe is a bit trickier but it is just simply subtracting the volume of the hole from the volume of the pipe.

CALCULATING VOLUMECALCULATING VOLUME

If the pipe were one inch thick, three feet wide and 8 feet long,then we would figure the volume of the entire pipe and subtract the volume of the hole to get the the volume of the material.

3.14 x (1 ½ ft.)² x 8 feet = total volume of pipe (56.52 ft³)

3.14 x (1ft 5 in.)² x 8 feet = volume of hole (50.41 ft³)

56.52 ft³ – 50.41 ft³ = 6.11 ft³

Volume of material x unit weight = total weight

If this pipe were steel then the unit weight would be 490 lbs.

6.11 x 490 lbs = 2,9994 lbs.

8 ft long

1 in. thick

3 ft wide

1. Finding the volume of a pipe is not too much different than finding the volume of a cylinder. You just have to do it twice and then subtract the volume of the hole from the total volume of the pipe.

2. It is helpful to know how to change fractions into decimals. Calculators are a must for this. To change 1 foot 5 inches (or 17/12ths) into a decimal, simple divide 12 into 17 which would be 1.4266.

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For thin pipe a quick way to *ESTIMATE the volume is to split the pipe open and calculate the volume like a cube. The formula would be:

π x diameter = width, so:

π x diameter x length x thickness x unit weight = weight of object

3.14 x 3 ft x 8 ft x 1/12 ft (or .08 ft) x 490 lbs = *3,077.2 lbs

8 ft long

3.14 (π) x 3 ft diameter = 9.42 (width)

1/12 ft = 1 in. thick

CALCULATING VOLUMECALCULATING VOLUME

1. This is only an estimate and should not be used with thick pipe.2. Simply spit the pipe down the middle and open it up into a thin plate.3. Then calculate the the volume of the cube that is created.4. To find the width, multiply pi times the diameter.

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WEIGHT TABLES

Weight tables are an excellent way to calculate load weight.If you are handling certain materials often, then having a chartthat gives you the weight per cubic foot, cubic yard, square foot,linear foot or per gallon. Here are a few examples:

METAL PLATES

STEEL PLATES weigh approximately 40 lbs per sq. ft. at 1 inch thick.1/2 inch thick would then be about 20 lbs. per sq. ft.

A steel plate measuring 8 ft. x 10 ft. x 1/2 inch would then weigh about 3,200 lbs. (8 x 10 x 40 lbs = 3,200 lbs.)

BEAMS

Beams come in all kinds of materials and shapes and lengths. STEELI-BEAMS weigh approximately 40 lbs a linear ft. at 1/2 inch thick and8 inches x 8 inches. If it were 1 inch thick then it would be 80 lbs a linear ft. If it were 20 feet long at 1 inch thick then it would weigh about1,600 lbs. (20 ft. x 80 lbs. = 1,600lbs.)

WEIGHT TABLESWEIGHT TABLES