Model 6 - OSHA

OSHA 10-Hour Construction Course: Module 6 Cranes & Other Hoists Page 1 of 19
OSHA MODULE 6 Cranes & Other Hoists

Learning Objectives
Upon completion of the lesson, participants will be able to:
List the four major causes of crane accidents

Describe the preplanning that is required before putting a crane into use
State the two main precautions that apply to working with cranes near power
lines
Introduction
Cranes, derricks, hoists, and other lifting devices pose significant safety issues for
both their operators and for workers in proximity to them. Moving large, heavy loads is
critical to the manufacturing and construction industries, and a lot of new technology has
been developed for these operations.
The U.S. Department of Labor's Occupational Safety and Health Administration (OSHA)
released a historic new standard, addressing the use of cranes and derricks in
construction and replacing a decades old standard. The significant number of fatalities
associated with the use of cranes and derricks in construction and the considerable
technological advances in equipment since the publication of the old rule, issued in
1971, led the Labor Department to undertake this rulemaking. This new standard will
comprehensively address key hazards related to cranes and derricks on construction
worksites, including the four main causes of worker death and injury: electrocution,
crushed by parts of the equipment, struck-by the equipment/load, and falls.
The final rule was published on August 9, 2010 by the Federal Register.
In 1998, OSHA's expert Advisory Committee on Construction Safety and Health

(ACCSH) established a workgroup to develop recommended changes to the current
standard for cranes and derricks. In December 1999, ACCSH recommended that the
Agency use negotiated rulemaking to develop the rule.
The Cranes and Derricks Negotiated Rulemaking Committee (C-DAC) was convened in
July 2003 and reached consensus on its draft document in July 2004. In 2006, ACCSH
recommended that OSHA use the C-DAC consensus document as a basis for OSHA's
proposed rule, which was published in 2008. Significant requirements in this new rule
include: a pre-erection inspection of tower crane parts; use of synthetic slings in
accordance with the manufacturer's instructions during assembly/disassembly work;

assessment of ground conditions; qualification or certification of crane operators; and
procedures for working in the vicinity of power lines.
The main four causes of crane accidents are:

1. Electrocution
2. Crushed by parts of the equipment
3. Struck-by the equipment or load
4. Falls
Contact with power lines causes nearly 45 percent of accidents involving the booms of
cranes.
Improper maintenance and failure to conduct regular inspections can also be harbingers
of trouble, and dropped loads, boom collapse, rigging failures, workers being struck by
the chassis as it rotates, lack of training, lack of communication, and other mishaps
cause accidents as well. Following safe work practice and complying with OSHAs
standards for crane safety can help minimize these risks.
General Requirements
The manufacturers specifications and limitations on the operation of a crane or derrick

should always be applied. When inspecting or observing a job site, always look for
clearly posted load capacities, easily available load tables, and general knowledge on
the part of crane operators and safety personnel. If the manufacturers specifications
are unavailable, a qualified engineer competent in this field should determine a set of
limitations for the crane or derrick equipment, and his or her determinations need to be
documented, recorded, and complied with throughout the duration of the job. Any
attachments used with a crane or derrick should never exceed the capacity, rating, or
scope recommended by the manufacturer or determined by the engineer.
The limitations of the equipment, like the rated load capacities, recommended operating
speeds, and any special hazard warnings, should be conspicuously posted and should
be obvious to any observer walking through the site. Any special instructions or
warnings should be easily visible from the operators station in the cab.
The windows of the cab should also be made of safety glass, or an equivalent like
Plexiglas. They should be reasonably clean, so that the operators visibility is
unimpaired, and the glass should introduce no visible distortions that might interfere with
the operators visibility or the safe operation of the machine.
The car and cab of the crane or derrick should be easily accessible to an operator in
reasonable physical shape. Guardrails, handholds, and steps should be provided. If
you are interested in more information about this issue, or if you suspect a safety
violation, The American National Standards Institute, or ANSI, standard B30.5 further
addresses this issue. If its important for rigging or service requirements, steps or a
ladder should provide access to the roof of the cab. Any surface of the crane or derrick
body that employees would stand on in the course of their work should be an anti-skid
surface.
Hand signals are often used in noisy jobsites to provide instructions to crane and derrick
operators. The signals are described in ANSI standards for each type of crane;
operators and signalmen should be familiar with all of the appropriate signals, and
illustrations of the signals should be conspicuously posted at the jobsite. Below is a
representative illustration of a hand signal chart.
No modifications or additions that affect the capacity or safe operation of a crane or

derrick should ever be made without the manufacturer's written approval, which should
be kept on file. No change to the equipment can ever be allowed to reduce its original
safety factor. If the crane has been modified, the capacity, operation, and maintenance
instructions should be changed accordingly.
Inspection
Each job site should have a qualified person, who is responsible for inspecting each
piece of machinery and equipment prior to each use. During the job, the qualified
person should also make sure the equipment is in safe operating condition. Defective or
damaged equipment poses a serious safety hazard to workers, because its behavior is
unpredictable. If any problems occur, the machine should be taken out of service, and
repaired or replaced before it is used again.
A thorough annual inspection of the hoisting machinery should be made by a qualified

person, or by an agency or company certified by the Department of Labor. FDOT and its
contractors maintain records of the dates and results of inspections for each hoisting
machine and piece of equipment, and these records should be available within a
reasonable period of time upon request by a safety inspector.
Crane Parts
The illustration below identifies important parts of a crane.

Types of Cranes
There are a number of different types of cranes for both general and more specific uses,
including
Mobile
Hydraulic
Overhead
Gantry
Tower
The primary examples well cover in this module are the hydraulic rough terrain crane
and the crawler lattice boom friction crane. Each is commonly used and yet they are
different enough to warrant exploring the reason proper training and precautions are so
vital to the industry.
There are several significant differences between these cranes, primarily in boom hoist
and load line controls. The somewhat smooth operation of the boom control
adjustments on the hydraulic cranes may falsely suggest that it is simple to operate.
The lattice boom friction cranes movement in its boom or its adjustment in load position
tends to be a little jerky, requiring more skill and experience to operate smoothly.
Another difference is their load charts. Due to the fixed boom lengths, the lattice boom
friction crane has a more simplified load chart. This requires extensive motion control
and anticipation of boom movement to accurately lift or place loads.
The hydraulic cranes load charts are more extensive because of variations in boom
length, which makes them more complex. Therefore, more training in multiple charts
is required.
The differences between these cranes are significant enough to require specific training
on each type of crane. Crane operators cannot expect to be totally knowledgeable and
proficient in the operation of the many diverse types of cranes available today. They
cannot be expected to move from one type of crane to another without adequate
education and training on the specifics of each piece of equipment.
A mobile crane generally means just that a crane that is mobile and consists of a
boom (arm) mounted on a movable platform with levers or pulleys that raise and lower it.
There is usually a hook for hoisting suspended from the boom.
The platform of a mobile crane can have a variety of means for traversing different job
locales; for instance, it can have traditional wheels, wheels designed for railroad tracks,
or a caterpillar track, which is especially useful for navigating uneven, unpaved (dirt)
surfaces. A mobile crane can help with work other than lifting material loads when
specific attachments are used to accomplish a task, such as a wrecking ball for
demolition work.
Truck mounted and rough terrain cranes are both essentially mobile as well. A truck-
mounted crane usually has outriggers to increase stability. Rough terrain cranes are
designed for use in the environment their name suggests, and have bases that are
similar to that of a giant 4-wheel drive truck. They, too, use outriggers for stabilization
and are usually called upon for materials-handling duties.
Gantry cranes are overhead cranes with supports that hold the crane in a fixed location.
They are most often used in factories, ports and railroads, where they unload and move
heavy and/or huge components used in manufacturing processes or containers off of
ships and trains. The bases are crossbeams that run on rails, so containers can be
moved from one location to another. Since the crane base itself cannot move, everything
that the crane is going to lift must be brought within the cranes operating area.
Tower cranes do not generally have a moveable base. Tower cranes are generally the
tallest type of crane, and they must be assembled piece by piece. The base looks similar
to a ladder, and the boom is perpendicular to the base. These are the cranes used to
construct tall buildings, and they are often assembled and attached to the building itself
during construction. They are an amazing sight to see as a skyscraper rises!
Preparation Before Startup The Seven Sisters of Safety
Before beginning to use any crane, all the steps on the checklist below need to have
been completed.
1. Contact power utility owners and determine precautions, including whether lines
will need to be de-energized for safetys sake. Know the location and voltage of
the overhead power lines!
2. Level the crane and ensure the support surface is firm and able to support the
load.
3. Know the capacities of your crane and its limitations, as well as any restrictions
particular to your job site such as unstable soil, the location of underground
power lines, utilities, or a predisposition for high-winds.
4. Make sure other personnel on the site are aware of hoisting activities and the
operational range of the boom (swing radius).
5. Barricade areas within the swing radius of the boom.
6. Ensure cranes have been properly maintained and inspected. Remember that
the competent person must inspect all machinery and equipment prior to and
during each 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!
7. Determine safe areas to store materials and place machinery.
Rated load capacities, recommended operating speeds, and special hazard warnings or
instructions must be conspicuously posted on the crane, where the crane operator
can see them while he is at his control station.
While OSHA states that overloading is responsible for a relatively small percentage of
mobile crane accidents (simply because relatively few lifted loads are ever at or near
capacity), it is still important for operators to be aware of rated capacities. Equally as
important is the consideration of the following load limiting factors:
Use of extensions, jibs and other attachments

Limits of wire rope, slings and lifting devices
Side loads
On its wheels
Lifting over the side
Ground not level
Wind
Cables and Rope
Wire rope should be taken out of service when any of the following conditions exist:
In running ropes, six randomly distributed broken wires in one lay, or three
broken wires in one strand in one lay.
Wear of one-third the original diameter of outside individual wires.
Kinking, crushing, bird caging, or any damage that distorts the rope structure.
Evidence of heat damage from any source.
Wear that results in a significant reduction from the nominal diameter of the rope.
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.
Mobile Cranes The Four Lifting Principles You Must Know
The four lifting principles that govern a cranes mobility and safety during lifting
operations are as follows:
1. Center of Gravity. That is the point in an object where its weight is concentrated;
or, stated another way, the point in an object around which its weight is evenly
distributed. The location of the center of gravity of a mobile crane depends primarily on
the weight and location of its heaviest components (boom, carrier, upperworks and
counterweight).
2. Leverage. Cranes use leverage to lift loads. Rotation of the upperworks (cab, boom,
counterweight, and load) changes the location of the center of gravity its leverage point
or fulcrum.
3. Stability. Relationship of the load weight, angle of the boom and its radius (distance
from the cranes center of rotation to the center of load) to the center of gravity of the
load. Stability can also be affected by the support on which the crane is resting. A
crane's load rating is generally developed for operations under ideal conditions; i.e., a
level firm surface. Surfaces that are not level or soft ground must therefore be avoided.
In areas where soft ground poses a support problem, mats and/or blocking should be
used to distribute a crane's load and maintain a level, stable condition.
4. Structural Integrity. The crane's main frame, crawler track and/or outrigger
supports, boom sections, and attachments are all considered part of the structural
integrity of lifting. In addition, all wire ropes, including stationary supports or attachment
points, help determine lifting capacity and are part of the overall structural integrity of a
crane's lifting capacity.
Structural integrity can also be affected by: the load chart capacity in relationship to
stability; the boom angle limitations which affect stability and capacity; and the
knowledge of the length of boom and radius in determining capacity.
Physical Safety of Workers on the Jobsite
Moving equipment can cause many different kinds of physical hazards to workers, from
pinching to friction burns to severe laceration. If belts, gears, shafts, pulleys, sprockets,
spindles, drums, fly wheels, chains, or other moving parts are exposed to contact by
workers at the job site, they should be covered by a guard (and usually a warning is
posted).
ANSI standard B 15.1-1958 Rev., the Safety Code for Mechanical Power Transmission
Apparatus, contains specification for guards in situations like this. If you see an exposed
moving part that could conceivably cause a hazard to employees, it is a safety problem.
Struck by accidents for employees working near cranes are regrettably common safety
hazards. Accessible areas within the swing radius of the rear of the rotating
superstructure of the crane should be barricaded in some way, so that employees
cannot be struck by the crane body or crushed against a fixed object. The barricade
might be as simple as yellow tape around stakes, or as complex as a fixed fence or
controlled access area.
Loads should never pass directly over workers at the site, and in general, workers
should be moved away from the path of travel of the load. Employees being struck by
moving loads or loads falling from the boom are one of the most significant causes of
serious and fatal accidents at construction sites. For similar reasons, under no
circumstances should a worker ride a load, or be lifted by a crane or derrick under any
circumstances except those outlined in the module concerning personnel hoists.
Lets look at a few case studies garnered from the NIOSH Alert, Preventing Worker
Injuries and Deaths from Mobile Crane Tip-Over, Boom Collapse, and
Uncontrolled Hoisted Loads (NIOSH Publication No. 2006-142)
On July 14, 1999, 3 male ironworkers (the victims), ages 39, 40, and 52 died after
falling approximately 300 feet to the ground when the suspended personnel platform
they were occupying was struck by the uncontrolled load of a heavy-lift crane (Figure
2). The victims were working in windy conditions during the construction of a county
sports stadium. The firm responsible for the assembly and erection of the stadium roof
had contracted with the victims employer to provide ironworkers and had also
contracted with a multinational contractor for the use of a heavy-lift crane.
The three ironworkers were suspended above the ground to observe the hoisting of a
450-ton roof section. The roof section had been hoisted to about 330 feet and
transported over its connection location by the heavy-lift crane crew. As the roof section
was being lowered into place, the heavy-lift crane began to tip over. The crane continued
tipping and the roof section collided with the personnel platform, knocking it and the
victims to the ground. Evaluation of investigative information indicated that the weight of
the hoisted load, side loads from wind, out-of-level ground conditions, and the swinging
motion of the hoisted load as the crane moved sideways combined to tip the crane
[NIOSH 1999].
In October of 1997, a 56-year-old truck driver was crushed when a crane tipped over
and the cranes boom landed on the cab of the dump truck in which he was sitting
(Figure 4).
The 50-ton, all-terrain crane had been set up near the access road to a construction site
in preparation for unloading components of a tower crane that would soon arrive on-site.
The crane operator had set up parallel to the access road and had fully extended the
cranes left outriggers. The right outriggers had been set but not fully extended, as they
would have blocked truck access to the construction site. This set-up was intended to be
temporary until building materials and equipment could be moved to make more room
for the all-terrain crane. The crane operator began to clear the area by lifting an empty
4-yard concrete bucket over the rear of the crane.
The operator swung the bucket over the right side of the crane, moving it between the
victims truck and another truck waiting in line. As he swung the cranes boom to the
right, he also began to boom down to extend the load radius for more clearance (i.e.,
lowered the crane boom to increase the distance between the load and the cranes
center of rotation).
When the bucket reached the area near the right front fender of the victims dump truck,
the operator lowered it to the ground. The crane tipped toward the load. The operator
attempted to regain stability by lowering the bucket more quickly, but was unable to
drop it fast enough, and the crane continued to tip. The cranes boom hit the truck cab
directly over the drivers seat, pushing the roof onto the victim and crushing him forward
in the seat. Measurements taken after the incident showed the cranes load lift capacity
had been exceeded for the boom length and angle used [NIOSH 1998].
NIOSHs investigators concluded there were numerous steps that could (and should)
have been taken to prevent a fatality such as the ones just described. To wit:
Proper training of crane operators in the mandatory use of load charts is important for
safe hoisting operations. Crane operators need to know and understand how to use load
charts provided by the crane manufacturer. LMI devices are an important safety feature
on modern cranes. However, these devices cannot replace the judgment of a trained
and qualified operator who has knowledge of safe practices regarding hoisted loads,
swing radius, and load chart information. LMI devices should be checked per the
manufacturers recommendations and if not working properly, tagged out-of-service until
repairs are made.
Crane operators and workers must follow the manufacturers recommendations for crane
set-up and rigging.
Workers must use caution so that they do not place themselves in dangerous areas
where they can be struck by falling loads or by falling or collapsing crane components.
Managers and safety professionals need to consider safe work practices for workers
who are required to work on or near operating cranes. All workers should use and follow
established hand signals such as the standard hand signals listed in ANSI B30.52004.
Cranes and Electrical Safety
Overhead power lines pose a particular problem for crane operation. Unless the lines
have been de-energized and visibly grounded at the point where work is being done
(consider any overhead wire to be energized, unless it is visibly grounded and the
project has specific indication from the owner), or insulating barriers have been put up to
prevent physical contact with the lines, there are several important steps that should be
taken to make sure the operator and anyone working near the crane are safe. These
steps are vital, and their observance should be obvious to any inspector.
In general, clearance of at least 10 feet should be maintained between power lines and
any part of the crane or load. The specific clearance requirements are as follows:
For lines carrying 50 kV or less, at least 10 feet.
For lines rated over 50 kV, 10 feet plus 0.4 inch for each 1 kV over 50 kV, or
twice the length of the line insulator.
If the crane is in transit with no load and the boom lowered, 4 feet for voltages
less than 50 kV, 10 feet for voltages between 50 and 345 kV, and 16 feet for
voltages up to 750 kV.
In a situation where it is difficult for the operator to maintain clearance visually, one or
more signalmen should help him or her stay far enough away from the lines and give
any other appropriate warnings. The appropriate hand signals for the type of crane
being used (and the situation) are the preferred form of communicating via signal.
Cage-type boom guards, insulating links, or proximity warning devices may be used on
cranes, but the crane still needs to meet every other requirement of the OSHA
standards.
Transmitter towers, like cellular phone towers, can cause a particular problem. The
electromagnetic energy they project can induce electrical currents in susceptible
equipment or materials, and special care should be taken to make sure no charge is
induced in the crane. Before work near a tower starts, the transmitter should be de-
energized, or tests should be made to determine if a charge is induced on the crane.
The following steps will help dissipate any electrical energy that might build up:
An electrical connection between the upper rotating structure supporting the
boom and the ground.
Jumper cables to an electrical ground, attached to any materials being handled
by the cranes boom
Nonconductive poles with large alligator clips or other similar protection can be
used by crews to attach ground cables to the load.
All employees should be kept clear of loads about to be lifted and of suspended loads!
Special Considerations
Crawler, locomotive, and truck cranes
All jibs should have positive stops, to prevent movement of more than 5 degrees above
the straight line of the jib and boom on conventional-type crane booms. Using cable-type
belly slings is not an appropriate substitute for following this requirement.
All mobile cranes should meet the appropriate ANSI standards (particularly ANSI B30.5-
1968, Safety Code for Crawler, Locomotive, and Truck Cranes). Instead of that
standards inspection records, FDOT and its contractors have to keep a certification
record which includes the date of inspection, the signature of the inspector, and a serial
number or other unique identifier for that particular crane. The most recent certification
record has to be kept on file until the next one is prepared, and (as with other inspection
records) the record should be available to any safety inspector within a reasonable
period of time.
Hammerhead tower cranes

As with any other crane, always maintain enough clearance between moving and
rotating structures of the crane and fixed objects to allow workers to pass without the risk
of injury.
Any worker who has duties to perform on the horizontal boom of a hammerhead tower
crane should have appropriate fall protection, like guardrails or a personal fall arrest
system, as covered in the Fall Protection module of this safety course.
Buffers should be provided at both ends of travel of the trolley, and cranes mounted on
rail tracks should be equipped with limit switches limiting the travel of the crane on the
track and stops or buffers at each end of the tracks.
Overhead and gantry cranes
The rated load capacity has to be plainly marked on each side of the crane, and if the
crane has more than one hoisting unit, each hoist should have its rated load marked on
it or its load block. The markings should be clearly and easily readable from ground
level.
Bridge trucks should have sweeps that extend below the top of the rail, and project in
front of the truck wheels. Except for floor-operated cranes, any crane with a power
traveling mechanism should have a gong, or another warning signal that is clearly
audible over any other noise at the jobsite.
Exhaust, Fuel, and Fire Safety
Gasoline exhaust contains carbon monoxide, which can pose a serious hazard to
workers, and low concentrations of other potentially hazardous chemicals (depending on
the particular fuel and the engine). Any time internal-combustion-powered equipment
exhausts into an enclosed space at a job site, the space should be tested to make sure
workers in the area are not exposed to toxic gases or oxygen-deficient atmospheres.
The tests should be available to inspectors upon reasonable request. All exhaust pipes
should be guarded or insulated if contact by employees is possible in the performance of
normal job tasks.
The fuel tank filler pipe should be located on the crane or derrick body in a position that
doesnt let spilled or overflowing fuel to run onto the engine, exhaust, or electrical
equipment. If this is unfeasible, protection should be provided against the eventuality of
fuel being ignited by a physically or electrically hot surface.
In the event that a minor fire occurs, someone nearby should be able to put it out.
Toward that end, an accessible fire extinguisher of at least 5BC rating should be
available and obvious at all operator stations or cabs of equipment.
Crane Conclusions
Its hard to overemphasize the fact that, even with evolving technology and innovations
such as boom angle indicators (onboard devices that help operators gauge the boom
position and thus, stability) cranes are extremely dangerous pieces of heavy machinery
that require extensive training and loads of awareness to operate safely.
In addition, OSHA states that, where necessary, for rigging or service requirements, a
ladder or steps shall be provided to give access to a cab roof.
Guardrails, handholds, and steps must be provided for easy access to the car and cab.
Platforms and walkways must have anti-skid surfaces.
Annual Inspections
Per OSHA 1926.550(a)(6), a thorough annual inspection of the hoisting machinery must
be made by a competent person or a government or private agency recognized by the
U.S. Department of Labor. The employer must maintain the dates and results of
inspections for each hoisting machine and attendant pieces of equipment.
What Needs to Be Inspected?
Tires for proper inflation, correct air pressure and absence of leaks
Clearance for tail swing
Wire rope wear
Physical damage to crane
Loose or missing hardware, nuts, or bolts
Fluid leaks
These are only some of the items that should be inspected on a regular basis. For more
complete inspection criteria, the crane manufacturer and/or supplier should be
contacted, and the Mobile Crane Inspection Guidelines for OSHA Compliance
Officers should be consulted.
Personnel Hoists
General Requirements
1. The employer shall comply with the manufacturer's specifications and limitations
applicable to the operation of all hoists and elevators. Where manufacturer's
specifications are not available, the limitations assigned to the equipment shall
be based on the determinations of a professional engineer competent in the field.
2. Rated load capacities, recommended operating speeds, and special hazard
warnings or instructions shall be posted on cars and platforms.
3. Hoisting ropes shall be installed in accordance with the wire rope manufacturers'
recommendations.
4. The installation of live booms on hoists is prohibited.
5. The use of endless belt-type manlifts on construction shall be prohibited.
Wire rope shall be removed from service when any of the following conditions exists:
In hoisting ropes, six randomly distributed broken wires in one rope lay or three
broken wires in one strand in one rope lay;
Abrasion, scrubbing, flattening, or peening, causing loss of more than one-third
of the original diameter of the outside wires;
Evidence of any heat damage resulting from a torch or any damage caused by
contact with electrical wires;
Reduction from nominal diameter of more than three sixty-fourths inch for
diameters up to and including three-fourths inch; one-sixteenth inch for diameters
seven-eights to 1 inches; and three thirty-seconds inch for diameters 1 to 1
inches.
Precautions for Safe Operation
Because using cranes or derricks to hoist personnel poses a serious risk to the
employees being lifted, any cranes and derricks that hoist personnel must conform to the
following rules:
Be placed on a firm foundation
Be uniformly level within 1 percent of level grade
Have a minimum safety factor of seven for the load line (wire rope) of the crane
or derrick (the line must be capable of supporting at least seven times the
maximum intended load)
Move the personnel platform slowly and cautiously, without any sudden jerking of
the crane, derrick, or platform
Have rotation-resistant rope with a minimum safety factor of ten
Have all brakes and locking devices on the crane or derrick set when the
occupied personnel platform is in a stationary working position
In addition, the combined weight of the loaded personnel platform and its rigging must
not exceed 50 percent of the rated capacity of the crane or derrick for the radius and
configuration of the crane or derrick. The crane operator must always be at the controls
when the crane engine is running and the personnel platform is occupied. The crane
operator also must have full control over the movement of the personnel platform.
Personnel Platforms
A qualified engineer, or another competent specialist qualified in structural design,

should design all lifting platforms. The platforms should meet the following
requirements:
Support platform weight and at least five times the maximum intended load.
Minimize tipping caused by personnel movement on platforms by having an
appropriate suspension system.
Keep tools, materials, and equipment from falling on employees below by having
a standard guardrail system that is enclosed from the toeboard to the mid-rail.
Platforms should also be designed to include the following elements, which should be
obvious upon inspection:
Inside grab rail
Adequate headroom for employees
Access gate, if provided, that does not swing outward during hoisting and is
equipped with a restraining device to prevent accidental opening
Permanent marking or plate that clearly indicates the platforms weight and rated
load capacity or maximum intended load
OSHA standards require head protection, in the form of hard hats and overhead
protection on the lift platform or cage, any time the hoist, crane, or derrick is exposed to
falling objects. Rough edges on the platform have to be ground smooth, to prevent
employees from cutting or scraping themselves. Any welding on the platform or its
components must be performed by a qualified welder who is familiar with the grades,
types, and materials specified in the platform design.
Platform loading standards require that:

Personnel platforms must not be loaded in excess of their rated load capacity or
maximum intended load as indicated on permanent markings.
Only personnel instructed in the requirements of the standard and the task to be
performedalong with their tools, equipment, and materials needed for the job
are allowed on the platform.
All materials and tools must be secured and evenly distributed to balance the
load while the platform is in motion.
The cable rigging for personnel platforms should conform to the OSHA requirements, as
follows:
Legs of bridles must be connected to a master link or shackle so that the load is
evenly positioned among the bridle legs when a wire rope bridle is used to
connect the platform to the load line.
Bridles and associated rigging for attaching the personnel platform to the hoist
line must not be used for any other purpose.
Hooks and other attachment assemblies must be closed and locked to eliminate
the hook throat opening (an alloy anchor-type shackle with a bolt, nut, and
retaining pin may be used as an alternative).
Note that mousing the practice of wrapping wire around a hook to cover the hook
opening is not a safe substitute for closing and locking attachment assemblies.
Mousing is prohibited by OSHA regulations.
Material Hoists
Precautions
As with personnel hoists, employees and contractors should always be aware of the
manufacturer's specifications as well as any limitations applicable to the operation of all
hoists and elevators. Safe work practice requires the rated load capacities,
recommended operating speeds, and any warnings or instructions about special hazards
to be posted on hoist cars and platforms. The same rules that apply to personnel hoists
apply to material hoists when it comes to wire rope. If there is damage to the rope, take it
out of service rather than risk dropping a load!
Operating rules, such as the signal system and allowable line speed, should be
established and posted at the operator's station of the hoist. Other rules and notices,
particularly the statement No Riders Allowed, should be posted on the car frame or
crosshead in an obvious location. No one should ever be allowed to ride on a material
hoist, except for the purposes of inspection and maintenance.
A safe construction site should never include endless-belt manlifts, and live booms
should never be installed on a hoist.
Hoistway and Platform Requirements
Entrances to hoistways should be always be gated or barred, to prevent falls. The gates
need to be substantial, and should guard the full width of the landing entrance. All
hoistway entrance bars and gates should be painted in a diagonal contrasting color
scheme for easy notice (like black and yellow warning stripes). If bars are used, they
should be at least equivalent in size to a wooden two-by-four, and have to be located at
least two feet from the hoistway line. They should also be between approximately three
feet from the floor. A gate or bar protecting the entrance to a hoistway should have a
latch.
Material hoist cages and platforms should have an overhead cover. The cover should
be two-inch planking, -inch plywood, or some other solid material of approximately the
same strength. The operator's station of a hoisting machine should also have overhead
protection of the same strengthagain, at least equal to tight planking at least two
inches thick.
All material hoist towers must be designed by a licensed professional engineer.
The hoist tower can be used with or without an enclosure on all sides, but whichever
alternative is chosen, the tower has to meet OSHA safety regulations. It is fairly easy to
spot a violation of the following conditions:
Enclosed hoist towers should be enclosed on all sides for the entire height,
except for landing access. The screen enclosure should use half-inch mesh, No.
18 U.S. gauge wire, or an equivalent screen.
If the hoist tower is not enclosed, the hoist platform or car must be totally
enclosed on all sides for the full height between the floor and the overhead
protective covering. The screen should use half-inch mesh of No. 14 U.S. gauge
wire, or an equivalent. The hoist platform enclosure should use gates for loading
and unloading. OSHA regulations require a 6-foot high enclosure on the unused
sides of the hoist tower at ground level.
The hoist car or platform should use an appropriate arresting device in case of rope
failure. The arresting device should be capable of exerting enough force to stop a falling
cage loaded to capacity.
Conveyors
OSHA standards for conveyor belts or devices are as follows:
Means for stopping the motor or engine shall be provided at the operator's
station. Conveyor systems shall be equipped with an audible warning signal to be
sounded immediately before starting up the conveyor.
If the operator's station is at a remote point, similar provisions for stopping the
motor or engine shall be provided at the motor or engine location.
Emergency stop switches shall be arranged so that the conveyor cannot be

started again until the actuating stop switch has been reset to running or "on"
position.
Screw conveyors shall be guarded to prevent employee contact with turning

flights.
Where a conveyor passes over work areas, aisles, or thoroughfares, suitable

guards shall be provided to protect employees required to work below the
conveyors.
All crossovers, aisles, and passageways shall be conspicuously marked by

suitable signs, as required by Subpart G, Signs, Signals, and Barricades.
Conveyors shall be locked out or otherwise rendered inoperable, and tagged out
with a "Do Not Operate" tag during repairs and when operation is hazardous to
employees performing maintenance work.
All conveyors in use shall meet the applicable requirements for design, construction,
inspection, testing, maintenance, and operation, as prescribed in the ANSI B20.1-1957,
Safety Code for Conveyors, Cableways, and Related Equipment.
In general, there is no such thing as a small crane accident or a minor personnel hoist
disaster. When dealing with huge machines and heavy materials, it always imperative to
remember that people are the only irreplaceable components involved. Take the time to
observe safety precautions and ensure that everything is done properly.
Conclusion
As discussed here and in other modules of the OSHA Safety Awareness courses for
FDOT, the number of factors contributing to crane safety are myriad and critically
important. These are large, heavy machines that at times seem to all but defy the
laws of physics in enabling projects to rise toward the sky, and a healthy respect for
their mass and power will serve you well in staying safe on the job.
Cranes & Other Hoists Fact Sheet

Cranes & Derricks
The main four causes of crane accidents are contact with power lines, overturns,
falls, and mechanical failure.
Improper maintenance and failure to conduct regular inspections can also be harbingers
of trouble, and dropped loads, boom collapse, rigging failures, workers being struck by
the chassis as it rotates, lack of training, lack of communication, and other mishaps
cause accidents as well. Following safe work practice and complying with OSHAs
standards for crane safety can help minimize these risks.
There are a number of different types of cranes for both general and more specific uses,
including
Mobile
Hydraulic
Overhead
Gantry
Tower
Preparation Before Startup The Seven Sisters of Safety
Before beginning to use any crane, all the steps on the checklist below need to have
been completed.
1. Level the crane and ensure the support surface is firm and able to support the load.
2. Contact power utility owners and determine precautions, including whether lines will
need to be de-energized for safetys sake. Know the location and voltage of the
overhead power lines!
3. Know the capacities of your crane and its limitations, as well as any restrictions
particular to your job site such as unstable soil, the location of underground power lines,
utilities, or a predisposition for high-winds.
4. Make sure other personnel on the site are aware of hoisting activities and the
operational range of the boom (swing radius).
5. Barricade areas within the swing radius of the boom.
6. Ensure cranes have been properly maintained and inspected. Remember that the
competent person must inspect all machinery and equipment prior to and during each
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!
7. Determine safe areas to store materials and place machinery.
Mobile Cranes The Four Lifting Principles You Must Know

Center of Gravity
Leverage
Stability
Structural Integrity
In general, clearance of at least 10 feet should be maintained between power lines and
any part of the crane or load.
Proper training of crane operators in the mandatory use of load charts is

important for safe hoisting operations. Crane operators need to know and
understand how to use load charts provided by the crane manufacturer. LMI
devices are an important safety feature on modern cranes. However, these
devices cannot replace the judgment of a trained and qualified operator who has
knowledge of safe practices regarding hoisted loads, swing radius, and load chart
information. LMI devices should be checked per the manufacturers
recommendations and if not working properly, tagged out-of-service until repairs
are made.
Crane operators and workers must follow the manufacturers recommendations

for crane set-up and rigging.
Workers must use caution so that they do not place themselves in dangerous
areas where they can be struck by falling loads or by falling or collapsing crane
components.
Managers and safety professionals need to consider safe work practices for
workers who are required to work on or near operating cranes. All workers should
use and follow established hand signals such as the standard hand signals listed
in ANSI B30.52004.
Personnel Platforms
A qualified engineer, or another competent specialist qualified in structural design,

should design all lifting platforms. The platforms should meet the following
requirements:
Support platform weight and at least five times the maximum intended load.
Minimize tipping caused by personnel movement on platforms by having an
appropriate suspension system.
Keep tools, materials, and equipment from falling on employees below by having
a standard guardrail system that is enclosed from the toeboard to the mid-rail.
Platform loading standards require that:

Personnel platforms must not be loaded in excess of their rated load capacity or
maximum intended load as indicated on permanent markings.
Only personnel instructed in the requirements of the standard and the task to be
performedalong with their tools, equipment, and materials needed for the job
are allowed on the platform.
All materials and tools must be secured and evenly distributed to balance the
load while the platform is in motion.
Material Hoists
As with personnel hoists, employees and contractors should always be aware of the
manufacturer's specifications as well as any limitations applicable to the operation of all
hoists and elevators. Safe work practice requires the rated load capacities,
recommended operating speeds, and any warnings or instructions about special hazards
to be posted on hoist cars and platforms.

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OSHA 10-Hour Construction Course: Module 6 Cranes & Other Hoists Page 1 of 19

OSHA MODULE 6 Cranes & Other Hoists

Upon completion of the lesson, participants will be able to:

List the four major causes of crane accidents

In 1998, OSHA's expert Advisory Committee on Construction Safety and Health

accordance with the manufacturer's instructions during assembly/disassembly work;

The main four causes of crane accidents are:

The manufacturers specifications and limitations on the operation of a crane or derrick

No modifications or additions that affect the capacity or safe operation of a crane or

A thorough annual inspection of the hoisting machinery should be made by a qualified

The illustration below identifies important parts of a crane.

Preparation Before Startup The Seven Sisters of Safety

5. Barricade areas within the swing radius of the boom.

7. Determine safe areas to store materials and place machinery.

Use of extensions, jibs and other attachments

Cables and Rope

Mobile Cranes The Four Lifting Principles You Must Know

Physical Safety of Workers on the Jobsite

Cranes and Electrical Safety

Crawler, locomotive, and truck cranes

Hammerhead tower cranes

Overhead and gantry cranes

Exhaust, Fuel, and Fire Safety

What Needs to Be Inspected?

Precautions for Safe Operation

A qualified engineer, or another competent specialist qualified in structural design,

Platform loading standards require that:

Hoistway and Platform Requirements

All material hoist towers must be designed by a licensed professional engineer.

OSHA standards for conveyor belts or devices are as follows:

Emergency stop switches shall be arranged so that the conveyor cannot be

Screw conveyors shall be guarded to prevent employee contact with turning

Where a conveyor passes over work areas, aisles, or thoroughfares, suitable

All crossovers, aisles, and passageways shall be conspicuously marked by

Cranes & Other Hoists Fact Sheet

Preparation Before Startup The Seven Sisters of Safety

5. Barricade areas within the swing radius of the boom.

7. Determine safe areas to store materials and place machinery.

Mobile Cranes The Four Lifting Principles You Must Know

Proper training of crane operators in the mandatory use of load charts is

Crane operators and workers must follow the manufacturers recommendations

A qualified engineer, or another competent specialist qualified in structural design,

Platform loading standards require that:

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