Importance of Crane Safety Audits and Crane Safety Training

Construction sites are dangerous. Be it whatever type of construction Even when everyone follows the safety policies and procedures enacted by the management team and the Occupational Safety and Health Administration (OSHA), accidents can still happen. One of the most tragic accidents that can happen on a construction site is a crane accident. These accidents can lead to catastrophic injuries, death, and millions of money in property damage.

Countless companies in the manufacturing and construction industries rely on overhead cranes to lift and transport materials. When installed and used properly, these systems make operations easier and safer. But, overhead crane accidents cause severe injuries and fatalities every year. Preventing these disasters requires workers to recognize certain hazards that occur during operation and follow safety procedures to avoid them.

There are multiple hazards that can arise regarding cranes in general. Many accidents involve large lift systems like tower cranes and mobile cranes. But hazards do exist with all types of cranes—including overhead cranes—and in all facets of crane operation

What Causes Crane Accidents?

Crane accidents can happen for a variety of reasons. These include:

• Crane touches a power line
• The crane drops its load
• The crane was constructed or assembled incorrectly
• Failures with rigging
• The boom collapses
• Crane is overloaded and collapses due to too much weight
• The crane operator is not qualified
• Improper maintenance of the crane
• A worker falls from the crane
• The wrong type of crane was selected for the job

For Example, Almost 45 percent of all crane accidents happen when cranes come into contact with power lines, according to statistics from OSHA.

Who Can Be Held Responsible for a Crane Accident?

So, who can be held responsible for crane-related accidents? Depending on the size of the project where the crane is operating, there could be multiple people held accountable:

• The crane operator
• The construction company
• The company that assembled the crane
• The project manager
• The site manager or property owner

It could be possible that all of the above could be at fault for a crane accident, which is why it’s important to work with an experienced attorney when injured in a crane accident.

Today A crane collapsed at Hindustan Shipyard Limited in Visakhapatnam. "The crane accident took place at 12 pm. The crane fell at the time of load testing. We are seeing from the last 90 days in Visakhapatnam that LG Polymer gas leak took place, there was a blast in Visakhapatnam container yard and now this happened.

All this is happening because there is no safety audit. The state government should arrange safety audits and cancel the license of those who do not have an audit done. Just an audit alone will not solve the problem. It is an organization activity from top to down everyone is responsible.

The work and safety culture should be ensured in a way so that with regular training, awareness about safety people do not take shortcuts or make wrong decisions thinking they will save time, money, and effort. Having access to the right tools, types of equipment is another major factor that will improve crane safety.

Analysis of overhead crane accidents reveals three common safety hazards that every company using overhead lift systems should be aware of to keep their workers safe. It’s important to be familiar with these hazards and learn to recognize them in the workplace in order to avoid them. The three most common hazards involving overhead cranes include electrical hazards, overloading, and materials falling/slipping from overhead hoists.

The following analysis of each hazard provides a description, potential risks, reasons why accidents occur, preventative measures to avoid them, and applicable OSHA requirements. One commonality that all three hazards share is the qualifications of crane operators. It is the responsibility of the crane owner and job supervisor to ensure that crane operators are competent and qualified to do the job. 

OVERHEAD CRANE SAFETY—THREE MAJOR HAZARDS AND PREVENTATIVE MEASURES

OVERLOADING

According to OSHA, 80 percent of all crane upsets and structural failures can be attributed to exceeding the crane’s operational capacity. When a crane is overloaded, it is subject to structural stresses that may cause irreversible damage. Swinging or sudden dropping of the load, using defective components, hoisting a load beyond capacity, dragging a load and side-loading a boom can all cause overloading.

OSHA estimates that one crane upset occurs for every 10,000 hours of crane use. Nearly 80 percent of these upsets can be attributed to predictable human error when the operator inadvertently exceeds the crane’s lifting capacity. Overloading most often occurs when poorly trained personnel are allowed to operate cranes. Oftentimes, operators mistakenly believe they are able to rely on their instinct or experience to determine whether a load is too heavy. It’s crucial that any crane operator know the weight of a load and the capacity of the crane. Using technologies such as load-measuring systems for training and planning can greatly reduce the hazard of overloading and operator incompetency.

OSHA requires workers to provide formal training for all crane operators, but operator certification is only required for operators using equipment with a maximum manufacturer-rated capacity greater than 2,000 kgs. But many simply do not adhere to these basic aspects. Employees who are not qualified are only permitted to operate the equipment as operators-in-training with a certified trainer. Formal training should ensure a working knowledge of crane load charts, and on-the-job training is a great preventative measure if the trainer is qualified.

Overall, most crane safety programs outline competent personnel requirements, and it’s a good idea to become familiar with them. Cranes have become more sophisticated, with the ability to lift heavier loads further and faster than ever before. Today’s operator must be well trained and have a clear understanding of load dynamics, lifting capacities at various configurations, and the conditions under which such lifting capacities are valid.

• 29 CFR 1910.179(g)(5)(iv)—Overhead and Gantry Cranes—Switches
• 29 CFR 1910.179(n)(4)(I)—Overhead and Gantry Cranes—Handling the load—Hoist limit switch
• 29 CFR 1910.179(a)(50)—Overhead and Gantry Cranes—Rated Load
• 29 CFR 1910.179(b)(8)—Overhead and Gantry Cranes—Designated Personnel
• 29 CFR 1910.179(a)(35)—Overhead and Gantry Cranes—Designated Employee
• 29 CFR 1926.550(g)(3)(ii)(C)—Cranes and Derricks—Instruments and Components
• 29 CFR 1926.21(b)—Safety Training and Education

ELECTRICAL HAZARDS

According to OSHA, nearly 50 percent of overhead crane accidents are the result of machinery coming into contact with a power source during operation. Power line contact is literally defined as the inadvertent contact of any metal part of a crane with a high-voltage power line. Power line contact most often occurs when the crane is moving materials nearby or under energized power lines and the hoist line or boom touches one of them. Usually, the person who is electrocuted is touching the crane when it comes into contact with the power line. But, the danger is not just limited to the operator. It extends to all personnel in the vicinity.

A single contact with power lines can result in multiple deaths and injuries. Each year nearly 200 people die from power line contact and about three times as many are seriously injured. Most victims are guiding the load at the time of contact, but risks extend to everyone present at a job site.

Power line contacts most often occur because safety planning isn’t considered and preventative measures haven’t been taken to avoid hazards. Planning is one of the biggest accident deterrents available. To start, it’s important to establish who is in charge of prejob safety planning before any cranes arrive at a worksite. Furthermore, cranes should be kept away from unsafe working areas; OSHA and ANSI both outline safe distances operators must maintain from a power source when working at a job site. Areas that are considered hazardous are referred to as danger zones, and crane operators should be clearly notified of all potential danger zones. The area within a 10-foot radius of a power line is considered an unsafe work area—or danger zone—and it must be clearly marked on the ground by insulated barriers, fences, tape, etc. This will help create visual clues for workers to ensure that the crane is always positioned so that the boom and hoist line can’t intrude in the danger zone.

OSHA also regulates that overhead crane operators use precautions when working near power lines—even outside of the 10-foot radius. This means, operators should consider all power lines as energized until the electric company tells him or her otherwise. Operators should also maintain a safe speed when operating near power lines. Crane booms or truck-mounted trolleys using an electrical remote control system for loading and unloading can also be very dangerous. If the boom contacts a power line, the operator holding the control box is usually electrocuted instantly. This type of equipment should never be used near power lines. A non-conductive, pneumatic or radio remote control system is a much safer choice when working near power lines.

Overall, it’s important for operators and workers to receive the appropriate training to avoid danger zones where electrocution can occur. Operators should have workers observing nearby to assist them whenever it is difficult to visually maintain the necessary clearance. Be sure that any ladders, tools, and systems are non-conductive, and ask the electric company to de-energize and ground power lines or install insulation whenever people are working near them.

• 29 CFR 1910.333(c)(3)—Selection and use of work practices—Working on or near exposed energized parts—Overhead lines
• 29 CFR 1926.550(a)(15)—Cranes and derricks—General requirements—Electrical distribution and transmission lines

MATERIALS FALLING

Falling materials is a major concern at any workplace or job site using overhead cranes. Visual impairment, two-blocking, slipping, mechanical failure, or operator incompetency can all result in serious injuries or fatalities. If materials are not properly secured, for instance, the load can slip and land on workers in the vicinity or cause major damage to property. For larger or mobile cranes, undesired movement of material can pinch or crush workers involved in the rigging process.

Statistics show that nearly 20 people died in 2012 as a result of accidents with overhead hoists. That’s because the loads being lifted by overhead hoists tend to be fairly heavy and cause serious damage if dropped. Slings and attachments that aren’t secured properly can be a major safety hazard, and when objects begin to slip, they will eventually crash to the floor below.

One way to reduce the risk of falling materials is to perform regular maintenance of hoists. Load testing maintenance ensures that you know how many pounds the hoist can handle, and it helps to maintain good working conditions. Maintenance should always be treated seriously when it comes to heavy machinery. If a moving part on an overhead crane wears out or breaks the hoist, it can cause serious damage. Performing regular maintenance ensures the hoist and overhead crane remain in good working order and that all operations run smoothly.

Aside from maintenance, improper securing of the load or the slings that carry the load is one of the leading causes of accidents with overhead hoists and cranes. If the load or sling holding the load isn’t properly secured, the objects can slip out, tip, and eventually crash to the ground below. Mechanical failure can also cause machinery to malfunction unexpectedly and drop a heavy load. To reduce the risk, OSHA mandates that operators make daily crane inspections. When mechanical problems do arise, operators should use the lockout/tagout procedure to prevent accidental startup or movement of the crane until the problem has been repaired.

Employees working around overhead cranes should always wear proper head, foot, hand, and eye protection. The crane operator and any workers below should also be aware of his/her surroundings and never walk under a lift. A crane operator must always lower a load to the ground before leaving the lift or during idle times. When moving items, he or she should never raise the load higher than required for clearance.

When operating a hoist, properly trained employees in the vicinity should understand that they are working in a dangerous area. Installing “Hoist Danger” signs around the work area will help to alert employees that a hoist is operating over their heads. Workers should be trained to stay clear of the hoist, and they should never walk beneath loads suspended in the air. Likewise, suspended loads should never be moved over employees and personnel should never be lifted or transported on a hoist.

Careful operation of the hoist is another important safety factor to consider whenever overhead cranes are used. The person responsible for managing the hoist should be well trained and qualified. Moving the crane too quickly and jerking the hoist when it’s bearing a heavy load can be hazardous to the crane operator and workers nearby. Changing or reversing direction should be done slowly and carefully. Reversing direction can cause heavy loads to spill, and swinging the load is very risky. Operators and controllers must maintain 100 percent focus on the task at hand to avoid potentially dangerous situations.

• 29 CFR 1926.550(d)(3)—Cranes and Derricks—Overhead and Gantry Cranes
• 29 CFR 1910.179—Overhead and Gantry Cranes—Holding Brakes and Control Braking
• 29 CFR 1910.179(e)(6)(i)—Exposed Moving Parts
• 29 CFR 1910.179(f)(1)(ii) —Overspeeding
• 29 CFR 1910.179(b)(8)—Overhead and Gantry Cranes—Designated Personnel
• 29 CFR 1910.179(b)(6)—Overhead and Gantry Cranes—Clearance from Obstruction
• 29 CFR 1910.179(a)(42)—Overhead and Gantry Cranes—Hoists

Ten Steps to Safer Operation of Cranes

The scenario is all too familiar to safety professionals, as cranes are some of the most misunderstood workhorses on job sites. Nearly everyone who works in construction is fascinated with cranes and their ability to lift and move massive loads with pinpoint accuracy. But all too often, workers fail to treat cranes with the respect they require.

When we think about crane accidents, we tend to remember the dramatic incidents that happened with huge cranes. However, those giant pieces of equipment are usually operated by professionals who are well aware of the hazards. The accident described earlier happened with one of those smaller, truck-mounted cranes that are used by a wide variety of contractors in an even wider array of settings. And while you may think that a 5,000 kg load is less dangerous than a 50,000kg load, rest assured that it can kill you just as quickly and effectively.

Crane accidents tend to be very costly in equipment losses, damage to property, and injuries to workers. The direct costs related to damage, injuries, and OSHA fines tend to be very small when compared to the indirect costs of lawsuits from victims’ families and owners of the damaged property. And, most of the time, those accidents are the result of not fully understanding how cranes work, ignoring the physics involved with their operation, or simply failing to follow basic steps to safeguard workers.

Years ago, safety rules governing crane operations were scattered here and there. But in November 2010, OSHA issued a new standard that collected safety standards into a single document. Along with that new standard is a certification process that will be fully implemented in 2017. It calls for crane operators and those working around cranes (such as the people making signals) to pass a written test and practical test of their skills.

While you don’t need to be a mechanical engineer to operate cranes safely, the following basic steps will help to ensure that you don’t encounter any safety issues.

1. Have a certified operator. Even though operator certification will not be required for a couple of years, safety-conscious contractors and owners would be wise to use identical standards on their job sites immediately. After all, a crane in the hands of an unqualified operator can be a deadly weapon. Riggers should also be properly trained on setting the crane up for the specific load and circumstances.

2. Inspect, inspect, and inspect. Verifying that the crane has received its annual inspection is only the beginning. It’s important to check the operating functions daily to ensure that everything is working properly and that there are no defects or cracks in the support members. The cranes of a generation ago were made with alloys that could handle overloading and other abuse. Today’s cranes use materials that are less tolerant of mishandling. Longtime operators are often surprised to discover that the tricks they used to push cranes beyond the limits in the past can easily create very dangerous situations with newer cranes.

Overhead cranes used in heavy industrial applications such as steelmaking need to be inspected just as carefully. Many of these cranes spend decades working in extreme environments such as melt shops. That constant exposure to intense heat and temperature swings can cause the beam and other structural members to become brittle and lose strength or even fail.

3. Know what’s below. The most powerful, carefully rigged crane is only as strong and stable as the surface upon which it stands. You need to know the classification for the soil or other material under the crane, and adjust your setup and load limits accordingly. While many cranes are equipped with outriggers, extending them doesn’t necessarily mean that you’ve provided a stable surface. Outriggers displace the weight on the lift much the way that snowshoes spread your weight out so you don’t sink into the snow. The pad and float at the end of the outrigger carry a great deal of compression force when the crane is under load. Too much force can cause them to punch through the ground, causing the entire crane to tip.

It’s important to know the load weight and how that is affected by the conditions of your job site. The crane’s load chart can help you determine whether your lift will be safe. The allowable load will depend on whether the tires or outriggers are being used, along with other factors. For example, asphalt may seem to be a stable surface, but on a warm day, it may become very flexible. Even concrete may not provide enough strength if there is a void beneath it.

We remember a situation when a mobile crane was placed on the top floor of a parking garage. The floor was strong enough to handle the crane’s weight when it sat on its tires, but once the outriggers were deployed and the lift began, the compression force flowing through one outrigger caused it to break through the floor. The crane tilted, and as the floor weakened under the additional compression, it fell through to the next floor, causing extensive (and expensive) damage.

One way to increase the safety of a crane is to place cribbing under the outriggers. However, you have to ensure that the cribbing is capable of handling the load given the materials and conditions underneath it without failing or cracking. Simply placing a sheet or two of plywood under each float usually won’t be enough.

4. Plan for swing. The counterweight and boom travel within a specific arc that’s called the swing radius. It’s important to ensure that the area within that radius is barricaded off, and to establish a control zone for those authorized to work in the immediate area. Also check the area every day to ensure that there are no objects the boom might strike, such as power lines. If such obstacles exist, be sure that the operator and other workers are aware of the plan for avoiding them.

5. Use cranes properly. Cranes are engineered for vertical lifting. That doesn’t stop some crews from trying to use them for sideloading or other improper activities. Using a crane to drag something across the ground or from under an obstacle puts extreme stress on the boom, the turntable, and all the structural members. It could potentially weaken key components and lead to their failure. If someone on the site has used a crane improperly, be sure to inspect it thoroughly to ensure that its integrity has not been impaired.

6. Stay in touch. Whether you use radios, air horns, or hand signals, there needs to be clear communication between the operator and the other workers. That’s especially critical when a crane is making a lift in which the operator cannot see the load, such as when air handling equipment is being delivered through an opening on another side of a structure. Don’t assume that everyone knows how instructions will be communicated. Follow OSHA’s specific guidelines, and make sure that everyone on the site knows exactly what each signal means.

7. Pay attention. We’ve seen plenty of sites on which operators are talking on cell phones while moving the crane, napping between lifts, or distracted in other ways that have the potential to create dangers for their fellow workers. Everyone associated with a crane needs to stay alert and focused on the job at hand – especially on critical or difficult lifts.

8. Avoid man-baskets. Sometimes it looks like the easiest way to put employees where they’re needed is to lift a man-basket to the work area. However, that approach creates hazards that must be tested and addressed before work begins, such as providing proper fall protection, verifying basket capacity, and checking that the basket is properly attached. In addition, the safety of the employees in the basket is entirely dependent on the skill of the operator, and a simple mistake could have tragic consequences. Before using a man-basket, consider whether an articulating boom lift or a scissor lift might provide a safer alternative.

9. Don’t use cranes for storage. In areas where site security is a concern, it’s not unusual to see laborers end the workday by attaching a compressor or similar piece of equipment to the crane and suspending it for safekeeping. It’s a common practice, but one that’s very risky. In addition to the danger that someone could walk beneath it, a strong wind could cause the load to sway – perhaps to the point of toppling the crane. But an even better reason not to do this is that most of today’s newer cranes are hydraulically-operated. A small leak anywhere in the system will eventually reduce the hydraulic pressure to the point where the boom will drop, and the suspended load will fall on whatever is below it – may be a more expensive piece of equipment.

10. Start with a plan. Each lift is different from another, and it’s important to review load weight capacities, the integrity of the equipment, the possible effect of wind, and other factors. The operator, riggers, and other workers involved with the lift should be part of that planning process.

After all, the standards requiring tag lines on loads, capacity limits, ground stability, and similar factors have all been adopted because incidents, injuries and fatalities demonstrated a need for them. Following those rules and ensuring that your operators and other workers have the right education, training, and experience will protect everyone involved.

iFluids Crane Safety Training, Audits and Assessments

As a leading Safety consultant, we perform conformity assessments, as well as statutory and voluntary inspections on cranes, hoisting, and lifting equipment. Plus, we can also provide training for operators of cranes and elevating platforms in accordance with local, international standards, and international best practices.

Our crane, hoisting, and lifting equipment inspection services include:

• Checking of brakes, clutches, sheaves, and wire rope assemblies
• Design studies and calculation reviews
• Dynamic and static load testing
• Inspection of all the structural load-bearing members, including sheaves
• Checking crane girders, rails, and columns of overhead cranes to assure structural integrity
• Line level and span crane gantry surveys
• Non-destructive testing (NDT) of load hooks for cracks and visual inspections for distortions
• Operational tests to assure that your unit is functioning properly
• Periodic inspections and inspection prior to use of mechanical, structural, electrical, and safety systems, as well as of wire ropes and chains
• Re-examination of all safety devices
• Regulatory compliance assessments
• Remnant life assessment
• Repairs supervision

Contact us today and discover how our third-party inspection can ensure crane safety, reliability, and compliance with statutory requirements.

iFluids can also help you in implementation, audit for OSHA (Occupational Safety and Health Administration) now ISO 45001:2018 specifies requirements for occupational health and safety (OH&S).

Contact [email protected]