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Policy
The crane and hoist safety program’s purpose is to define work practices and inspection procedures to help ensure that overhead crane operators at [Company Name] are protected from potential hazards associated with moving equipment and materials. This program applies to all employees who operate and use overhead cranes, portable hoists, chains and slings, and personnel platforms.
Responsibilities
Supervisors who may be required to comply with the crane safety program shall:
- Attend training on the crane/hoist safety program requirements, which include chain, sling, and hoist inspections.
- Assure program requirements are observed with respect to daily, monthly, and annual inspections. Establish and maintain an inspection checklist recordkeeping system.
- Ensure crane operator fitness for duty.
- Maintain a certification record for inspection that includes inspection date and signature of person who performed the inspection.
The crane operator shall:
- Attend training on the crane/hoist safety program requirements, which include chain, sling, and hoist inspections.
- Conduct appropriate inspections, when required, and complete required documentation.
Fitness for Duty
An overhead crane (cranes/hoists that are two or more tons) operator must be physically fit, thoroughly trained, and competent. They must not be using any drugs that could impair physical, visual, or mental reactions or capabilities and must understand all regulations regarding crane safety.
Inspections
Overhead crane inspections are divided into frequent, monthly, and periodic classifications. Inspection checklists are completed as part of the inspection process. Inspection checklists shall be available for inspection.
Frequent Inspections
- Deterioration or leakage in lines, tanks, valves, drain pumps, and other parts of air or hydraulic systems.
- Rope slings, hooks, and other lifting equipment shall be visually inspected prior to each day's use. All parts, including chains, cables, ropes, hooks, etc., on overhead and gantry cranes, shall be visually inspected daily for deformation, cracks, excessive wear, twists, stretch, or other signs of deterioration that may pose a hazard during use.
- Hooks and chains shall be visually inspected daily and monthly with a certification record that documents the inspection date, the signature of the person who performed the inspection, and equipment serial number/another identifier. Any hooks with cracks or that have more than 15% more than normal throat opening or more than 10% twist from the plane of the unbent hook must be replaced.
Monthly Inspections
All running ropes should be prepared, including a certification record that includes inspection date and signature of the person who performed the inspection. Any deterioration that results in appreciable loss of strength shall be inspected and a determination made as to whether further use of the rope constitutes a safety hazard. These can include:
- Reduction of rope diameter below a nominal diameter due to loss of core support, internal or external corrosion, or wear of outside wires.
- Three broken wires in one strand in one lay length or six broken wires in any one lay length.
- Worn outside wires.
- Wires that are corroded or broken at connections.
- Corroded, cracked, bent, worn, or improperly applied end connections on the equipment nameplate.
- Severely kinked, crushed, cut, or broken strands.
Periodic Inspections (see attachments)
Periodic inspections shall be conducted by a trained employee or a contract-certified inspection service. A complete crane inspection shall be performed at least every 12 months and should include the following items:
- Note any cracked corroded, worn, or loose members or parts.
- Note and replace loose bolts and tightening those bolts.
- Test the limit indicators (wind, load, etc.), power plant, and electrical apparatus.
- Perform load testing at no more than 125% of the rated load unless otherwise recommended by the equipment manufacturer.
- Examine electrical apparatus for any signs of pitting or any controller contractor, limit switch, and push button station deterioration.
- Travel distance steering.
- Test the braking system for excessive wear on the lining, pawls, and ratchets.
- Hooks and cables – if any adjustments must be made to the unit, the crane will not be operated until all guards have been installed, all safety devices reactivated, and all maintenance equipment moved. If any defect is found, the crane will not be operated until the repair or the adjustment is made.
Rated Load Marking
The crane’s rated load shall be plainly marked on each side of the crane. If the crane has more than one hoisting unit, each hoist and each hoist attachment should have the rated load clearly marked. The marking shall be clearly legible from the ground/floor. The load shall not exceed the rated load of the crane or hoist.
Electrical Equipment
All wiring shall adhere to the National Electrical Code. The control circuit shall not exceed 600 volts. The pendant control voltage shall not exceed 150 volts AC and 300 volts DC. The pendant shall be supported by some means to prevent strain on the electric wire. The pendant control buttons shall be clearly marked as to their function. Lockout and tagout procedures will be used while maintenance is being done.
Holding Brakes
Holding brakes shall be applied automatically when power is disconnected. Holding brakes shall have an adjustment means. All brake drums shall be maintained with a smooth surface. Brakes may be applied by mechanical, electrical, pneumatic, gravity, or hydraulic means.
Crane Operation
- Operator shall not leave their position at the controls while a load is suspended or pass under a suspended load on the hook.
- Employees shall not walk under a suspended load.
- To attach a load, operator must be familiar with appropriate rigging and hoisting techniques – use a hoist chain/rope free of kinks/twists, a block hook with slings (sling should clear all obstacles), or other approved devices to attach the load.
- To move a load, it should be well secured and properly balanced in the sling/lifting device before it is lifted more than a few inches.
- Before starting the hoist, the hoist rope should not be kinked, and the multipart lines should not be twisted around each other. The hook should be brought over the load to prevent swinging.
- There should be no sudden acceleration or deceleration of a moving load.
- A load should not contact any obstructions.
- While any employee is on the load or hook, there will be no hoisting, lowering, or traveling.
- The operator will avoid carrying loads over people.
- The operator will test the brakes each time a load approaching the rated load is handled. The brakes will be tested by raising the load a few inches and applying the brakes.
- The load will not be lowered below the point where less than three full wraps remain on the hoisting drum. The upper limit switch shall never be used as an operational control.
- The operator will not leave his position while a load is suspended.
- The operator needs to be aware of the appropriate chain, hoist, and sling requirements.
Chains, Slings, and Hoists
Damaged/defective slings, chains, or hoists should be destroyed. Slings shall not be shortened with knots, belts, or other makeshift devices. Sling legs shall not be kinked. Slings shall not be loaded more than their rated capacities. They shall be securely attached to their loads.
Allow Steel Chain Slings
All steel chain slings should have a permanently affixed, durable identification stating size, grade, rated capacity and reach, and inspection date. Worn or damaged alloy steel chain slings or attachments should not be used until repaired.
Wire Rope Slings
Fiber core wire rope slings of all grades should be removed from service if they are exposed to temperatures more than 200 degrees. Wire rope slings should be removed from service if any of the following is present:
- Six randomly distributed broken wires in one rope lay or three broken wires in one strand in one rope lay.
- Wear or scraping of one-third the original diameter of outside individual wires.
- Kinking, crushing, bird caging, or any other damage is noted.
- Corrosion of the rope or end attachments.
- Evidence of heat damage.
- End attachments are cracked, deformed, or worn.
- It is determined that hooks have been opened more than 15% of the normal throat opening measured at the narrowest point or twisted more than 10 degrees from the plane of the unbent hook.
Metal Mesh Slings
Each metal mesh sling shall have a durable marking that states the rated capacity for a vertical basket and choker hitch loadings permanently affixed to it. If handles are used on metal mesh slings, the rated capacity must be at least equal to the metal fabric and exhibit no deformations after load testing. Metal mesh slings must be immediately removed from service if any of the following conditions are present:
- A broken weld or brazed joint along the sling edge.
- A reduction in wire diameter of 25% due to abrasion or 15% due to corrosion.
- Lack of flexibility due to distortion of the fabric.
- A 15% reduction of the original cross-sectional area of metal at any point around the handle eye.
- Distortion of the female handle so that the depth of the slot is increased more than 10%.
- Distortion of either handle so the width of the eye is decreased more than 10%.
Natural and Synthetic Fiber Rope Slings
Natural and synthetic fiber rope slings, except for wet frozen slings, may be used in a temperature range from -20 to 180 degrees without decreasing the working load limit. For operations outside of this range, follow the manufacturer recommendations. Natural and synthetic fiber rope slings shall be immediately removed from service if there is abnormal wear, powdered fiber between strands, variations in the size or roundness of strands, discoloration/rotting, or hardware distortion in the sling.
Each sling should be marked or coded to show the rated capacities for each type of hitch and type of synthetic web material. Nylon web slings should not be used where fumes, vapors, sprays, mists, or acid/phenol liquids are present. Polyester and polypropylene web slings shall not be used where fumes, vapors, sprays, or caustic mists are present. Web slings with aluminum fittings shall not be used where fumes, vapors, sprays, mists, or liquid caustics are present. Synthetic polyester web slings should not be used with temperatures more than 180 degrees. Polypropylene web slings should not be used at temperatures more than 200 degrees. Synthetic web slings shall be immediately removed and destroyed if there are acid/caustic burns, melting/charring of any part of the sling surface, broken/worn stitches, fittings distortion, snags, punctures, tears, or cuts.
PPE
All employees who handle the wire slings and the hoist cables shall wear leather gloves to prevent any hand injury.
Mobile Cranes
The employing department shall comply with manufacturer specifications and limitations applicable to the operation of any cranes or derricks. The attachments used with a crane shall not exceed the recommended capacity, rating, or scope. The rated load recommended capacities, operating speeds, and special hazard warnings/instructions shall be conspicuously posted on all equipment. The requirements are:
A designated competent person will inspect all machinery and equipment prior to and during each use to make sure it is in safe operating condition. If a defective part is found, all parts must be repaired or replaced.
A thorough annual inspection of the hoisting machinery shall be made by a competent person. The inspection dates and results for each hoisting machine and piece of equipment will be maintained by each department. The department will prepare a certification record, which will include the crane inspection date and serial number/another identifier. The most recent certification will be retained on file until a new one is prepared.
- All accessible areas within swing radius of the rear of the rotating superstructure of the crane shall be barricaded to prevent an employee from being struck or crushed by the crane.
- All exhaust pipes shall be guarded or insulated in areas where contact by employees is possible in the performance of normal duties.
- All windows in cabs shall be safety glass or equivalent. There should be no visible distortion that will interfere with the safe operation of the machine.
- Guard rails, handholds, and steps shall be provided on cranes for easy access to the car and the cab. G platforms and walkways shall have anti-skid surfaces.
- An accessible fire extinguisher of 5BC rating or higher shall be available at all operator stations or cabs of equipment.
- If the equipment or machinery must be operated next to electrical lines, then the following procedures must be followed:
- For electrical lines that are rated 50 KV or below, the minimum clearance between the lines and any part of the crane or load shall be 10 feet.
- For lines rated over 50 KV, the minimum clearance between the lines and any part of the crane or load shall be 10 feet plus 0.4 inches for each 1 KV over 50 KV, or twice the length of the line insulator, but never less than 10 feet.
- If the equipment is in transit with no load and boom lowered, the equipment clearance shall be a minimum of 4 feet for voltages less than 50 KV and 10 feet for voltages over 50 KV, up to and including 345KV, and 16 feet for voltages up to and including 750 KV.
- A safety observer shall be designated to observe clearance of the equipment and give timely warning for all operations where it is difficult for the operator to maintain the desired clearance by visual means.
- Any overhead wire shall be considered an energized line unless documentation is available to determine that the electrical lines are de-energized.
Frequent Inspection Checklist – Overhead Crane
Inspect Daily
Date: Inspected By:
Location: Crane Make:
Model: Serial Number:
Lifting Capacity:
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Equipment |
Satisfactory |
Unsatisfactory |
N/A |
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Stop button control operational |
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Fluid leaks |
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Controls operational |
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Warning/indicator lights |
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Alarms |
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Other |
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Slings/Hooks/Lifting Equipment |
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Chains |
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Cables |
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Ropes |
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Hooks |
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Running ropes |
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Comments:
Periodic Inspection Checklist – Overhead Crane
Inspect at least annually
Date: Inspected By:
Location: Crane Make:
Model: Serial Number:
Lifting Capacity:
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Equipment |
Working |
Faulty |
N/A |
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Bridge |
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Motor |
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Brake |
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Shaft couplings |
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Shaft bearings |
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Gears |
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Wheels |
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Girders and connections |
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Guards and covers |
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Bumpers |
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Bumper bolts |
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Controls |
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Master switches |
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Push button |
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Wiring |
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Main Hoist |
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Motor |
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Brake |
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Couplings |
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Gears, shaft, and bearings |
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Upper block |
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Lower block |
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Hook, magnetic particle |
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Hook and throat opening measurement |
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Hook |
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Hoist cable |
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Rope drum |
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Guards |
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Limit switch |
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Cable attachment to drum |
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Trolley |
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Motor |
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Brake |
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Couplings |
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Gears, shaft, and bearings |
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Frame |
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Wheels |
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Bumpers |
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Guards |
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Rails |
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Conductors |
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Collectors |
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Runways |
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Rails including span |
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Rail joints |
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Main conductors |
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Main collectors |
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Inspection copy and date |
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Authorized user sign |
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Lubrication |
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Capacity signs |
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Warnings signs |
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Lockout mechanism |
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Comments:
Periodic Inspection Checklist – Ratchet Chain Hoists
Inspect monthly
Date: Inspected By:
Location: Crane Make:
Model: Serial Number:
Lifting Capacity:
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Equipment |
Working |
Faulty |
N/A |
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Load Chain |
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Remove any foreign material from the chain |
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Inspect both load and lift chain for wear using a gauge |
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Inspect chain for gouges, nicks, arc burns, twisted, bent, and worn or damaged links |
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Lower hook and throat opening measurement |
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Upper hook and throat opening measurement |
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Safety latch |
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Hook swivel |
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Hook pin |
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Self-energizing brake |
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Ratchet mechanism |
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Inspect sheaves for wear and freedom of movement |
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Inspect dead end pins |
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Attachment for the chain to hoist |
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Comments:
Inspection Checklist – Electric Chain Hoist
Inspect monthly
Date: Inspected By:
Location: Crane Make:
Model: Serial Number:
Lifting Capacity:
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Equipment |
Working |
Faulty |
N/A |
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Structural Support System |
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Mounting base |
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Vertical support column |
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Horizontal support column |
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Support and beam – maximum rated capacity stenciled on the beam |
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Main Hoist |
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Clean the chain by removing any foreign material such as dirt and grease and inspect the chain for wear using a gauge |
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Slack the chain and observe if wear exists at interlink bearing surface between the links |
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Inspect the chain for gouges, nicks, arc burns, twisted, bent, and worn or damaged links |
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Inspect the loose end-link, loose end screw and dead-end block and clevis pin on the double reeved units |
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Inspect sheave wheel for freedom of movement |
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Mechanical Load Spring Brake |
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Electrical brake |
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Lower hook and throat opening measurement |
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Upper hook |
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Hook Swivel |
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Hook pin |
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Chain drum |
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Guards |
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Limit switches Operation |
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Inspect all connections are made, and screw terminals are tight |
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Check ground screws to see that ground wires of the pendant push button cable and power cord are secure |
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Master switch |
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Other |
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