PEDESTAL MOUNTED CRANE SAFETY TRAINING

INTRODUCTION
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Accountability
The material presented within this course is for
educational and training purposes only. All parties
involved in the development, distribution and
maintenance of this course shall be held harmless from
any incident resulting from misuse of the content
beyond the guidelines and purposes herein stated.
Before you begin you should understand that it is your
responsibility to adhere to the laws and regulations
presented within the following course and its
corresponding materials. Likewise, it is your further
responsibility to strictly follow any additional guidelines
specific to your own workplace. Good Luck & Stay
Safe!

Note to Instructors: the first few slides in this presentation can be drawn upon as desired
and used to initiate dialog as to the importance of safety training and operator
responsibility. If you choose to skip these slides, the official presentation begins on slide 12.

PEDESTAL MOUNTED CRANE SAFETY TRAINING

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Its required everywhere you go.

Why Safety Training?

OPERATIONS
HAZARDS

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Why Safety Training?

Its as easy as 1, 2, 3!

1. Training reduces the risk of accidents and

injuries to you and those you work with

2. Training reduces operating costs (How?)

3. OSHA requires it no matter who you are or
how long youve been operating.

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INTRODUCTION

Welcome to the Hard Hat Training series. Today you will learn about pedestal cranes that are
mounted on maritime docks and vessels. We will strive to provide information that will
increase your knowledge and help to make you a better operator.

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Cranes are the workhorses that have increased the economic growth and productivity in
construction, mining, logging, maritime, production and service facilities. It is not uncommon
while driving in urban areas to see mobile cranes, tower cranes and maritime cranes all in a
short period of time, performing a wide variety of jobs.

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Maritime cranes are essential in the on and off load of products, machinery and the manufacture
and repair of ships and boats.

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From large gantry cranes used to lift containers on and off ships to small swinging jibs used
for lifting much smaller loads, training is needed to ensure safe operation and productivity.

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During this training we will cover the anatomy of these cranes and stress the importance of
inspecting them each day before it is put into service.

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We will talk about lifts that are critical lifts and the additional planning that is required.

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We will discuss the more common hazards associated with cranes in the maritime industry.

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We will discuss some basic rigging principles and how to safely inspect and use lifting slings
and other common lifting hardware.

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We will discuss the safety considerations of making a lift and the importance of good
communication and proper hand signals.

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Upon completion of this training, you should be familiar with the types of cranes used by your
company, have an increased knowledge of how to inspect and safely operate them, and be able
to recognize the common hazards that surround their use.

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Strictly defined, a maritime crane is any type of crane that works around or is mounted on a
dock, vessel or in a shipyard and is used for on and off-loads of marine vessels or the repair and
construction of ships.

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Pedestal mounted cranes are perhaps the most common found on board vessels and docks.

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Swinging jib cranes are the simplest dock crane that often consist of just a fixed boom, manual
swing and electric winch for the hoist line.

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Some larger ships and many derrick barges have lattice boom, friction cranes that have
capacities from 25 tons to over 250 tons.

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Portal cranes (sometimes called whirleys) and container cranes are perhaps the most visible,
sticking out against the horizon like huge mechanical dinosaurs.

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Maritime Crane Regulations

These are the main OSHA standards concerning cranes involved in maritime operations but
certainly not all of them. Many states have additional standards as do some industries such as
offshore oil platforms, etc.

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OSHA requires cranes to be inspected at the beginning of each day that it is in use. This is
sometimes referred to as a pre-shift or frequent inspection.

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The operator or a designated person is required to do this inspection but they do not have to
be lengthy. You are basically looking for obvious things that might be wrong with the crane.

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These are the main components of the pedestal crane that we will discuss.

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Typically, the operator station is found near the pedestal or in an area overlooking the hatch or
the dock. Others are attached to the turret of the crane and rotate with the crane as it swings.

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Before engaging the power switch, make sure that the controls are in the neutral position.
Each lever should be marked correctly and not stick. If any control is stuck on when the power
switch is turned on then that control is live and could have severe consequences.

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Other cranes have pendant controls that also allow the operator to run the crane from different
locations but are limited to the length of the pendant. Inspect the pendant daily for frays,
broken connectors and that the controls are properly marked.

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Turret section components

RIGGING

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The crane is only as strong as the structure it is mounted on. Check the supports, gussets and
welds that attach it to the dock or vessel. If it is mounted on a wooden dock then the timbers
need to be checked from time to time and replaced if they show signs of dry rot or weakness.

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Cracks in the paint around the bolt or loose washers are a sure indication that there has been
movement and that the bolt should be replaced.

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Components of the Boom

OPERATIONS

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The boom tip should be examined for bends and twists. Grooves in the sideplates or in the
flanges of the sheaves are a sure sign of side loading. Severe grooves will require the sheaves
of the boom tip to be rebuilt or replaced.

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Also, very common is an assortment of brands of rotation-resistant wire rope. The nonrotating characteristic is secured by building into the rope two layers of strands, one having
Right Lay and the other Left Lay. The tendency of one layer of strands to rotate in one
direction is counteracted by the tendency of the other layer of strands to rotate in the
opposite direction.

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All wire rope, if left on the crane long enough will eventually fatigue and fail. Heavy loads will
accelerate the wear of wire rope.

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Always check the spooling on the drum before each lift. Bad spooling is usually the result of
slack in the line when the block or hook is laid on the ground. Cranes with an insufficient
headache ball or weight on the hoist line will have more problems spooling correctly because
there is not enough tension on the line.

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Two-blocking the hoist line may cause birdcaging for the same reason. As the hook is brought
into the boom tip it can overstress the wire rope and when released abruptly it can become
birdcaged.

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Hook Assembly Components

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6 Common Hazards

OSHA statistics have shown that there is certain inherit dangers associated with crane operations
even during normal working conditions. We will discuss five of the most common hazards
associated with pedestal crane operation and show how to recognize these hazards and avoid or
minimize them. They are: two blocking, hit by fallen load, hoisting personnel, view obstruction,
and poor rigging practices.

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Some companies simply consider a critical lift as one that is near the maximum capacity of
the crane. 75% of the capacity is a common figure used. However, there could be some other
situations that would make a lift more dangerous than others. If any of the following
conditions are present then the lift should be planned and precautions put in place.

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Two-blocking the Crane

Two-blocking occurs when the hoist block or hook assembly comes into contact with the upper
block or boom tip, causing the hoist line to break and the hook and load to fall, endangering
workers below. Consider the following accident:

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The following accident profiles will show how quickly things can go wrong when lifts are not
planned properly. Add to that a few safety procedures that were ignored and fatalities or
injuries were the result. These profiles were taken from the OSHA website. The names of
the company, equipment, and location have been omitted.

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What went wrong?

RIGGING

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What went wrong?

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A trial lift of an empty basket will be conducted by the crane operator to insure the personnel
transfer system is rigged properly and fully functional to each location it is to be hoisted or
positioned.

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Operator's View Obstructed

Safe use of a crane is compromised when the vision of an operator, rigger or signaler is blocked,
and employees cannot see what the others are doing.

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What went wrong?

RIGGING
RIGGING

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The advantages of synthetic slings are their comparative low cost, light weight and the pliability
of its fabric. The slings we will discuss in this section are web slings, round slings and fiber rope
slings.

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Fiber rope slings are made from natural and synthetic materials and are formed by 3 strands
wrapped around each other or multiple strands woven together. Because there are so many
types of materials that are used to make them it is essential that you know the type of material
and its capacity before use.

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Eyes in fiber ropes are formed by splicing it back on itself with at least four full tucks. Only a
competent person should perform this procedure.

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Synthetic Sling Inspection

A program for the inspection of lifting slings is your best safeguard against sling damage and
abuse.

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Check the stitching to see if the sling has been overloaded, putting stress on the stitching
causing it to pull out. Another way to damage the stitching is to put the eye of the sling over
a hook or shackle that is too wide.

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Wire Rope and Chain Sling Inspection

Wire rope slings are very durable and can be used in a variety of situations.

They also have

their limitations. Theyre not as pliable as synthetic slings and tend to become kinked if put
into a tight choker. Inspect each sling before use for the following:

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Capacity tags are required and must have the capacity, a description of the sling, size of chain
and sling length, and manufacturer.

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All shackles used for lifting must have the safe working load or working load limit printed on
the shackle body as well as the manufacturer and country where it was made. Never use a
shackle that is not load rated or is without these markings.

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This chart shows the reduction of the capacity of the shackle when it is pulled to the side.
Note that there is no reduction if there is a 120-degree included angle or more.

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Shouldered eyebolts can be used for side picks but only inline with the eye of the bolt and with
major reductions in the capacity. For example if you were to attach a sling to an eyebolt at a
45 degree angle, you will loose 70 percent of its capacity.

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Swivel hoist rings are a great substitute for eyebolts. Their load rating is the same at all
angles. The bail will swivel and line itself up with the sling. Always make sure have the right
bolt size and length and that you know the load rating.

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Basic Rigging Practices

Before you make the lift there are certain things you must take into consideration. To lift a load
safely you must know the weight of the load, where its center of gravity is and the stresses that
will be imposed on the load and the rigging gear as you make the lift.

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Here is the weight of some common materials. Understand that if you are using approved
calculations, it will be very difficult to get an exact weight. If by using these calculations you
determine that the weight of the load is close to the maximum capacity of the crane then you
should probably take the time to weigh it just to make sure you are not going to overload the
crane.

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Load's Center of Gravity

The definition of the center of gravity is: 'a point in an object around which all the weight of
that object is evenly distributed. Determining the center of gravity in a load is key to safe
rigging and lifting.

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Sling Angles

Anyone that is an operator of lifting devices should have a thorough understanding of sling
angles and the stresses that low angles can put on a sling and the compression it can have on
a load.

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All that is needed to calculate these stresses is the weight of the object and a measuring tape.
As shown in the slide above, the length of the sling is divided by the height of the sling
connection to the top of the load. The answer is then multiplied by that portion of the load that
it would support and this will be the stress in the sling.

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The ideal sling angle should be 60-degrees or more and by ANSI standards should never be
below 30-degrees. An easy way to determine if you have at least a 60-degree sling angle is to
take the sling that you would want to use and stretch it out between the two pick points on
the load. If the sling is equal to or longer than the distance between the two pick points, then
the angle will be 60 degrees or more. If the sling is shorter then you should probably
calculate the stress the sling will see before preceding or choose longer slings.

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If more control is needed, wrap the sling around the load twice before threading it through the
opposite eye. This hitch is called a double-wrap choker and will provide even more control
since it provides more contact area to the load.

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It is usually unwise to use just one sling to lift a load, especially loose materials or long,
unbalanced loads. Most vertical hitches are used in tandem with a lifting beam or in a bridle.

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A 3-leg bridle will have more capacity than a 4-leg bridle. This is because there is equal leg
loading on a 3-leg bridle. On a 4-leg bridle, two of the legs will be supporting most of the load
while the other two legs mostly provide balance. Hence, the capacity of a 4-leg bridle will be
equivalent to a two-leg bridle.

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SAFE OPERATION GUIDELINES

Before you operate a crane you must be trained and authorized, be familiar with the type of crane
you are going to use, and you should have read the operator's manual and understand the safe
operation portion of it.

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There should be a warning label attached to the

pendant controls. Follow all warning labels and signs
on the crane. If labels are missing or illegible,
replace them.

RIGGING

OPERATIONS

Need Pendant Warning Tags?

Pictured Right: 8.75x2.5 flexible, heavy duty
vinyl tags (English on front/Spanish on back).
Available through Safety Provisions, Inc.:
1 for $10 or in packs of 10 for $90.00 + shipping.

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Inspect the crane at the beginning of the shift. Never use a crane in need of repairs.

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The wire rope should be inspected daily, especially how it is spooled on the drum. Insure that
the running crane is reeved with sufficient parts of line for the lift.

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On cranes that have load charts for different capacities you need to know the radius of the pick
and placement of the load to prevent overloading.

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OSHA regulation states, the employer shall ensure that the operator does not leave his position
at the controls while the load is suspended. Always put the load down and secure it before
leaving the area.

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Do not load the hook tip. Insure that the slings are not loose and the eyes are in the saddle of
the hook.

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Before hoisting the load, check for unsecured or loose parts that might shift or fall. Start lifts
slowly and avoid shock loading. Make sure the load comes up level.

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Tilting up panels or walls improperly can also be dangerous. Never attempt to yard or drag a
load. And especially never attempt to yard or drag a load to the side. This will damage the
pinion gear on the swing motor.

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Never hoist a load over the heads of employees. Never allow a rigger to stand under a load as it
descends for the purpose of controlling it. Use a tag line instead.

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OPERATIONS

If this cannot be accomplished, a signal system should be used. Standard signals will be shown
in this training; however, it may be necessary to create special signals in certain circumstances.

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OPERATIONS

A hand signal chart with the standard hand signals for the type of crane you are operating
is required to be posted on the crane or in the work area. Below is a typical hand signal
chart used for cranes.

Need Hand Signal charts?

Pictured 5x14 all-weather vinyl decals available
through Safety Provisions, Inc. 1 for $12 or in packs
for 5 for $45.00. (orange or green). Glossy wallet
cards also available (as is or with your logo).

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STABILITY

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HAZARDS

RIGGING/OPER
OPERATIONS

The following hand signals have corresponding video clips, which can be used to further
clarify any confusion pertaining to how a sign should be given. To access these clips refer to
the Hand Signal folder located in the Poster, Other folder. Follow the Content Map to
locate them if needed.

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INTRODUCTION

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STABILITY

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HAZARDS

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OPERATIONS

Swing Boom. This signal is given by pointing the hand in the desired direction of travel. Try
to keep your thumb down so as not to confuse it with the boom up signal. An alternate version
of this sign consists of bringing your arm in front of you, across your torso, again pointing in
the desired direction of travel.

PEDESTAL MOUNTED CRANE SAFETY TRAINING

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OPERATIONS

Boom Up/Boom Down. The signal for raising or lowering the boom is given by
holding your arm out to one side with you thumb up or down with the other fingers
folded in.

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HAZARDS

RIGGING/OPER
OPERATIONS

Telescope In/Out. The signal to telescope is given by raising your arms in front of you
with your thumbs pointing in toward each other for telescoping in or out and away from
each other for telescoping out.

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INTRODUCTION

ANATOMY
ANATOMY

HAZARDS
HAZARDS

RIGGING
RIGGING

OPERATIONS
OPERATIONS

Cranes, like all equipment, can inflict serious injury or death when misused or abused. Improper
training, poor operation, failure to perform preventive maintenance, and failure to inspect can
have serious consequences.

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INTRODUCTION

ANATOMY
ANATOMY

HAZARDS
HAZARDS

RIGGING
RIGGING

OPERATIONS
OPERATIONS

Safety is the responsibility of everyone involved in crane operations, from operators to

maintenance personnel. You can help ensure safe operation of cranes by knowing and
following all safe work practices and safety regulations that are applicable in your
workplace.