Transcript Crane_Training_Program.ppt

NEAL, KUHN & HUFFSTEDER, INC.
Safety / Risk Management Consulting
Group
K
N H
Cranes and
Derricks
OSHA 1926.453
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Crane and Hoist Safety
N H

1999 will see approximately 125,000
cranes in operation with an additional
100,000 in general industry.

Approximately 250,000 crane operators
–
Averaging 1 death per thousand
operators
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Crane and Hoist Safety

Many cranes are located in populated
areas and the risk to civilians is
increasing.

Safe clearance on the site is essential
although not always possible.
N H
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Crane and Hoist Safety

N H
OSHA programs
–
–
Last standard update was in the 70’s
Many advancements have been made, but not
addressed
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GENERAL REQUIREMENTS
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
The employer shall comply with the
manufacturer’s specifications and
limitations applicable to the operation of
any and all cranes and derricks.

There is a very large percentage of
accidents caused by human error in
exceeding the recommended limits !!!!!!
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General Requirements

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Modifications
–
No modifications or additions which affect the
capacity or safe operation of the equipment
shall be made by the employer without the
manufacturer's written approval and if
changes are made, the capacity, operation,
and maintenance instruction plates, tags, or
decals, shall be changed accordingly. In no
case shall the original safety factor of the
equipment be reduced.
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General Requirements

N H
Modifications
–
Many failures result from personnel adding to
or modifying the crane in manners which it was
not designed.
–
Typical modifications
 Adding
of a torque arm
 Adding a “Jib”
 Adding of a power pack
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General Requirements

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Rated load capacities, and recommended
operating speeds, special hazard
warnings etc. SHALL be conspicuously
posted on all equipment. They shall be
visible to the operator when at the
controls.
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General Requirements

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Hand signals shall be those prescribed by
the applicable ANSI for the type crane in
use. An illustration of the signals shall be
posted at the job site.
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General Requirements

The employer shall designate a
competent person who shall
inspect all machinery and equipment
prior to each use as well as during use.
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General Requirements

Daily Inspections
Inspected ??
Yes or No
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General Requirements

Daily Inspections
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General Requirements

Daily inspections
Rusted and Bent
This needs to be
replaced prior to
use.
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COMPETENT PERSON

What constitutes a
“Competent Person” ????
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Competent Person

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A “ Competent Person” is one who is
able to recognize and correct actual
and/or potential hazards involved with
crane operation; knows how to safely
operate the crane AND who has the
Authority to ensure a safe operation.
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General Requirements

N H
A thorough, annual inspection of the
hoisting machinery shall be made by a
competent person, or by a government or
private agency recognized by the U.S.
Department of Labor.
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WIRE ROPE

Terminology
N H
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WIRE ROPE

Wire rope shall be taken out of service
for a number of reasons and should be
inspected daily.
N H
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Wire Rope

N H
Reasons for removal from service
–
In Running Ropes, Six randomly distributed
broken wires in one lay or three broken wires in
one strand in one lay.
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Wire Rope

N H
Reasons for removal from service
–
–
Wear of 1/3 the original diameter of outside
individual wires, Kinking, crushing, bird
caging, or any other damage resulting in
distortion of the rope structure.
Evidence of any heat damage from any cause.
Wire Rope

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N H
Reasons for removal from service
–
Reductions from nominal diameter of:
Rope Size
Reduction
Up to 5/16”
< 1/64”
3/8” - 1/2”
< 1/32”
9/16” - 3/4”
<3/64”
7/8” - 1 1/8”
< 1/16”
1 1/4” - 1 1/2”
< 3/32”
Only a
competent
person with the
proper calipers
can make this
determination
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Wire Rope

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Reasons for removal from service
–
Reductions from nominal diameter of rope
– WHO
REMEMBERS ALL
THE MEASUREMENTS OF
THE LAST OVERHEAD ???
Cranes are the one piece of equipment
that really need the charts etc.
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PROPER SET-UP
 Level
 Stable
 Clearance
 Reach
N H
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N H
BASIC RIGGING

No matter what size crane or hoist, it still
is dependent on the rigging setup
300
8 TONS
150
8 TONS
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BASIC RIGGING
N H
Load charts

Chain size
Single
600 >
450>
300>
7/32
2,500
4,300
3,550
2,500
9/32
4,100
7,100
5,800
4,100
3//8
7,300
12,600
10,300
7,300
1/2
13,000
22,500
18,400
13,000
5//8
20,300
35,000
28,500
20,300
Load charts apply to all components of the lift:
Master links, Grab hooks, Chains, Web slings etc.
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BASIC RIGGING

N H
Protecting the overall stability of the rig
by using throat latches.
–
Must be in place and functional
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BASIC RIGGING

Rigging it properly
Load blocks etc. must
be rigged properly.
N H
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Guarding

N H
All moving parts of the crane shall be
properly guarded to prevent accidental
contact with personnel
–
–
–
–
–
Belts
Sprockets
Gears
Drums
Shafts
Fly wheels
Pulleys
Chains
Other moving parts
Guarding

Swing radius protection
–
Accessible areas within the swing radius of the
rear rotating part of the crane , either
permanently or temporarily mounted, shall be
barricaded to prevent employees being struck.
 OSHA has
made an interpretation
on this issue that strikes down
a lot of current ideas.
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N H
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Guarding

Swing radius protection
A very
dangerous
situation
unless
protected.
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Guarding

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All exhaust pipes etc. shall be protected
from employee contact.
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Guarding

N H
ALL windows in cabs shall be of safety
glass, or equivalent that introduces no
visible distortion to the operator.
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Guarding
N H
Where necessary for rigging or service, a
ladder or steps shall be provided for
access to the cab roof.
 Guardrails, handholds and steps shall be
provided for easy access to the car and
cab.
 Platforms etc. shall have anti-skid
walking surfaces.

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Fire Protection

N H
At least a 5BC rated fire extinguisher
shall be available at all operator stations
or cabs of equipment.
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ELECTRICAL SAFETY

Your primary means of protection is to
have all exposed overhead
electrical lines de-energized
when working in the area.

Real life dictates that this
is usually not the case.
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N H
Electrical Safety

When lines cannot be de-energized,
proper clearance must be maintained:
VOLTAGE
MINIMUM CLEARANCE
50 kV or below
10 Feet
< 50 kV
> = 750 kV
10 Feet + 0.4” for each 1kV over
50 kV up to and including 345 kV
16 Feet
These are MINIMUMS
!!!!
Electrical Safety

N H
Things to consider when deciding on the
“Clearance”
1.
– 2.
– 3.
– 4.
–
Clearance from What ??
Drift
Load swing (Tag Lines)
Boom and Jib
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Electrical Safety

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A person 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.
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Electrical Safety

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Monitor Person MUST have absolute
authority to stop the operations and can
only be overridden by the operator on the
side of safety.
–
ie: Monitor says OK, Operator says STOP
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Electrical Safety

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Overhead lines
–
Any overhead wire shall be considered to be
an energized line unless and until the person
owning such line or the electrical utility
authorities indicate that it is not an energized
line and it has been visibly grounded;
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Electrical Safety


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INDUCED ELECTRICAL CHARGES
Prior to work near transmitter towers where an
electrical charge can be induced in the
equipment or materials being handled, the
transmitter shall be de-energized or tests shall be
made to determine if electrical charge is induced
on the crane. The following precautions shall be
taken when necessary to dissipate induced
voltages:
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Electrical Safety
N H
INDUCED ELECTRICAL CHARGES
 The following precautions shall be taken
when necessary to dissipate induced
voltages:

–
The equipment shall be provided with an
electrical ground directly to the upper rotating
structure supporting the boom;
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Electrical Safety

N H
INDUCED ELECTRICAL CHARGES
–
Ground jumper cables shall be attached to
materials being handled by boom equipment
when electrical charge is induced while
working near energized transmitters. Crews
shall be provided with nonconductive poles
having large alligator clips or other similar
protection to attach the ground cable to the
load.
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Electrical Safety

N H
INDUCED ELECTRICAL CHARGES
–
Combustible and flammable materials shall be
removed from the immediate area prior to
operations
Suspended loads,
picking the load

All employees shall be kept clear of loads
about to be lifted and of suspended loads.
This employee was killed
because he was adjacent to
an improperly lifted load.
The hoist line was not
vertical over the load
causing it to swing and fall
on the employee.
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N H
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ACCIDENTS
N H
FAMOUS LAST
WORDS:
I’TLL NEVER
HAPPEN
HERE !!
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N H
ACCIDENTS
The operator was asked, by the project rigging superintendent, to
walk the above 4000 Manitowoc with 300 feet of boom off of the
mats it was sitting on onto soft soil. The operator told the super,
"I'll do what you want, but if I do, the crane will turn over." The
rigging superintendent replied, "That is not your problem, let me
worry about that. You are to operate the crane and follow
instructions from supervision." With that, the operator got back in
the seat, made sure the area was clear of other workers, knuckled
the crane into travel, set the throttle at a slow speed and climbed
off of the crane. No, fatalities, no injuries. Believe it or not, neither
man was fired.
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N H
ACCIDENTS
The crane was left on a barge near the edge of a river
over a week-end. Rain upstream caused the river to
rise and wash the sand from under one end of the
barge. Out of four barges left on the bank, two went
into the river, one was lost and never found. An
expensive lesson for the contractor.
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N H
ACCIDENTS
The above hydraulic crane was turned over by a young operator in
Puerto Ordez, Venezuela in 1979. He picked a load up (precast concrete
stadium seats) near the crane with his boom up at a high degree of angle.
He proceeded to boom down and before he realized that he had more
load than the crane could handle, at the radius the load had reached, it
was too late. He tried to get down on the load, but since the crane was
hydraulic, he couldn't let it down fast enough. Fortunately the operator
jumped clear before it crushed the cab.
Isn't it amazing how we all tend to learn faster after a
"Been There - Done That" experience.
The roll-over protection landed on my left knee and pinned
me down. It took an hour and forty-five minutes to get
another machine to the site to lift it off of me. Diesel was
running under me, and I was losing blood fast. My left arm
was broken in five places and all but mangled. I now have
a steel plate in it holding the five breaks together. I lost
about fifty percent use of the arm. Thank God, I can still
pull control levers with it.
K
N H
Am I now paranoid about seat belts? You bet. When I
mount a piece of rubber tired equipment now, the first
thing I do is fasten the seat belt. I pulled a stupid stunt, but
I will not be fool enough to do it again.
Been There, Done That
It is very embarrassing to publicize this, especially since that is me, Doyle
Peeks, trapped under that 580 Case loader/backhoe. I have put this here in
hopes it may keep someone else from repeating what I did. The accident
happened on October 6, 1988 near Dallas, Texas on Lake Ray Hubbard. I had
well over thirty-five years of operating experience. I just got too confident. I
thought I could go running down a slopped embankment without rolling the
machine. I had always thought that if a machine ever started to roll that I could
hang on to something and not be thrown off of the machine. Boy, was I ever
wrong. It happened so fast, I was on the ground before I knew what was
happening. I grabbed at everything I could and couldn't find a thing to hold on
to.
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N H
ACCIDENTS
This accident happened in St. Croix, U.S.V.I. in 1974. The
crane was climbing a grade into a tank farm and the
operator decided he wanted to swing around to see where
they were going. Caution: Don't swing a machine when it
is moving or in an unstable position.
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N H
ACCIDENTS
All cranes have limits.
They will tip when those limits are exceeded.
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N H
ACCIDENTS
Inexperience usually results in the above
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ACCIDENTS
Inexperience usually results in the above
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Accidents Leave Victims
My husband was killed in Louisville, Kentucky,
on December 18, 1998. He was standing near
an HTC-835 crane. The counterweight came
around and struck him in the back. He was
pinned between the counterweight and the bed
of the truck. He died at the hospital 1 hour
later.
There was no warning tape around the
crane.
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N H
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THE MOTHER OF ALL CRANE COLLAPSES
N H
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N H
THE MOTHER OF ALL CRANE COLLAPSES
 Civil
–
Damages
VERDICT AT A GLANCE
The $99.25 million jury award to the three widows of
the ironworkers killed in the Miller Park crane collapse
breaks down this way:
• $94 million in punitive damages against
Mitsubishi Heavy Industries of America
• $4.2 million, or $1.4 million to each widow,
for the pain and suffering of the
ironworkers
• $1.05 million, or $350,000 to each widow,
for loss of companionship
The verdict went to
appeal.
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Statistics
N H
US crane accidents claim 50 lives every year.
More than 500 US construction workers died in crane
accidents between 1984 and 1994, according to a study of
Occupational Health and Safety Administration (OSHA).
The International Union of Operating Engineers revealed
that 502 workers died in 480 separate accidents. Power
line contact was by far the most common cause of
accidents, accounting for 39 percent of all fatalities.
Other major causes included assembly/dismantling (12
percent), boom buckling (8 percent), rigging failure (7
percent) and upset/overturn (7 percent).
SUSPENDED PERSONNEL
PLATFORMS

STOP RIGHT HERE !!!!
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N H
SUSPENDED PERSONNEL
PLATFORMS

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N H
The use of a crane or derrick to hoist
employees on a personnel platform is
prohibited, except when the erection, use,
and dismantling of conventional means of
reaching the worksite, such as a personnel
hoist, ladder, stairway, aerial lift, elevating
work platform or scaffold, would be more
hazardous or is not possible because of
structural design or worksite conditions.
SUSPENDED PERSONNEL
PLATFORMS

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N H
Hoisting of the personnel platform shall
be performed in a slow, controlled,
cautious manner with no sudden
movements of the crane or derrick, or the
platform.
SUSPENDED PERSONNEL
PLATFORMS

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N H
Load lines shall be capable of supporting,
without failure, at least seven times the
maximum intended load, except that
where rotation resistant rope is used, the
lines shall be capable of supporting
without failure, at least ten times the
maximum intended load.
SUSPENDED PERSONNEL
PLATFORMS

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N H
Load and boom hoist drum brakes, swing
brakes, and locking devices such as pawls
or dogs shall be engaged when the
occupied personnel platform is in a
stationary position.
SUSPENDED PERSONNEL
PLATFORMS

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N H
The crane shall be uniformly level within
one percent of level grade and located on
firm footing. Cranes equipped with
outriggers shall have them all fully
deployed following manufacturer's
specifications, insofar as applicable, when
hoisting employees.
SUSPENDED PERSONNEL
PLATFORMS

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N H
The total weight of the loaded personnel
platform and related rigging shall not
exceed 50 percent of the rated capacity
for the radius and configuration of the
crane or derrick.
– BACK
TO THE LOAD CHART
SUSPENDED PERSONNEL
PLATFORMS
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N H

The use of machines having live booms (booms
in which lowering is controlled by a brake
without aid from other devices which slow the
lowering speeds) is prohibited.

The load line hoist drum shall have a system or
device on the power train, other than the load
hoist brake, which regulates the lowering rate
of speed of the hoist mechanism (controlled
load lowering.) Free fall is prohibited.
SUSPENDED PERSONNEL
PLATFORMS

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N H
All operator controls, gauges etc. must be
visible and in working order when lifting
personnel.
SUSPENDED PERSONNEL
PLATFORMS

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N H
A positive acting device shall be used
which prevents contact between the load
block or overhaul ball and the boom tip
(anti-two-blocking device), or a system
shall be used which deactivates the
hoisting action before damage occurs in
the event of a two-blocking situation
(two-block damage prevention feature).
PLATFORM DESIGN
FEATURES

The personnel platform and suspension
system shall be designed by a qualified
engineer or a qualified person competent
in structural design.

The suspension system shall be designed
to minimize tipping of the platform due
to movement of employees occupying the
platform.
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N H
PLATFORM DESIGN
FEATURES

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N H
The personnel platform itself, except the
guardrail system and personnel fall
arrest system anchorages, shall be
capable of supporting, without failure, its
own weight and at least five times the
maximum intended load.
PLATFORM DESIGN
FEATURES

Each personnel platform shall be
equipped with a guardrail system
which meets the requirements of
Subpart M, and shall be enclosed
at least from the toeboard to
mid-rail with either solid
construction or expanded metal
having openings no greater than 1/2
inch (1.27 cm).
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N H
PLATFORM DESIGN
FEATURES
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N H

A grab rail shall be installed inside the
entire perimeter of the personnel
platform.

Access gates, including sliding or folding
gates, shall be equipped with a
restraining device to prevent accidental
opening and shall not swing outward.
PLATFORM DESIGN
FEATURES
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N H

Headroom shall be provided which allows
employees to stand upright in the platform.

In addition to the use of hard hats, employees
shall be protected by overhead protection on
the personnel platform when employees are
exposed to falling objects.
PLATFORM DESIGN
FEATURES

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N H
The personnel platform shall be
conspicuously posted with a plate or
other permanent marking which
indicates the weight of the platform, and
its rated load capacity or maximum
intended load.
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PLATFORM LOADING
N H

Personnel platforms shall be used only for
employees, their tools and the materials
necessary to do their work, and shall not be
used to hoist only materials or tools when not
hoisting personnel.

Materials and tools for use during a personnel
lift shall be secured to prevent displacement.
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PLATFORM LOADING

N H
Materials and tools for use during a
personnel lift shall be evenly distributed
within the confines of the platform while
the platform is suspended.
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RIGGING THE PLATFORM

N H
When a wire rope bridle is used to connect the
personnel platform to the load line, each bridle
leg shall be connected to a master link or
shackle in such a manner to ensure that the
load is evenly divided among the bridle legs.
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RIGGING THE PLATFORM

N H
Hooks on overhaul ball assemblies, lower
load blocks, or other attachment
assemblies shall be of a type that can be
closed and locked, eliminating the hook
throat opening.
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RIGGING THE PLATFORM

All eyes in wire rope slings shall be
fabricated with thimbles.
N H
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TRIAL LIFTS
N H

A trial lift with the unoccupied personnel
platform loaded at least to the anticipated lift
weight shall be made from all locations of
entry, hoisting and positioning

This trial lift shall be performed immediately
prior to placing personnel on the platform.
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TRIAL LIFTS

N H
The operator shall determine that all
systems, controls and safety devices are
activated and functioning properly and
that all configurations necessary to reach
those work locations will allow the
operator to remain under the 50 percent
limit of the hoist's rated capacity.
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TRIAL LIFTS

N H
After the trial lift, and just prior to
hoisting personnel, the platform shall be
hoisted a few inches and inspected to
ensure that it is secure and properly
balanced. Employees shall not be hoisted
unless the following conditions are
determined to exist
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TRIAL LIFTS

N H
A visual inspection of the crane or
derrick, rigging, personnel platform, and
the crane or derrick base support or
ground shall be conducted by a
competent person immediately after the
trial lift
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TRIAL LIFTS

N H
At each job site, prior to hoisting
employees on the personnel platform, and
after any repair or modification, the
platform and rigging shall be proof tested
to 125 percent of the platform's rated
capacity by holding it in a suspended
position for five minutes
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WORK PRACTICES

N H
Except over water, employees occupying
the personnel platform shall use a body
belt/harness system with lanyard
appropriately attached to the lower load
block or overhaul ball, or to a structural
member within the personnel platform
capable of supporting a fall impact for
employees using the anchorage.
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WORK PRACTICES
N H

Employees shall keep all parts of the
body inside the platform during raising
lowering, and positioning

Tag lines shall be used unless their use
creates an unsafe condition.
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WORK PRACTICES
N H

The crane or derrick operator shall remain at
the controls at all times when the crane engine
is running and the platform is occupied.

Hoisting of employees shall be promptly
discontinued upon indication of any dangerous
weather conditions or other impending danger.
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WORK PRACTICES

N H
Employees being hoisted shall remain in
continuous sight of and in direct
communication with the operator or
signal person. In those situations where
direct visual contact with the operator is
not possible, and the use of a signal
person would create a greater hazard for
the person, direct communication alone
such as by radio may be used.
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PRE-LIFT MEETINGS

N H
A meeting attended by the crane or
derrick operator, signal person(s) (if
necessary for the lift), employee(s) to be
lifted, and the person responsible for the
task to be performed shall be held to
review the appropriate requirements of
paragraph (g) of this section and the
procedures to be followed.