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Perform a risk assessment for crane operations

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Here's a risk assessment for crane operations in the United States, focusing on hazard identification, risk assessment, and control measures based on OSHA regulations and best practices.

Hazard Identification:

  • Crane Tip-Over: Ground instability, exceeding load limits, improper setup [1], and failure to account for wind conditions can lead to crane tip-over.
  • Load Dropping: This can occur due to rigging failure, exceeding load limits [1], or mechanical failure of the crane.
  • Struck-By Hazards: Workers can be struck by the load, crane components, or rigging equipment.
  • Electrical Hazards: Contact with overhead power lines can cause electrocution.
  • Mechanical Failures: Brake failure, wire rope failure, or other mechanical issues can lead to accidents [2].
  • Falls: Workers may fall from the crane or the load during rigging or maintenance.
  • Swing Radius Hazards: Personnel within the swing radius of the crane can be struck by the rotating crane [3].
  • Crushing Hazards: Occur during rigging, hoisting, or movement of materials.

Risk Assessment:

Assess the likelihood and severity of each hazard. Factors to consider include:

  • Likelihood: Frequency of the task, condition of equipment, experience of personnel, and environmental conditions.
  • Severity: Potential injuries (minor to fatal), property damage, and environmental impact.

Control Measures:

Prioritize the following control measures in the order of elimination, substitution, engineering controls, administrative controls, and PPE.

  1. Elimination:
    • Where possible, eliminate the need for crane operations by using alternative methods.
  1. Engineering Controls:
    • Use cranes with appropriate safety devices: Load moment indicators, overload protection systems, anti-two block devices, and outrigger monitoring systems.
    • Ensure proper ground support: Use outrigger pads or mats to distribute the load over a larger area.
    • Maintain equipment: Regularly inspect and maintain cranes and rigging equipment according to manufacturer's recommendations and OSHA standards [4].
  1. Administrative Controls:
    • Qualified Personnel: Ensure that crane operators, riggers, and signal persons are properly trained and certified [5].
    • Lift Planning: Develop a detailed lift plan that includes load weight, rigging configuration, crane location, and potential hazards. Review the plan with all personnel involved in the lift.
    • Load Limits: Never exceed the crane's rated capacity [1]. Verify the weight of the load using a reliable method [1].
    • Communication: Use clear and consistent hand signals or radio communication between the operator, rigger, and signal person.
    • Weather Conditions: Monitor weather conditions and suspend operations if wind speed, ice, or other factors create a hazard [4].
    • Pre-Operation Inspection: Conduct daily inspections of the crane and rigging equipment before each shift [4].
    • Fall Zones: Erect barricades or caution lines to prevent unauthorized personnel from entering the fall zone [5].
    • Tag-Out Procedures: Implement tag-out procedures for equipment that is out of service [4].
    • Operational Procedures: Adhere to manufacturer's procedures for safe operation [5].
    • Emergency Procedures: Establish and communicate emergency procedures for responding to accidents or equipment failures.
    • Swing Radius Control: Ground personnel should maintain a safe distance from the machine. Remain out of the swing radius/ swing zone, and always check for ground personnel in the swing radius/swing zone. Do not operate with ground personnel in the swing radius/ swing zone [3].
  1. Personal Protective Equipment (PPE):
    • Hard hats: Required for all personnel in the work area.
    • Safety glasses: To protect against flying debris.
    • High-visibility clothing: To ensure workers are visible to crane operators and other equipment operators.
    • Gloves: To protect hands from cuts and abrasions.
    • Safety boots: With steel toes and slip-resistant soles.

Monitoring and Review:

  • Regularly inspect cranes and rigging equipment.
  • Conduct periodic audits of crane operations to ensure compliance with safety procedures.
  • Review accident and incident reports to identify trends and areas for improvement.
  • Update the risk assessment and control measures as needed to reflect changes in equipment, procedures, or regulations.

Specific Considerations for the United States:

  • OSHA 29 CFR 1926 Subpart CC: Cranes and Derricks in Construction outlines specific requirements for crane operations in the construction industry [5].
  • State and Local Regulations: Be aware of and comply with any additional state or local regulations regarding crane operations.

By implementing these control measures and continuously monitoring crane operations, you can significantly reduce the risk of accidents and injuries.

5 source record(s)

Sources used for this answer

[1] CAT 374 Excavator Operation and Maintenance Manual

Page 43

Open source document

Source excerpt

## Operation Guidance - · Ground personnel should maintain a safe distance from the machine. Remain out of the swing radius/ swing zone, and always check for ground personnel in the swing radius/swing zone. Do not operate with ground personnel in the swing radius/ swing zone. - · When setting height or load restrictions, make sure that any work tools that are attached are in the least favorable position. - · Check for the correct operation once the restriction has been set. - · Validate proper settings both initially and periodically during machine operation. - · Do not move the (machine) quickly when close to a restriction setting. - · Do not operate the machine in a reckless manner. - · Do not travel with the restriction set. - · Reset the load restriction if the machine is moved to a different location. - · Always check settings or reestablish desired settings after leaving the machine for any period to ensure desired performance. - · If the proper setting procedure has been followed, but the system does not appear to be functioning properly, consult your Cat dealer. Hazard recommendations: - · Return the joysticks to the neutral position once a limit has been reached - · Operate the machine at a slow speed - · Do not travel ## Lifting operations with the machine - · Ensure that Lift Mode is selected during lifting operations - · Operate the machine at a safe speed - · Take special care when traveling with a load attached - · Do not operate the machine in a reckless manner i07889511 ## Operation SMCS Code: 7000 ## Machine Operating Temperature Range The machine must function satisfactorily in the anticipated ambient temperature limits that are encountered during operation. The standard machine configuration is intended for use within an ambient temperature range of -18 °C (0 °F) to 43 °C (109 °F). Special configurations for different ambient temperatures may be available. Consult your Cat dealer for additional information on special configurations of y…

[2] Safety and Health Regulations for Construction (OSHA)

Page 140

Open source document

Source excerpt

## 29 CFR 1926 (OSHA) - (o) Compliance with rated capacity. (1) The equipment must not be operated in excess of its rated capacity. - (2) The operator must not be required to operate the equipment in a manner that would violate paragraph (o)(1) of this section. - (3) Load weight. The operator must verify that the load is within the rated capacity of the equipment by at least one of the following methods: - (i) The weight of the load must be determined from a source recognized by the industry (such as the load's manufacturer), or by a calculation method recognized by the industry (such as calculating a steel beam from measured dimensions and a known per foot weight), or by other equally reliable means. In addition, when requested by the operator, this information must be provided to the operator prior to the lift; or - (ii) The operator must begin hoisting the load to determine, using a load weighing device, load moment indicator, rated capacity indicator, or rated capacity limiter, if it exceeds 75 percent of the maximum rated capacity at the longest radius that will be used during the lift operation. If it does, the operator must not proceed with the lift until he/she verifies the weight of the load in accordance with paragraph (o)(3)(i) of this section. - (p) The boom or other parts of the equipment must not contact any obstruction. - (q) The equipment must not be used to drag or pull loads sideways. - (r) On wheel-mounted equipment, no loads must be lifted over the front area, except as permitted by the manufacturer. - (s) The operator must test the brakes each time a load that is 90% or more of the maximum line pull is handled by lifting the load a few inches and applying the brakes. In duty cycle and repetitive lifts where each lift is 90% or more of the maximum line pull, this requirement applies to the first lift but not to successive lifts. - (t) Neither the load nor the boom must be lowered below the point where less than two full wraps of rope remain on t…

[3] Safety and Health Regulations for Construction (OSHA)

Page 141

Open source document

Source excerpt

## 29 CFR 1926 (OSHA) - (v) Rotational speed of the equipment must be such that the load does not swing out beyond the radius at which it can be controlled. - (w) A tag or restraint line must be used if necessary to prevent rotation of the load that would be hazardous. - (x) The brakes must be adjusted in accordance with manufacturer procedures to prevent unintended movement. - (y) The operator must obey a stop (or emergency stop) signal, irrespective of who gives it. - (z) Swinging locomotive cranes. A locomotive crane must not be swung into a position where railway cars on an adjacent track could strike it, until it is determined that cars are not being moved on the adjacent track and that proper flag protection has been established. - (aa) Counterweight/ballast. (1) The following applies to equipment other than tower cranes: - (i) Equipment must not be operated without the counterweight or ballast in place as specified by the manufacturer. - (ii) The maximum counterweight or ballast specified by the manufacturer for the equipment must not be exceeded. - (2) Counterweight/ballast requirements for tower cranes are specified in §1926.1435(b)(8).

[4] Safety and Health Regulations for Construction (OSHA)

Page 138

Open source document

Source excerpt

## Subpart CC-Cranes and Derricks in Construction ## §1926.1417 Operation. - (a) The employer must comply with all manufacturer procedures applicable to the operational functions of equipment, including its use with attachments. - (b) Unavailable operation procedures. (1) Where the manufacturer procedures are unavailable, the employer must develop and ensure compliance with all procedures necessary for the safe operation of the equipment and attachments. - (2) Procedures for the operational controls must be developed by a qualified person. - (3) Procedures related to the capacity of the equipment must be developed and signed by a registered professional engineer familiar with the equipment. - (c) Accessibility of procedures. (1) The procedures applicable to the operation of the equipment, including rated capacities (load charts), recommended operating speeds, special hazard warnings, instructions, and operator's manual, must be readily available in the cab at all times for use by the operator. - (2) Where rated capacities are available in the cab only in electronic form: In the event of a failure which makes the rated capacities inaccessible, the operator must immediately cease operations or follow safe shut-down procedures until the rated capacities (in electronic or other form) are available. - (d) The operator must not engage in any practice or activity that diverts his/her attention while actually engaged in operating the equipment, such as the use of cellular phones (other than when used for signal communications). - (e) Leaving the equipment unattended. (1) The operator must not leave the controls while the load is suspended, except where all of the following are met: - (i) The operator remains adjacent to the equipment and is not engaged in any other duties. - (ii) The load is to be held suspended for a period of time exceeding normal lifting operations. - (iii) The competent person determines that it is safe to do so and implements measures necessary to …

[5] Safety and Health Regulations for Construction (OSHA)

Page 139

Open source document

Source excerpt

- (f) Tag-out -(1) Tagging out of service equipment/functions. Where the employer has taken the equipment out of service, a tag must be placed in the cab stating that the equipment is out of service and is not to be used. Where the employer has taken a function(s) out of service, a tag must be placed in a conspicuous position stating that the function is out of service and is not to be used. - (2) Response to 'do not operate'/tag-out signs. (i) If there is a warning (tag-out or maintenance/do not operate) sign on the equipment or starting control, the operator must not activate the switch or start the equipment until the sign has been removed by a person authorized to remove it, or until the operator has verified that: - (A) No one is servicing, working on, or otherwise in a dangerous position on the machine. - (B) The equipment has been repaired and is working properly. - (ii) If there is a warning (tag-out or maintenance/do not operate) sign on any other switch or control, the operator must not activate that switch or control until the sign has been removed by a person authorized to remove it, or until the operator has verified that the requirements in paragraphs (f)(2)(i)(A) and (B) of this section have been met. - (g) Before starting the engine, the operator must verify that all controls are in the proper starting position and that all personnel are in the clear. - (h) Storm warning. When a local storm warning has been issued, the competent person must determine whether it is necessary to implement manufacturer recommendations for securing the equipment. - (i) [Reserved] - (j) If equipment adjustments or repairs are necessary: - (1) The operator must, in writing, promptly inform the person designated by the employer to receive such information and, where there are successive shifts, to the next operator; and - (2) The employer must notify all affected employees, at the beginning of each shift, of the necessary adjustments or repairs and all alternative measures.…

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