DOE HOISTING AND RIGGING

ADVISORY COMMITTEE

&

FALL ZONE DANGER ZONE

AU-11 Learning Topic September 16, 2020

Bill Schleyer, Sr. Safety Professional & Chairperson, HRAC

NA-513

AGENDA

Introduction to the HRAC

Issues HRAC will tackle

Fall Zone/ Danger Zone Overview

History of accidents confirms is a real risk that need control

WHAT IS THE HRAC?

DOE Hoisting and Rigging Advisory Committee is the long standing community of practice offering

• Chartered by AU-10 Office of EHSS

• Advice to the DOE through our AU-11 Sponsor, Maurice Haygood

• Helps Maintain the DOE-STD-1090-2020, Hosting and Rigging [Update just published in July!!!]

• Recommends safe performance methods for DOE

• Technical Standards provide non-mandatory best practices and acceptable methods for meeting requirements

HRAC GENERAL• History of accidents confirms H&R is a real risk

• 60+ participants representing DOE sites --not all sites

• Private sector support and participation – learn with private sector

• Meet every 2-3 months

• Working a list of issues and opportunities

• Collaborate to improve safe hoisting and rigging performance

• While not HRAC function, some members sit on Consensus Standards Committees

• --ASME B30.2 - Overhead and Gantries sub-committee

• --ASME B30.17 - Cranes and Monorails Sub-committee

WHERE ARE WE?

ISSUES—WHAT HRAC IS WORKING

Prioritized by HRAC members

Can do a few well. Try keeping up with others.

Divide and conquer using working groups

Issues:

Training

Improve Operations

HRAC management

o Sustainability and mentoring

o Sling protection

o Fall Zone and Danger Zone

o Safe by Design

o New Technology integration

o Common training

o Site methods operations shared

o Subcontracting includes safety

o Standards and our role

DO YOU KNOW THE H&R EXPERTS AT

YOUR SITE?

Reach out and connect.

How can you participate?

FALL ZONE AND

DANGER ZONEThanks to the many DOE and Private Sector Contributors for the content.

55 -110

We lift frequently in tight spaces with ordinary, special, production and critical lifts.

Workers and Materials are always at risk.

WHY IS FALL ZONE/

DANGER ZONE

IMPORTANT?

Real world. People are dying from lifting accidents and at

greater numbers than most hazards!!

.

REAL HAZARDS – REAL ACCIDENTS

An Accident Investigation Board was appointed to investigate the December 19, 2018, construction lifting accident that resulted in serious injuries.

Worker using forklift to hold elevated metal HVAC frame dropped it ~12 feet—near miss

2020- Reactor 15-Element Rack Separation During Critical Lift bottom portion of the rack separated from the upper grid plate. The bottom of the rack tipped over.

Fatal Occupational Injuries Involving Cranes-- From 2011 to 2015, the Census of Fatal Occupational Injuries reported 220 total crane-related deaths, an average of 44 per year over this 5-year period. (BLS)

Failure of Lifting Points during Lift of Batch Plant Silo

2017-Girder Dropped During Lift by Mobile Crane

Lift fixture slipped from the end of telehandler tines and conveyor to the floor

FALL ZONE -- DEFINED

OSHA defines- in 1926.1401- Fall zone means the area (including

but not limited to the area directly beneath the load) in which it is

reasonably foreseeable that partially or completely suspended

materials could fall in the event of an accident.

Danger Zone not defined specifically in standards. It exists in the

“not limited to” and addresses reasonably foreseeable fall or

energy release. “Danger” is a warning term.

DANGER ZONE -- DEFINED

Danger is a Warning word that seeks to get emotional awareness

Hazard is a condition including a scenario where harm is possible

Danger Zone is NOT an OSHA defined term for Fall zone and associated hazards

Dangerous areas is OSHA defined for some crane operations, e.g. 1926.1435

Concept of DANGER ZONE is to capture workers attention, emotional connection, so each is aware and consider hazards and risks

Sites often have different warning terms. Teach and apply to site practices

Danger Zone is ANY area or location potentially impacted by failures or events during the life-cycle process of the lift

Control hazards and warn of danger

CONCEPT – NOT A MATH EQUATION

Fall Zone is SET by risk owners with

technical support of Qualified HR Workers

Hazards are lift dependent and varying

Danger zone around Fall Zone

Expect the unexpected

Danger Zone

Fall Zone

FALL ZONE / DANGER ZONE IS NOT AN EXACT

MEASURED SPACE

PLAN TO ADDRESS FALL ZONE /

DANGER ZONE

ISMS and Work Planning and Control

MINDSET OF DANGER ZONE HAZARDS

Untrained users may be unaware of the subtlety of “but not

limited to, directly below the load”.

Erroneously the focus may be placed solely on the “directly

below the load” without regard to “but not limited to”.

Key point -- awareness of the potentially deadly consequences

of the fall zone must involve more than falling loads. The release

of tension in any attitude, i.e., vertical (up and down), and/or

horizontal (to and from), at any angle can result in severe injury or

death.

LIFT PLAN TO

CONTROL FALL ZONE

Processes defined in Site Practices

Apply ISMS

Work planning and control process applies

Lift planning process

Evaluate the Sphere of Influence

Energy Trace Barrier Analysis tool

ALARP- no reasonable lower risk alternative

COMMUNICATE

Pre-Job= increase understanding of risk/control using diagrams, signs, and instructions to workers.

Authorize the lift activity

PRINCIPLES OF INTEGRATED SAFETY MANAGEMENT

• LINE MANAGEMENT RESPONSIBILITY FOR SAFETY. Line management is directly responsible for the protection of the workers, the public, and the environment.

• CLEAR ROLES AND RESPONSIBILITIES. Clear and unambiguous lines of authority and responsibility for ensuring safety are established and maintained at all organizational levels within the Department and its contractors.

• COMPETENCE COMMENSURATE WITH RESPONSIBILITIES. Personnel possess the experience, knowledge, skills, and abilities that are necessary to discharge their responsibilities

• BALANCED PRIORITIES. Resources are effectively allocated to address safety, programmatic, and operational considerations. Protecting the workers, the public, and the environment is a priority whenever activities are planned and performed.

• IDENTIFICATION OF SAFETY STANDARDS AND REQUIREMENTS. Before work is performed, the associated hazards are evaluated and an agreed-upon set of safety standards and requirements is established which, if properly implemented, will provide adequate assurance that the workers, the public, and the environment are protected from adverse consequences.

• HAZARD CONTROLS TAILORED TO WORK BEING PERFORMED. Administrative and engineering controls to prevent and mitigate hazards are tailored to the work being performed and associated hazards.

• OPERATIONS AUTHORIZATION. The conditions and requirements to be satisfied for operations to be initiated and conducted are clearly established and agreed upon.

“

”

FACTORS IN EVALUATING FALL ZONE/

DANGER ZONE

If you don’t recognize the hazard, you can’t control the load,

potential fall, or released energy

FACTORS IN

DEFINING

FALL ZONE /

DANGER ZONE

Predict, analyze where load can fall

Load shape, Center Gravity, size

Rigging

Attachment points and order of attachment

Attaching and unhooking steps

Height above surface

Route and range of Motion

Swinging

Projectile/Recoil/Released tension

Load control precision

Working Slopes, walking conditions

Weather

Sphere of Influence

Every Direction

Many options for

energy release

USN Synthetic Line Snapback

20©2020 Lift-It Manufacturing Co., Inc.

Visualize Danger Zone

21

EVALUATE THE SPHERE OF INFLUENCE

As an example, consider a scenario in which a spreader bar is

used to lift a load and it is connected to the crane with a two-leg

bridle sling. Imagine the sphere of influence if during use, just one

of bridle legs were to break. The load may fall “directly below”,

but the spreader bar, while still connected to the crane with the

remaining bride leg may be propelled into the “but not limited

to” zone.

DEFINE THE CONTROLS

Keep Everyone out of the Fall Zone

DEFINE clearly in plan when qualified person is allowed in Fall Zone

-Assigned workers with competencies

-Specific functions and scope of action

-Temporary worker exposure to hazard-shortest time

The better the hoisting and rigging, unexpected energy release is much less likely. Thus hazards in Fall Zone and Danger Zone are more controlled

Personnel shall not pass under orstand under a suspended load.[ASME B30.9 (2018) 9-5.10.2 (c)]

Personnel should not stand in line or next to slings under tension.[ASME B30.9 (2018) 9-5.10.2 (b)]

SET THE CONTROLS

--

DEFINE THE SAFETY

EXPECTATIONS

“

”OSHA 1926.1425 for Cranes and Derricks in Construction

Hoisting routes minimize employee exposure

No employee in Fall Zone unless hooking or guiding, attaching load, receiving, tilt-up, ...

OSHA specifics apply-

rigged by qualified rigger

self closing hooks or equivalent

NEVER UNDER – NEVER ON – NEVER IN-LINE.

Graphics from Mike Gelskey, Sr.

OSHA 1926.1425 “Keeping Clear of the Load” regulations detail the requirements and provide

good guidance. A summary includes:

Avoid carrying loads over people. Plan the load travel path to minimize exposure to

individuals on the site.

When a suspended load is not moving, it is only permissible to have an employee in the fall

zone if they are:

hooking, unhooking or guiding the load

doing the initial attaching of the load to a component or structure; or

operating a concrete bucket.

The load must be rigged to prevent unintentional displacement.

Hooks with self-closing latches or their equivalent must be used.

The load must be rigged by a qualified rigger.

When a load is being landed, only employees needed to receive a load are permitted to be

within the fall zone.

During a tilt-up or tilt-down operation, no employee must be directly under the load and only

employees essential to the operation are permitted in the fall zone if it is not feasible for the

employee to perform that operation from outside the fall zone.

OSHA 1926.1425 “KEEPING CLEAR OF THE LOAD”

MINIMUM FALL ZONE AND DANGER ZONE CONTROLS

SAFETY CONTROLS TO

MEET OSHA COULD

INCLUDE

Define rigging material and process considering danger zone

Set Engineered controls – fixtures, tables, lifting beams

Erect and maintain control lines, warning lines, railings or similar barriers areas. (1926.1424(a)(2)(ii))

Alignment guides

Use Precise load control devices improve operator control

Tag lines, pike poles, boat hooks, and gripping reaching devices

Control lateral loads and forces

Control swinging

Eliminate rapidly released energy

Control Fall impact area as if it WILL fall

PLANNING IS

DETAILED

PLANNING IS

DETAILED

SPHERE OF

INFLUENCE AND

ROUTE

Hoisting and Rigging is hazardous

Hoisting and Rigging done well has controlled

risk and pre-conditions safe performance

Work the lift plan...

PLEASE ASK QUESTIONS!

HOISTING AND RIGGING ADVISORY

COMMITTEE

FALL ZONE AND DANGER ZONE

Thank you for being engaged and seeking organizational learning.