Risk Engineering The proposed OSHA crane standard Zurich Services Corporation

Risk Engineering

The proposed OSHA crane standard

Zurich Services Corporation

Risk Engineering

What and when

Based on the final publication of the Crane and Derrick Advisory Committee (CDAC), published in 2004OSHA finally published the Proposed Rule October 8, 2008. The public comment period expires today – January 22, 2009

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Why is a new standard needed?

OSHA 1910.180 and 1926.550 are 39 years oldThere have been no revisions since original publicationThere were some oversights in the original There have been many technological advances for crane equipment in the last for decadesThe new standard gets away from SHOULD and includes more SHALL statementsFocusing on competent persons and giving more defined descriptions of personnel’s responsibilitiesTaking multiple ANSI/ASME standards and creating their own (some are more stringent)

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Comparison of standards

OSHA 1910.180 – 17 pagesOSHA 1926.550 – 15 pagesASME B30.5 – 46 pagesNew Subpart N – 1,110 pages

Photo credits: 1) US Army (public domain), 3 by Bill Davis, 1 from Craneaccidents.com with permission

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Operator qualifications1910.180 – nothing1926.550 – nothing1926.1400 – 8 pages

Photo credit: Bill Davis

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Tower cranes1910.180 – nothing1926.550 – ¼ page1926.1400 – 7 pages


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Floating cranes1910.180 – nothing1926.550 – 1 page1926.1400 – 9 pages


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Overhead and gantry cranes1910.180 – nothing1926.550 – ½ page1926.1400 – 1 page


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Signaling1910.180 – nothing1926.550 – nothing1926.1400 – 3 pages

Use of standard signals is mandatorySignalers must be qualified


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Wire rope1910.180 – nothing1926.550 – nothing1926.1400 – 3 pages


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Ground conditions1910.180 – nothing1926.550 – nothing1926.1400 – 1 page


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Assembly and disassembly1910.180 – nothing1926.550 – nothing1926.1400 – 6 pages


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Power lines1910.180 – nothing1926.550 – ¼ page1926.1400 – 11 pages


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Inspections1910.180 – 4 pages1926.550 – nothing1926.1400 – 11 pages


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Personnel platforms1910.180 – nothing1926.550 – 8 pages1926.1400 – 12 pages

Photo credits: Bill Davis

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What’s new?

Inspection criteriaFall protectionSignal person qualificationPower line safety (really big)Ground conditionsAuthority to stop operationsOperational aidsThe really big one – Operator qualifications


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What’s included?

Hoisting personnelTower cranesDerricksWire ropeMultiple crane liftsOverhead and gantry cranesDesign, construction and testing


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What is a crane (what is included in the standard?)

Crane on rails


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Crane crawlers


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Carry-deck cranes


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Locomotive cranes


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Rough terrain cranes Commercial truck mounted cranes


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Cranes on barges Floating cranes


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Boom trucks


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Derricks


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Tower cranes


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Mechanic’s trucks with hoisting devices*Pedestal cranesSide boom tractorsDedicated pile driversAny other machine configured to hoist and lower, and horizontally move a suspended load


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What is not a crane (not included in the standard)?

Concrete pump


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Excavators


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Wheel LoaderTrack LoaderPower Shovel

Dummy in a bucket


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Fork lifts


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Digger derricks


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Tow trucks*Vehicle mounted work platformsSelf-propelled elevating work platformsStacker cranesMechanic’s trucks with hoisting devices*


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Come-a-longs and chainfallsDedicated drilling rigsGin poles for communication tower workTree trimming


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Big definitions for people

A/D supervisorAppointed personCompetent personDedicated spotterOperatorQualified evaluatorQualified personQualified rigger


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Crane setup

Ground conditions and supporting material Must be ensured to be adequate by the GC/CM or other controlling entity – where there is no controlling entity, requirements shall be met by the employer

Good Not good


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Crane setup (continued)

Lengthy procedures for crane assembly/disassemblySpecifications on supervision knowledge and authorityCrew training and instructionsNo person under the boom during pin removalProper outrigger blocking is mandatory


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Crane setup – power lines

No part of crane, line or load may be able to reach within 20 feet of a power line during setupExceptions: De-energize and ground power lines – or - Use of a dedicated spotter – or - Proximity alarms*Assembly/disassembly below power lines is prohibited


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Power lines in crane operations

Must identify work zone and either mark boundaries, use range limiting devices or range control warningsMust determine if any part of crane, line or load could get within 20 feet (if less than 350kV of a power line – 50 foot clearance for all lines over 350kVIf yes, must either deenergize and groundOr maintain 20 foot clearanceOr use table A


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Power line minimum clearancesTable A - (almost the same as ASME B30.5)

Voltage (kV) minimum clearance distance (feet)Up to 50 1050 to 200 15200 to 350 20350 to 500 25500 to 750 35750 to 1000 45Over 1000 as established by line owner

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Power lines in crane operations (continued)

Special requirements for working below power linesNon-conductive rigging requiredTraining of operators and crew required to include:

Procedures to follow after power line contactOperator’s emergency proceduresSafest means to evacuate equipmentDanger of a potential energized zoneNeed for crew to avoid approachSafe clearance from power lines

Photo credit – OSHA website (public domain)

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Power lines in crane operations (continued)

All power lines are presumed to be energized unless confirmed to be deenergized by the utility owner/operator AND visibly grounded at the worksiteAll power lines presumed to be uninsulatedShall understand limitations of insulating links, proximity alarms and range control devices, if usedDedicated spotters shall be trained

Diagram: D. Dickie, used with permission

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Inspection criteria

Each shift (daily or more often)MonthlyAnnual comprehensiveAfter modificationAfter repair or adjustment


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Inspection criteria

Documented monthly inspectionsKept on file for three months

Annual inspection by a qualified personDocumentedDetail inspection criteriaFunctional testingKept on file for 12 months or next annual inspection

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Inspection criteria (continued)

Severe serviceShock load, corrosive atmosphere, etc.Inspect exposed items/conditionsDocument

Not in regular useIdle more than three monthsMonthly inspection must be performedDocument

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Wire rope inspection

Shift inspectionMonthly inspectionAnnual inspection


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Safety devices

Mandatory equipmentCrane level indicatorBoom stops (except hydraulic booms)Jib stopsLocks for foot pedal brakesIntegral check valves for hydraulic outriggersRail clamps and stops for equipment on rails

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Operational aids

Required equipment – must be in service except where specified temporary alternative measures are metBoom hoist limiting deviceLuffing jib limiting deviceAnti two-block device (cranes manufactured after 2/28/92)Exceptions:

Lattice booms used for draglineClam shellScrap magnetDrop ballMarine operations Pile driving work

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Operational aids (continued)

Boom angle or radius indicatorJib angle indicator (luffing jibs)Boom length indicator (telescopic booms)Load weighing devices (load moment indicators, rated capacity indicators or rated capacity limiters - cranes manufactured after 3/29/03)Outrigger position indicators (cranes manufactured after 1/1/08)Hoist drum rotation indicator (if drum is not visible to operator)

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Fall protection

Fall protection above six feet, with exceptions:While at a work station or going to and from a work stationWhen walking point to point along a horizontal lattice boom that has been lowered to the ground and supported

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Fall protection (continued)

Anchorages may be any part of the boom or to any substantial piece on the equipment (existing equipment only).Exception: Fall protection must be used when working over 15 feet during the assembly or disassembly.

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Operator certification


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Operator certification (continued)

No physical examinations or mandatory drug testing requirementsRe-certification must be completed every five yearsFour acceptable methods of certifying employees

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Option (1) – Certification by an accredited crane operator testing organization:

Accredited by a nationally recognized accrediting agencyCertification is portableValid for five yearsProgram must be reviewed by a nationally recognized accrediting agency every three years

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Option (2) – Qualification by an audited employer program:

Developed or approved by an auditor certified by an accredited crane operator testing organizationAuditor is not an employee of the employerTests should be administered per nationally recognized test administration standardsProgram shall be audited within the first three months, then once every three years.Qualification is not portable and valid for five years.

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Option (3) – Qualification by the US military:Qualification is not portable Valid for the period of time stipulated by the issuing entity

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Option (4) – Licensing by a government entity:Meets or exceeds requirements of this subpartValid only within the jurisdiction of the government entityValid for time specified by the government entity, but no longer than five years

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Pennsylvania requirements

Operators must get a state license by October 2010To get a license, must have an accredited certification Applies to most construction cranes – excludes mobile cranes less than 15 tons, tower cranes less than 10 tons, digger derricks, forklifts, tow trucks, bucket trucks, longshore, manufacturing, coal mining

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Certification criteria Written test

– Controls and operational performance

– Ability to calculate the load/capacity

– Procedures for power line contact

– Site preparation

– Ability to read/locate manuals/charts relevant to the equipment being operated

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Certification criteria (continued)

Practical examination

– Ability to perform pre-shift inspection

– Operational and maneuvering skills

– Application of load chart information

– Application of safe shut-down and securing procedures


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Employer must revoke operators license if they have reason to believe the employee is not qualified to operate.All programs shall have provisions for retraining employees.The current training records must be on file during the operator’s employment.

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Signal-person qualification

Qualified evaluator must conduct the training Training requirements:

Know and understand signals to be used, as well as all forms of signals (i.e., voice, hand, radio, etc.).Be competent in the application of the type of signals to be used.Have basic understanding of crane operation and limitations, including the crane dynamics involved in swinging and stopping loads and boom deflection from hoisting loads.Must be able to effectively communicate to crane operator (i.e., english-english, spanish-spanish, etc.)

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Power line safety


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Power line safety –assembly/disassembly

If any part could get within 20 feet from the power line, then:

Employer must confirm with the utility operator that the line has been de-energized

Or elseDetermine the line’s voltage and the minimum approach distance permitted in specified table

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Power line safety – assembly/disassembly (continued)

Prevent encroachment by:Conducting a planning meeting with a competent, qualified personUtilizing a dedicated spotter who is in constant contact with the operatorWhen boom is elevated, additional measures must be in place (i.e., proximity alarm, device limiting the range of movement, elevated warning line or barricade, etc.)

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Power line safety – assembly/disassembly (continued)

No part of the crane is allowed below a power line unless the utility operator has confirmed proper grounding. If the chart is used to determine encroachment distance, then the utility operator must provide voltage information within two working days of request.All lines must be assumed energized, unless confirmation is given from utility operator.There must be at least one electrocution hazard warning sticker conspicuously placed in the cab.

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Power line safety – crane operations

Work zone must be identified.An insulating link or device must be installed at a point between the load and the load line to prevent the load from becoming energizedNon-conductive rigging must be used if the rigging may be within the table distances.Use non-conductive tag lines, if needed.

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Power line safety – crane operations (continued)

Non-conductive barricades to prevent unauthorized personnel from enteringIf power line is energized then no one other than the operator can touch the crane or rigging.Only essential personnel are permitted within the work area.Crane must be properly grounded.Procedures from the pre-lift meeting on working within safety zone of power lines must be documented and available on-site.

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Power line safety – crane operations within Table A

Prohibited except where the employer demonstrates the following:

Determines it is not feasible to do the work without breaching the minimum-approach distanceAfter consulting with the utility operator, it is determined that de-energizing the line is not feasible

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Power line safety – crane operations within Table A (continued)

The utility operator, or PE qualified in electrical power transmission, determines the minimum clearance distance that must be maintained. Factors include conditions affecting atmospheric conductivity, time necessary to bring the equipment to a stop, wind conditions, etc.Power lines are presumed energized, unless the utility operator confirms the line is de-energized. Photo credit: Bill Davis

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Power line safety - crane operations within Table A (continued)

A planning meeting with the employer and utility operator/PE is held to determine the procedures that will be followed to prevent electrical contact such as:

– Deactivate the device that automatically reenergizes the circuit in the event of a power line contact

– Use of a dedicated spotterThe utility operator or employee of the utility operator supervises and has the authority to stop work at any time to ensure safety.

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Ground conditions

The controlling entity shall:

Ensure that ground preparations necessary to meet the requirements of a good, level, drained site is adequate to support the equipment in use.Locate all hazards that are identified in documents available.


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Authority to stop operations

Whenever there is a concern as to safety, the operator shall have the authority to stop and refuse to handle loads until a qualified person has determined that safety has been assured.


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Operational aids

Operations shall not begin unless the operational aids are in proper working order, except where the employer meets the specified temporary alternative measures:

Category ICategory II

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Operational aids – Category I

Boom hoist limiting deviceLuffing jib limiting deviceAnti two-blocking device If a deficiency occurs, the employer must be able to demonstrate that the replacement parts have been ordered within seven days of notification. Repairs shall take place within seven days of receipt of the parts.


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Operational aids – Category II

Boom angle or radius indicatorJib angle indicatorBoom length indicatorLoad-weighing device, load-moment indicator, rated capacity indicator or rated capacity limiterOutrigger position monitor/sensor (new)Drum rotation indicator (new) Photo credit: Bill Davis

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Operational aids – Category II (continued)

If a deficiency occurs, the employer must ensure the part is repaired within 30 days. Exception:

If the employer has documented the replacement parts were ordered within seven days of occurrence, the repair shall be completed within seven days of receipt of the parts.

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Wire rope

Competent person to conduct visual inspections before each shift, monthly and annuallyCategorize deficiencies in:

Category ICategory II Category III


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Wire rope (continued)

Shift inspection – before each shiftMonthly inspection – all wire ropes, including running ropes (documented)Annual inspection – At least every 12 months, unless not feasible due to set-up. More detailed, including wire rope that is normally hidden during daily/monthly inspections, etc. (documented)

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Wire rope – Category I

Category ISevere distortion, significant corrosion, electric arc, etc.If a category-I deficiency is identified, an immediate determination shall be made by the qualified person as to:

– Replacement of the wire rope, or

– If the deficiency is localized, the wire rope may be severed at the bad spot and may be continued to be used. Photo credit: Bill Davis

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Wire rope – Category II

Category IIVisual broken wires Reduction of nominal rope diameterIf a Category II deficiency is identified, an immediate determination shall be made by the qualified person as to:

– Based on manufacturer recommendations, remove or monitor the wire rope for continued deterioration.

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Wire rope – Category II (continued)

The qualified person determines when to replace the wire rope (no more than 30 days the deficiency is identified).A qualified person assesses the deficiency in light of the load and other conditions of use and determines it is safe for continued use.A qualified person establishes the parameters of use.All workers who conduct shift inspections are notified.The qualified person’s findings and procedures are documented.

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Wire rope – Category III

Category IIIElectrical contact to power lineCore protrusion or other distortion indicating core failure in rotation-resistant wire ropeIf a category-III deficiency is identified, operations involving use of the wire rope shall be prohibited until:

– Wire rope is replaced (power line contact)

– Deficiency is localized and problem corrected

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Multiple-crane lifts

A multiple-crane lift must be planned with the following requirements:

Plan must be developed by a competent, qualified personPlan must be designed to ensure that the requirements of the Subpart are metLift must be supervised by a competent,-qualified person


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Overhead and gantry cranes

All permanently installed cranes must meet 1910.179 except for 1910.179(b)(1)All cranes not permanently installed must meet the same requirements, except a few definitions and manufacturer dated standards


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Design, construction and testing

Shall meet certain sections of ASME B30.5Sections not covered in ASME B30.5 have been added Allows two options when testing mobile cranesApplies to all cranes, manufactured after date of standard, used in the United States.

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Mandatory training

Overhead power linesSignal personsCompetent/qualified personsOperatorsCrush/pinch pointsTag-out

Photo credit: J. McRoy, face in the photo is the author – Bill Davis

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Conclusion (what should we do now?)

Start training signal people (and instruct others to keep their hands in their pockets)Plan on how, when and where to get crane operators trained, and testedCCO already mandatory in these states:

California Minnesota New JerseyHawaii West Virginia NevadaMontana New Mexico OregonRhode Island UtahWashington(2010) Pennsylvania (in progress)South Carolina (DOT projects only)

Make sure the equipment and supporting documentation meets the new rules

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© 2008 Zurich Services Corporation. All rights reserved. The information in this publication and presentation was compiled by Zurich Services Corporation from sources believed to be reliable. Further, all sample policies and procedures herein should serve as a guideline which you can use to create your own policies and procedures. We trust that you will customize these samples to reflect your own operations and believe that these samples may serve as a helpful platform for this endeavor. Any and all information contained herein is not intended to constitute legal advice and accordingly, you should consult with your own attorneys when developing programs and policies. We do not guarantee the accuracy of this information or any results and further assume no liability in connection with this publication and presentation and sample policies and procedures, including any information, methods or safety suggestions contained herein. Moreover, Zurich Services Corporation reminds you that this cannot be assumed to contain every acceptable safety and compliance procedure or that additional procedures might not be appropriate under the circumstances. The subject matter of this publication and presentation is not tied to any specific insurance product nor will adopting these policies and procedures ensure coverage under any insurance policy.

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Risk Engineering The proposed OSHA crane standard Zurich Services Corporation