Crane Safety: Overhead Operations Training Video by Summit Training Source

Crane Safety: Overhead Operations Training DVD and Video Program
  • SKU: 6402
  • Copyright: 2007
  • Runtime: 18 mins.
  • Producer: Summit Training Source
What's in The Box
  • (1) 18 Minute Training DVD
  • (1) Facilitator Guide with Quiz (printable download)
  • (1) Handbook (printable download)
  • (1) Customizable Powerpoint Presentation (printable download)
  • (1) Certificate of Completion (printable download)
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OSHA Compliant, Guaranteed This product is compliant to OSHA's Overhead and Gantry Crane Standard (29 CFR, 1910.179)
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Product Description

Overhead Crane Training & Safety Complies with OSHA 29 CFR 1910.179 and ASME B30.2-2001

Crane operators are responsible for the crane, the item being moved, and most importantly, the safety of themselves and others working around the crane. There are currently 80,000 and 100,000 cranes being used in general industries. With this many cranes in use, there are approximately 250,000 crane operators and industry workers who are at risk of suffering serious injury or death in crane accidents each year.

Summit’s engaging, new training video/DVD uses high-end graphics and on-site footage to illustrate the dangers of overhead cranes if not operated properly. Following safe work practices and procedures is the only way to work safely with overhead cranes. This program includes cab controlled, pendant and wireless radio overhead cranes.

This video program covers:

  • Common terminology
  • Daily Safety Inspections
  • Basic Crane Operations
  • Sling and lifting attachments
  • Safe work practices
  • Format: DVD
  • Language: English and Spanish
  • Length: 18 mins.
What's in The Box

What's In The Box

  • (1) 18 Minute Training DVD
  • (1) Facilitator Guide with Quiz (printable download)
  • (1) Handbook (printable download)
  • (1) Customizable Powerpoint Presentation (printable download)
  • (1) Certificate of Completion (printable download)

Video Transcript

Crane Safety (Overhead Operations)
Everyday more overhead cranes are being use in general industry. This increases the amount of people connecting with crane operations. Overhead cranes are used in many industries to move heavy and oversize objects that are the material handling methods cannot. Crane operators are responsible for the crane, the item being moved and most importantly, the safety of themselves and others working around the crane. The average man lift 180 pounds, if you are operating a crane that can lift 50 tons that's equivalent to the lifting power of 550 men, which is quite the responsibility for one person to have. 

There are currently between 80,000 and 100,000 cranes being used in general industries with this many cranes in used there are approximately 250,000 crane operators and industry workers who are at risks of suffering serious injury or death in crane accidents each year. In this program, we will cover common terminology, daily safety inspections, basic crane operation techniques, sling and lifting attachments, safe work practices and procedures.

Requirements and Qualifications
You must be trained and tested before you can operate an overhead crane. The following physical qualifications shall be met by a crane operator. Operators must have sufficient;

- Strength
- Endurance
- Agility
- Coordination
- Speed of Reaction to meet the demands of equipment operations

There should be no history of seizures or loss of physical control.

Terminology and Functions
You should know and understand, general terms associated with your overhead crane and its operation. This gives you a better understanding on how the crane operates and will enable you to better communicate to maintenance personnel. The bridge consists of girders, tracks and ties, walkway and drive mechanism which carries the trolley and travels in the direction parallel to the runway. The trolley is the carriage that contains the hoisting mechanism and moves from end to end on the bridge. The hoist is a machinery unit that is used for lifting and lowering the load. There are three basic types of crane controls;

There are cab controlled cranes, the cab is the enclosure which houses the operator, controls and switches. Pendant handheld controls are mounted in a handheld control box that the operator utilizes at floor level. The boxes hardwired to the overhead crane. Wireless or handheld or belt mounted controls are mounted in a wireless radial controlled box, that is either handheld or secure to the operator's belt. The cranes controls must be permanently identified by function and direction. The hoist drum is a spool that winds or unwinds the hoist cable to raise or lower the load. The load path is the route that the load will travel. The load shadow is the area beneath the load path that shall be kept clear of personnel during the movement of the load. Definitions on board terms can be found in the operator's manual.

Daily Inspections
As an operator, you should be come familiar with your crane like you would with your automobile. You should be able to notice any changes in the way it performs. You must conduct pre-operation safety inspection at the beginning of each shift. Daily checks should include the following;

First, move the crane to a clear area. Listen for any unusual sounds from the crane. Does the warning bells sound properly? Check to see that the crane has been lubricated and the bridge and the trolley breaks function properly. The most crucial of all tasks in the pre-operation safety inspection is the hoist limit switch, the limit switch is an emergency stopping device and should only be used as such. It is designed to prevent the load block from hitting the sheave or entering the hoist drop. To test the hoist limit switch, raise the load block with a couple of feet of the limit switch and then stop. Then inch the load block upward by either placing hoist lever between the first position and neutral. Continue in this manner until the counter weight trips and the limit switch stop the hoist. If the counter weight fails and doesn't trip the limit switch, stop the load bock before it hits the sheave. If the engine tests is successful, lower the block about 5 feet and try the limit switch at full speed. If the limit switch fails at anytime during or operation of the crane. Shutdown the crane and notify your supervisor. You must not operate the crane until repairs have been made. 
Lower the bottom block to the floor and inspect the hook at the bottom lock for scratching or damage. Inspect the load chain or wire rope. If there's more than 10% wear, elongated links or knots in the load chains they should be replace. I wire rope cannot have more than 10% wear. If the wire rope has 70 strands then no more than 7 strands may be damage. Wire ropes with damage, kinks or bird caging should be replace immediately. Look for deterioration or leakage in lines, tanks, valves, drain pumps and other parts of air or hydraulic systems. When the hook is in it extreme low position, there should be no less than two wraps of rope remaining on the drum. Lockout and tag for repair any crane or hoist that fails any of the previous tests. Once all of the pre-operation safety inspections have been completed, sign the inspection form and log it in the appropriate space. Overhead cranes are large heavy pieces of equipment which carry a variety of heavy loads. They move throughout the work area and are capable of causing serious damage and harm to equipment and co-workers. following work safe practices is a must. Only authorized 
Initial Inspection Required
- New
- Reinstalled
- Altered
- Repaired 
- Modified 

Once a crane is place in the service, it will require two different types of inspections;

  • Frequent Inspections
    • daily to monthly
    • quarterly intervals
  • Periodic Inspections
    • Annually
    • 500 hours of use whichever comes first
Basic Operations
As mentioned earlier, it is the operators responsibility to know the capabilities and limitations of the crane you operate. Signs of an experienced operator are, smooth controlled lifts, only straight vertical lift should be performed. This reduces stress on the hoist lines and avoid unnecessary swinging of the load. Check the center of gravity before lifting any load. To avoid shock loading take up the slack in the chain or wire rope before lifting the load. Never travel with the load directly over the heads of the workers on the ground. Sound the warning devices often as necessary, beyond the constant lookout and to strike equipment in the area or other cranes on the same track. The operator is responsible for the safety of the people below the load. You need only to raise the load high enough to safely clear objects and make sure to never drag a load. When the load is not in the direct control of the operator it should be in a fully lowered position. Under hook devices should not be stored in the suspended position.
Cab Controlled
When working with a cab controlled crane, there are some certain things you need to be aware of. Never lift a load until you have received a signal from the crane follower. If more than one person is assisting from the ground you should accept signals from only one designated person. The only exception is that anyone is allowed to give the emergency stop signal. It is important that an operator stay in constant contact with the signal man. Make sure all crane followers are clear from the load. Whenever practical they should walk ahead of the load being carried by the crane. When working with overhead cranes communication is very important to the safety of everyone involved. 
Signals to the operators shall be in accordance with the standard hand signals unless voice communication equipment is used. At the end of your shift or if it becomes necessary to leave the crane. Bring it to an authorized location, see that all controls are in the off position. Make a final visual inspection of the cab. Leave the cab in a clean condition for the next operator and walk to the area where on and off access is available.
Slinging Procedures
Majority of Accidents
  • Incorrect slinging procedures
  • Unsafe lifting attachments
  • Overloading under the hook lifting devices

Determine the weight of the load and make sure it is within the safe working load of the crane. Remember that the safe working load tag on the lifting device changes according to the weigh on what you attached it to the load. For example, the capacity of fiber slings changes a great deal if the sling is use in a basket manner as opposed to a choke manner. A knot in the sling can reduce the capacity up to 80%. Never use a lifting device without the approved working load tag. If you can't find a safe working load tag, don' take any chances. Find the sling that is labeled. There are three key factors that can have a negative impact on the sling and affects its capacity.

Three Key Factors
  • Load balance 
  • Angle 
  • Load movement

An unbalanced load can create a greater force on the sling than the actual weight of the load itself. The angle of the sling also reduces its capacity . The greater the angle the less its capacity. Avoid swinging the load. Swinging cause increase stress to the sling and the crane. Do not apply the load to the tip of the hook, this will result in spreading the hook opening and could cause the load to slip. Make sure all lifting devices are seen to be settle of the hook. If there's a safety locks check that is is properly closed. Once satisfied that the lift is within the capabilities of the crane proceed at a cautious phase to your destination. Keep all parts of your body away from loads being raised or lowered. Once the load is been lifted, never attempt to touch the hook. 

Power Magnets
Lifting with power magnets requires extra caution and attention to details. Most magnets are damage before they are worn out. After you turn the power on. let the magnet set for 5 to 10 seconds to let the magnet build up the full power allowing you to get a full load. Never carry a load over equipment  or co-workers. When working on the floor stay out of the load path. If the magnet's power is lost the load will fall. Use smooth controlled movements when carrying a magnetized load. Energy heats the magnet, and a hot magnet will not carry as big a load as it cool one. And remember to always make the return trip with the magnet de-energized.
Safe Work Practices
An operator and any worker directing a lift, must use the proper protective equipment for the area. If the top of the load is lifted to a height greater than 5 feet, then the load is considered an overhead hazard and head protection needs to be worn. There are several common mistakes to be aware of that could save your equipment or your life. Always know the load limits of the crane and under the hook devices and never overload any of the single individual components that are part of the lifting device. Do not attempt any side pull no matter how light the load is. A side pull is any force or operating condition that restricts the load block, chain, wire rope and hoist body from forming a straight line with the direction loading. Overhead cranes are designed to lift straight up and lower straight down. This is especially important when operating a dual hoist crane. Another mistake made is lifting the load until it hits the upper limit switch. The upper limit switch is a safety device not an operational device. Just because the crane work yesterday doesn't mean that yo can assume with more work today. The simplest and most overlooked rule of crane operations is daily inspection. 
We need to be aware of the operating environment and make sure your path is clear. Before you move the load identify any potential hazards. When you're done using the handheld controls move the crane to its designated position and make sure that all buttons are in the off position. Overhead cranes are large heavy pieces of equipment which carry a variety of heavy loads. They move throughout the work area and are capable of causing serious damage and harm to equipment and co-workers. Following safe work practices is a must. Only authorized individuals should operate the crane. As the operator you are responsible to know the capabilities and limitations of your crane. Never attempt to lift that exceeds the capacity of the crane you are operating. You should also never attempt to lift that you feel unsafe. Sound the warning device when making a lift and travelling with a load. If you are operating a crane that has multiple cranes on the same tracks you will need to be aware of where you crane is in relation to the other cranes at all times. Keep your mind on the task  could had. Always keep the load in your line of vision and constantly be aware of any potential hazards. If at any time the crane malfunctions stop the crane immediately and report the malfunction to your supervisor. Remember not to leave your load suspended in the air. We have discussed;
  • Common terminology
  • Daily safety inspections
  • Basic crane operation techniques
  • Sling and lifting attachments
  • Safe work practices and procedures

At the beginning of each shift, you must conduct a pre-operation safety inspection. Basic operation of the overhead crane, safe work practices and procedures should be followed. Overhead cranes are valuable pieces of equipment in the production process. They travel to your facility carrying heavy loads, this causes the potential for serious risks and dangers if safe work practices and techniques aren't followed. Perform only straight vertical lift and always use smooth starts and gradual stops. Never carry a load over a co-worker's head. Remember that the hoist upper limit switch is a safety device not an operational device. following safe work practices and procedures is the only way to work safely with overhead cranes.


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