Indoor Cranes Safe Lifting Operations Training Video & DVD by Coastal Training / DuPont

Indoor Cranes Safe Lifting Operations Training DVD
  • SKU: CRA000-DVD
  • Runtime: 23 mins
  • Producer: Coastal Training / DuPont
What's in The Box
  • (1) 23 Minute Training DVD
  • a customizable powerpoint™ presentation
  • informative training points and bonus material for refresher or training talks
  • video-enriched training organized by learning objectives that facilitates discussion
  • a printable leader's guide
  • resourceful web links to organizations such as osha, fema, nsc and the cdc, where viewers can download and print information on regulatory standards
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Product Description

Coastal's Indoor Cranes: Safe Lifting Operations Training DVD

This program is specifically designed for non-licensed operators of indoor cranes to give them the knowledge they need to safely operate several types of indoor cranes. It covers:

  • Pre-operation safety inspection
  • Rigging techniques
  • Lifting and moving
  • Format: DVD
  • Language: English or Spanish
  • Length: 23 mins.
  • a customizable powerpoint™ presentation
  • informative training points and bonus material for refresher or training talks
  • video-enriched training organized by learning objectives that facilitates discussion
  • a printable leader's guide
  • resourceful web links to organizations such as osha, fema, nsc and the cdc, where viewers can download and print information on regulatory standards
What's in The Box

What's In The Box

  • (1) 23 Minute Training DVD
  • a customizable powerpoint™ presentation
  • informative training points and bonus material for refresher or training talks
  • video-enriched training organized by learning objectives that facilitates discussion
  • a printable leader's guide
  • resourceful web links to organizations such as osha, fema, nsc and the cdc, where viewers can download and print information on regulatory standards

Video Transcript

Indoor Cranes Safe Lifting Operations
Cranes - they come in all shapes and sizes to form a multitude of jobs, help to increase productivity and make your job easier.
Cranes are, well, cranes. They have been around for years. Think for a moment how different your life would be without that old jib crane or bridge crane. Your job would go slowly, productivity would go down, you might end up with a sore back.
You probably take that crane in your work area for granted, unless of course it's out of service when you need it. And that could happen if you or someone else improperly operated. In addition to losing the services of a crane, improper operation can lead to material damage and personal injury. 
Studies have shown that the two leading causes of crane accidents are:
  • A lack of understanding and knowledge of the part of the operator
  • And plain, old carelessness
The objective of this program is simple, to reduce accidents and breakdowns. We'll all benefit from this by reducing injuries and repair costs, we save money. And by keeping the crane operational, productivity is increased. 
This program will focus on the inspection and safe operation of shaft-operated power hoist equipment or indoor cranes. Not because this type of hoisting equipment is involved in the majority of crane accidents but because these cranes are most often operated by someone who's expertise is in another field. In other words, these cranes are operated by workers who are not crane operators by train.
There are several types of hoist and crane configurations:
  • Jib cranes
  • Mother wheels
  • Gantry cranes
  • And bridge cranes, are the most common ones.
They can be operated by electricity or air and can use wire rope or chain to do the lifting. Some loads once lifted must be moved manually while others use mechanical means. The lifting capacity of these cranes can vary from 250 to more than 20,000 pounds. Most shaft cranes are operated from the floor controlled by either a push button pendant or a pull rope. Some are even radio controlled. Overhead cranes may be cab operated by people especially trained to do this. Viewing this program does not qualify you to operate this type of crane. 
That's a quick introduction to shaft-operated power hoist equipment. Before operating any hoisting equipment, ask your supervisor if there are any special requirements or certifications that must be met. In the next segment we'll walk through a pre-operation safety inspection.
Shaft cranes are supposed to be inspected by the operator at the beginning of each shift. Notice that I said, supposed to be inspected, because in many cases, this inspection is not being done. Failure to perform a pre-operation safety inspection is the leading cause for crane accidents. There is really no reason not to do the inspection. It's easy and only takes a few minutes. Remember, carelessness causes accidents.
The start of safety inspection can be divided into two parts:
  • Visual
  • Operation
Start the inspection by looking for any tags of the crane. If you find a red "danger do not operate" tag, go no further and terminate the inspection. Every crane has to be inspected and weight tested for certification, either when they are new, modified or even overloaded. Many companies place a certification tag on a hoist or a crane for the operator. Check with your supervisor or maintenance department if you are unsure of the certification. 
Next, visually inspect the entire crane for any obvious physical damage such as loose or missing parts. If the hoist can move laterally on a trolley then check to be sure that some type of end stop is in place in each end of the mother wheel or crane beam to prevent the trolley from running off the beam. If the trolley is on a bridge or gantry crane, make the same check to be sure that the crane cannot run off the end of the runway.
Next, check the hoist chain or wire rope, make sure that it is not twisted, kinked, or otherwise damaged. Also, if the hoist uses wire rope then make sure that it is properly seated in its drum and sheave grooves. The rope mush not have any slack in its raps on the drum, it must lay in the grooves without overlapping itself and it must not lay across groove bridges. Make sure that you know where the disconnect switch to the hoist or crane is located. It should be somewhere nearby within easy reach and it should only disconnect the hoist or crane.
Finally, check the areas in which the crane will be operated. Make sure there is no obstacle or obstruction in the cranes path. Visually the crane checks up, tags, certification papers, no physical damage, and the work area unobstructed.
Now, let's move on to the operational tests. Operate the crane several feet in its direction that it can travel. Listen for any unusual noises and look for jerky movements. This is also a good time to check the control stations. Make sure all the buttons are labeled to indicate the function each one controls. Operate each button to make sure it is functioning properly, that it doesn't stick. Especially make sure that the up button causes the hook to raise and the down button causes the hook to lower. If they don't, then do not use the hoist and do not attempt to fix it by swapping wires in the control station. 
Now, check the upper hoist limit switch, to do this slowly raise the block to trip the limit switch. Now, lower the hoist block to activate the lower limit switch if the crane is so equipped, if not, stop the block before it contacts the floor. With the block in this position, look at the take-up drum, at least two turns of rope should remain on the drum, if the crane is equipped with the lower limit switch, one turn is permitted. 
One last thought concerning hoists limit switches, this switches are safety devices intended to prevent accidental over travel of the block, they are not intended for constant duty service. The hook must have a safety latch which closes the throat of the hook, if the latch is bent or its spring is broken or if it is otherwise damaged, the latch must be replaced before the hook can be used. If the latch swings freely across the hook throat or even very nearly does, then the hook has been stretched and it must be replaced before the hoist can be used. Do not put a longer latch on a hook to make-up for the stretching.
The newer generation crane comes equipped with a much safer hook. The safety latch hook is designed to operate completely locked closed. Opening the hook jaws requires pushing in a lock button, this type of hook will eliminate hook loading, a major cause of accident and equipment damage. An ANSI warning tags should be located on the control station or lower hook block with some reminders about many of the checks we just covered. This crane has passed all phases of inspection and is now ready for service. If the hoist fails any part of the inspection, tag it out and notify your supervisor.
In the next segment, we will discuss rigging techniques and guidelines for selecting and inspecting rigging gear.
Rigging the Load
If phase 1 of safe crane operations is the pre-start of inspection then phase 2 would be rigging the load for the lift. In this segment, we'll discuss determining the weight of the load to be lifted, selecting the proper rigging gear and using sound rigging practices to secure the load. Before lifting a load, you must know that it is within the lifting capacity of the crane which should be stenciled on both sides of the hoist. Determining the weight of an object can be as easy as checking the manufacturers plate, shipping papers, work orders or design drawings.
But sometimes you'll have to figure out the weight on your own. This can be accomplished by doing some simple math using a chart that lists the weight for certain materials. Here's an example, this steel plate is the size of a standard sheet of plywood 4x8 feet, determine the area of the plate by multiplying 4 times 8 (4 x 8). The area equals 32 square feet. Refer to a chart that tells you how much steel plate of a given thickness weighs per square foot. This plate is one inch thick, according to the chart, 1 inch steel plate weighs 40.8 lbs per sq. foot. Multiply 32 x 40.8 lbs per sq. foot to find out that the steel plate weighs 1306 lbs, admittedly that was a simple example, but the idea is the same for more complicated shapes, sizes and types of material. 
Another method for determining weight is to use a dynamometer, they are extremely helpful in quickly determining the weight to be lifted. Some dynamometers or scales can give an audible warning of near capacity loads and some can even connect to the hoist controls to stop an over capacity lift. As a last resort, you can estimate the weight of an object, use common sense, compare the questionable load to a similar load you lifted in the past with a known weight or get a second estimate from a co-worker. Make a decision from both answers, when you use this method it is good to comply a safety factor. Some shaft has a safety factor of 50%, that means if the estimated weight of the load is more than 50% of the crane's lifting capacity, you can't use that crane for the lift. Ask your supervisor about the safety regulations for your work area. Now we know the weight of the load and it is within the lifting capacity of the hoist.
Let's talk about the rigging gear necessary to rig the load. Always select sound rigging gear that is within the safe working load of the fiber or wire rope. Most wire ropes length have the safe working load or SWL inscribed on the end fitting. If the SWL is not inscribed, call the manufacturer or refer to the standard chart for weight load test. The safe working load of a fiber sling may have a different label. Vertical, choker and basket weight limits are usually sewn on the inside of the strap. 
General rule of thumb: If you have a fiber sling without an SWL label, get a bigger sling that has has the limit sewn right on it. Don't take a chance.
Wire rope must be inspected before use, look at the rope, does it show evidence of severe kinking, crushing or heat damage. Inspect the outside wires of each strand, it's normal to find broken wires in these area. However if you find six or more broken wires within one lay of strand length, the rope should not be used.
Check the end fittings, are they corroded, cracked, bent or improperly applied. If more than one broken wire exists within one lay length of the end fitting, the sling should not be used. 
Other rigging gear needed for the jobs such as shackles must also be checked for load lifting capacity and inspect it prior to use. If there is any doubt about whether a sling or shackle is fit for use, it should be replaced at once. Never risk, danger a life or damage a property by taking a chance. With that said, let's rig the load for a lift.
Cranes are design for vertical lifts only, side pulling and end pulling results in many hoisted crane breakdowns. These improper lifting methods can bend or break the cable guide, jam the wire rope in the hoist housing and damage the drum. More importantly, they can directly or indirectly cause the chain or wire rope to break and suddenly drop. 
Attached the slings to the load and hoist rope. Pack corners and sharp edges to prevent cutting or damaging the rope.How do we determine the number of slings needed? Several factors come to mind, balancing the load is an important consideration in determining the location and number of slings needed. If the load is not balanced, it could swing dangerously or slipped out of place when lifted. On rare occasions, one sling could be used. Weight is the largest factor, if the load weighs 1000 pounds then the sling must have an SWL of 1000 pounds, this just means that if you use two slings they have an SWL of 500 pounds each? NO! When more than one sling is used, you must consider sling angles. At this chart shows each sling must be capable of handling 577 lbs, if the sling angle is 60 degrees but notice how the load per sling increases as the sling angle decreases. 
Hold two buckets of water at your side, then, hold them up so that they are almost parallel to the ground, kind of helps you understand the concept of sling angles. 
There is a way to figure out the added stress due to sling angles by using this chart and this formulas. Let's start with this: two legs at 90 degrees, each leg is supporting 500 lbs, now let's get to this and figure out how much more weight each sling is supporting. W = 1000 lbs, N = 2 for the numbers of legs, K is the stress factors which according to the chart is 15.4% which we write like this .154. 1000lbs/2=500. 500x154=77 add 77 to each leg to get 577 pounds. When using more than two slings, you still need to divide by two because two legs must be capable of bearing the weight while the others help balance the load. Since the load can and probably will shift, all the slings must have the same lifting capacity and be made of the same material. 
You'll probably say, how do I figure out the sling angle? Let's make it easy, this is 90 degrees, half of 90 is 45 degrees, somewhere between is 60 degrees, since you should never have a sling angle of less than 45 degrees, that's all you need to know. And if you really want to make it easy just memorize the stress factor for 45 degrees which is 41.4% and always flag that into the formula.
In the next segment, we'll lift the load and get it where it needs to be.
Lifting & Moving
Lifting and lowering the load in a safe manner can be accomplished by paying attention to what you are doing and following some simple do's and don'ts. From a safety stand point, one factor is paramount. Conduct all lifting operations in such a manner that if they're aware of equipment failure, no one will be injured. The hard part is done, don't mess up now.
First, make sure that all hands are clear of any potential pin points and for very large loads, make sure that no one is positioned between the load and another object. The load could swing and crush someone. Slowly raise the hoist block to ease the slack out of its sling. Check the load hook to make sure that the slings are fully seated in the saddle of the hook. Now, slowly lift the load a few inches. This will minimize any swinging of the load and allow you to check your rigging job. If you do detect slippage, abort the lift. If everything is okay, lift the load in one smooth motion high enough to clear all obstructions and push it to the desired location or use mechanical means if the crane is so equipped.
Watch the crane in this position, slowly lower it. Stop the hoist block when it is low enough to unhook the slings. Jib cranes should be stored against the wall or in an approved location. Use the lower hook flat to swing the jib bone into place. A successful lift, the load is where it's needed, nothing was damaged and nobody got hurt. There maybe times when you would need to use the larger capacity cab operated crane, you may rig it but this crane will be operated by an experience certified crane operator. 
The operation we have discussed at this point was still be applicable. But now you will find it necessary to communicate to the crane operator what it is you wanted to do. You will use a standard set of hand signals. All crane hand signals can be found in the ANSI B 30 standard manuals and work area signs showing the signals available from many safety material suppliers. 
First, let's direct the crane to the load. All hand signals must be in clear sight of the overhead crane operator. Move the trolley to the load, then, stop. Lower the hook with the spreader and slings to the proper height to connect the load. Lift the load a few inches, stop and check the load. Make sure that everything is safe. Lift the load to the proper height and stop. Move the trolley to the pre-determined location and stop. Check your path. Make sure it's clear. Give the signal to move the bridge. If anything crosses your path, give the emergency stop signal. Both arms waving straight up from your side. Once the problem is removed, continue to your destination, as the load approaches tell the operator to slow down and then stop. Lower the load and stop the hoist flat low enough to remove the slings. 
Now let's take a look at some don'ts:
  • Don't abuse the controls by jabbing them unnecessarily. Doing this only shortens the life expectancy of the hoisting crane. 
  • Don't use the pendant control station to swing the jib bone into place.
  • Don't leave a suspended load unattended. 
  • Don't pass a load over people or allow anyone to walk under it. 
  • Don't pull a load, you can't see where you're going. 
  • Don't allow yourself to be distracted.
  • Don't allow unused slings or ropes to remain on the hook. They can inadvertently snag other objects when the crane is moving. 
  • Don't leave the hoist block low enough for someone to hit.
  • If you're using a radio control to operate a crane, never operate a transmitter when you can't see the load and the entire crane.        

That's about it. We inspected the crane, rig the load and safely move it to the desired location. You probably knew most or all of what's have been said, yet we still have crane accidents. You know what you are supposed to do, but for some reason you don't do it. Excuses don't cut, they don't ease the pain of injury or reduce the cost of damaged equipment. Play it safe, never operate a crane or hoist if you are faint, feel sick or used medication. Use common sense, pay attention to what you are doing. Ask yourself what could go wrong with each job and why? Then, guard against them from happening. Never consider any job, routine.


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