Crane Operation Safety Procedures

This document outlines critical safety procedures for crane operation, focusing on pre-lift inspections, load limits, and emergency shutdown protocols. Adherence to these procedures is essential to prevent accidents and ensure the safety of all personnel involved.

Pre-Lift Inspection Procedures

A thorough pre-lift inspection is crucial to identify potential hazards and ensure the crane is in safe operating condition. This inspection should be conducted by a qualified person before each shift or series of lifts.

Inspection Items

• Structural Components: Inspect the crane's structure for any signs of damage, such as cracks, deformation, or corrosion. Pay close attention to welds and connection points.
• Wire Ropes and Cables: Examine wire ropes and cables for wear, fraying, kinks, and proper lubrication. Check cable drums and sheaves for damage and proper alignment.
• Hooks and Lifting Devices: Inspect hooks for cracks, deformation, and proper latch operation. Verify that slings, shackles, and other lifting devices are in good condition and have the correct capacity for the intended load.
• Hydraulic Systems: Check hydraulic hoses, cylinders, and pumps for leaks, damage, and proper operation. Ensure that hydraulic fluid levels are within the recommended range.
• Electrical Systems: Inspect electrical wiring, connections, and controls for damage and proper function. Verify that all safety devices, such as limit switches and overload protection systems, are operational.
• Brakes and Controls: Test the crane's brakes and control systems to ensure they are functioning correctly. Verify that all controls are clearly labeled and easily accessible.
• Safety Devices: Confirm the proper functioning of all safety devices, including but not limited to: anti-two block devices, boom angle indicators, and load moment indicators.
• Outriggers and Stabilizers: If the crane is equipped with outriggers or stabilizers, inspect them for proper operation and ensure they are fully extended and locked before lifting operations begin.

Load Limits and Capacity

Understanding and adhering to the crane's load limits is paramount to preventing crane failure and accidents. The operator must be fully aware of the crane's load chart and how to interpret it for various operating configurations.

Key Considerations for Load Limits

• Load Chart: Always refer to the crane's load chart to determine the maximum allowable load for a given boom length, angle, and radius. Never exceed the rated capacity.
• Gross vs. Net Capacity: Be aware of the difference between gross and net capacity. Deduct the weight of all rigging and attachments from the gross capacity to determine the net load capacity.
• Dynamic Loading: Account for dynamic loading effects, such as sudden stops or starts, which can significantly increase the stress on the crane. Reduce the load accordingly.
• Environmental Factors: Consider environmental factors such as wind speed, which can affect the crane's stability and reduce its lifting capacity. Consult the manufacturer's recommendations for operating in windy conditions.
• Level Ground: Ensure the crane is set up on firm, level ground. Uneven ground can reduce the crane's stability and lifting capacity.
• Qualified Rigger: Use a qualified rigger to properly attach the load to the crane. Improper rigging can lead to load instability and accidents.

Emergency Shutdown Procedures

Having well-defined emergency shutdown procedures is crucial for responding to unexpected events and preventing further damage or injury. All crane operators and personnel involved in lifting operations must be familiar with these procedures.

Shutdown Steps

• Immediate Stop: In the event of an emergency, immediately stop all crane operations. Use the emergency stop button if necessary.
• Lower the Load: If possible, safely lower the load to the ground. Avoid sudden or uncontrolled movements.
• Secure the Crane: Once the load is lowered, secure the crane to prevent any further movement. Engage all brakes and locking mechanisms.
• Power Down: Shut off the crane's power supply. Disconnect the main power switch or turn off the engine.
• Evacuate: If the situation poses an immediate threat, evacuate the area and ensure all personnel are accounted for.
• Report: Report the incident to the appropriate authorities and conduct a thorough investigation to determine the cause and prevent future occurrences.

Additional Safety Precautions

• Ensure operators of other overhead and floor level machines are aware of the MEWP's presence. Disconnect power to overhead cranes. Barricade floor area if necessary.
• Exercise extreme caution at all times to prevent obstacles from striking or interfering with operating controls and persons in the platform.
• Warn personnel not to work, stand, or walk under a raised boom or platform. Position barricades on floor if necessary.
• Under all travel conditions, the operator must limit travel speed according to conditions of ground surface, congestion, visibility, slope, location of personnel, and other factors.
• Be aware of stopping distances in all drive speeds. When driving in high speed, reduce drive speed before stopping. Travel grades in low speed only.
• Do not use high speed drive in restricted or close quarters or when driving in reverse.

Maintenance Hazards

• Shut off power to all controls and ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs.
• Shut off power to all controls and remove the key to ensure that all moving parts are secured from inadvertent motion prior to performing any adjustments or repairs.
• Never work under an elevated platform until it has been fully lowered to the full down position, if possible, or otherwise supported and restrained from movement with appropriate safety props, blocking, or overhead supports.
• DO NOT attempt to repair or tighten any hydraulic hoses or fittings while the machine is powered on or when the hydraulic system is under pressure.

Towing, Lifting, and Hauling

• Never allow personnel in platform while towing, lifting, or hauling.
• Ensure boom is in the stowed position and, if equipped, the turntable locked prior to towing, lifting or hauling. The platform must be completely empty of tools.
• When lifting machine, lift only at designated areas of the machine. Lift the unit with equipment of adequate capacity.

Crushing and Collision Hazards

• Always post a lookout when driving in areas where vision is obstructed.
• Keep non-operating personnel at least 6 ft (1.8 m) away from machine during all operations.
• During operation, keep all body parts inside platform railing.

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