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Overhead Crane Safety 29 CFR 1910.179

Document Number: 107
Introduction
Overhead cranes are used in many industries to move heavy and oversized
objects that other material handling methods cannot. These cranes have
a railed support structure called a bridge, and a wheeled trolley that
travels across the bridge horizontally. Several varieties of overhead
cranes exist including gantry, semi-gantry, cantilever gantry, storage
bridge and wall cranes.
OSHA regulates overhead cranes through 29
CFR 1910.179 Overhead and Gantry Cranes. This regulation covers general
requirements, design, inspection, and maintenance requirements, as well
as operations.
General Requirements
- All overhead cranes installed after August 31, 1971, must meet the
specifications of the American National Standard Institute (ANSI) /
American Society of Mechanical Engineers (ASME) Safety Code for Overhead
and Gantry Cranes, ANSI B30.2.
- Cranes can be modified and load capacity rerated as long as the modifications
and associated structure is thoroughly checked for the new rated load
by a qualified engineer or the equipment manufacturer.
- The rated load of the crane shall be plainly marked on each side of
the crane. If more than one hoist is present, each hoist will have its
rating shown.
- Clearance must be maintained above and to the side of cranes. Walkways
cannot be placed in a crane operating zone that would compromise employee
safety when the crane is in operation. Parallel cranes must have adequate
clearance between the two bridges if no walls or structures are between
them.
- Only designated personnel will be permitted to operate a crane.
Design Requirements All overhead
cranes are required to have characteristics to promote their safe use.
The OSHA regulation specifies design requirements on the construction
of the cab and its controls; foot-walks, ladders and stairways; bridge
and trolley bumpers; hoist, holding, trolley and bridge brakes; electrical
components; hoisting equipment; and warning devices.
Inspection Requirements Due to the
large and heavy objects often being transported by overhead cranes, routine
inspections are necessary to ensure continued operation of the crane and
the safety of the employees around the crane. An initial inspection of
the crane prior to initial use of new and altered cranes is necessary.
Once placed into service, overhead cranes will require two different types
of inspections. Frequent inspections are done at daily to monthly intervals,
while periodic inspections are completed at monthly to annual intervals.
The purpose of the two inspection types is to detect critical components
of the crane and to determine the extent of wear, deterioration or malfunction.
Initial Inspection
Items to be Inspected
- Hoisting and lowering
- Trolley travel
- Bridge travel
- Limit switches, locking and safety devices
- Load test of not more than 125% of rated load
Frequent Inspections
| Items to be Inspected |
Frequency |
| Operating mechanisms for maladjustment |
Daily |
| Deterioration or leakage in pneumatic and hydraulic parts |
Daily |
| Hooks with deformation or cracks (visual) |
Daily |
| Hooks with deformation or racks (written record with signature of
inspector and date) |
Monthly |
| Hoist chains and end connections for wear, twist or distortion (visual) |
Daily |
| Hoist chains and end connections for wear, twist, or distortion
(written record with signature of inspector and date) |
Monthly |
| Running Rope and end connections for wear, broken strands, etc.
(written record with signature of inspector, rope identity and date) |
Monthly |
| Functional operating mechanisms for excessive wear |
As needed |
| Rope reeving according to manufacturers recommendations |
As recommended |
Periodic Inspections
Items to be inspected
- Deformed, cracked or corroded members
- Loose bolts or rivets
- Cracked or worn sheaves and drums
- Worn, cracked or distorted parts such as bearings, gears, rollers,
etc.
- Excessive wear on brake system parts
- Inaccuracies in load, wind and other indicators
- Electric or fossil-fuel motors
- Excessive wear of chain drive sprockets and chain
- Deteriorated electrical components such as pushbuttons, limit switches
or contactors
Maintenance Requirements
A preventive maintenance program based on the crane manufacturer's recommendations
must be implemented. If any deteriorated components or unsafe conditions
are detected during the required inspections, they must be completed before
the crane is allowed to be used. Only designated personnel may perform
the required maintenance and repairs. The requirements of 29
CFR 1910.147, The Control of Hazardous Energy or lockout/tagout, should
be used to de-energize the crane (See EZ
Facts® Document #170 for more information).
Operation
The manufacturer's instructions must be followed when operating the
crane. Attach the load to the block hook by means of slings or other approved
devices, making sure the sling is clear of all obstacles. Once the load
is properly secured and balanced in the untwisted sling, slowly raise
the load. Horizontal movement must also begin slowly to prevent the load
from swinging or coming into contact with other obstacles.
The crane warning signal or horn must be sounded when the load or hook
comes near or over personnel. Carrying loads over personnel is not recommended.
A load should not be left suspended.
Audible and discernible voice communication should be kept with the operator
at all times. If this cannot be accomplished, a signal system should be
used. Standard signals as shown on the next page; however, it may be necessary
to create special signals in certain circumstances. In these circumstances,
the signals must be understood and agreed upon by all individuals using
the crane. .
Commonly Asked Questions
| Q. |
Where are the standard crane signals located? |
| A. |
The signals are located in ANSI/ASME
B30.2-2005. These are standard signals recommended by ANSI; however,
OSHA does not require the signal system in its Overhead and Gantry
Crane regulation. The manufacturers of overhead cranes may also provide
their own version of crane signals. |
| Q. |
Do standards exist for other types of cranes? |
| A. |
Yes, several. Here are just a few: OSHA 29
CFR 1910.180 regulates the operation of Crawler Locomotive and
Truck Cranes; 29
CFR 1910.181 covers Derricks; 29
CFR 1910.183 covers Helicopter Cranes; and 29
CFR 1910.178 covers Powered Industrial Trucks. The ANSI/ASME
B30.2-2005 covers Portal Tower and Pillar Cranes; ANSI/ASME
B30.5-2004 covers Mobile and Locomotive Cranes; and ANSI/ASME
B30.11-2004 covers Monorails and Underhung Cranes. |
Standard Hand Signals for Controlling Overhead and
Gantry Cranes
Hoist: With forearm vertical, forefinger pointing up, move
hand in small horizontal circle. |
Lower: With arm extended downward, forefinger pointing down,
move hand in small horizontal circles. |
Bridge Travel: Arm extended forward, hand open and slightly
raised, make pushing motion in direction of travel. |
Trolley Travel: Palm up, fingers closed, thumb pointing in
direction of motion, jerk hand horizontally. |
Stop: Arm extended, palm down, move arm back and forth horizontally. |
Emergency Stop: Both arms extended, palms down, move arms back
and forth horizontally. |
Multiple Trolleys: Hold up one finger for block marked "1"
and two fingers for block marked "2." Regular signals follow. |
Move Slowly: Use one hand to give any motion signal and place
other hand motionless in front of hand giving the motion signal. |
 |
Magnet is Disconnected: Crane operator spreads both hands
apart--palms up. |
Sources for More Information
29
CFR 1910.179, Overhead and Gantry Cranes
ANSI B30.2-1983, Overhead and Gantry Cranes
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Please Note: The information contained in this
publication is intended for general information purposes only. This publication
is not a substitute for review of the applicable government regulations
and standards, and should not be construed as legal advice or opinion.
Readers with specific questions should refer to the cited regulation or
consult with an attorney.
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