period of time
16 Mobile Mobile Crane Crane Operations Operations
16 Mobile Mobile Crane Crane Operations Operations
Only crane operators who have been adequately trained, and has adequate experience and fully complies with the competency requirements of the Lifting Equipment Management System (EP 200803208668) are all owed to ope rate cran es.
16.1 Documents 16.1 Documents
The following documents must be present on mobile cranes:
1. Crane manual.
2. The current certificate of examination.
3. The safe working load charts in English or Bahasa Malay. the charts must be kept in a book, folder or envelope in t he operator’s cabin. Lifting must not
take place unless the load charts are in the crane cabin. Although the crane’s l oad capacity indictor system may appear to be operating correctly, the load charts must be available to
v e r i f y t ha t t he cr a ne i s no t be i ng o v e r l o ade d.
The lifting capacities specified on a load chart must never be exceeded, except during testing of the crane by the third party surveyor under controlled conditions.
The lifting capacity of a crane is limited by:
1. Structural strength when the working radius is small; and 2. Stability when the working radius is greater
The load charts on most cranes have a bold line or shaded area dividing the chart into two segments. The divided segments show the crane operator, which capacities are, limited by
structural strength, and which are limited by stability. Ratings above the bold line are based on structural strength, while the ratings below the bold line are based on t he stability of the crane. If a crane is overloaded in the structural area of the load chart, a structural or
mechanical component of the crane may fail. However, if the crane is overloaded in the stability area of the load chart, the crane may overturn.
On some mobile cranes, there may be numerous load charts for differing boom and counterweight configurations. The load charts may be complex and include numerous conditions that must be complied with to ensure the crane can safely l ift a load. Two important factors that are often overlooked when reading load charts are:
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1. The need to subtract the mass of the hook block and lifting slings from the gross capacity of the crane at the particular radius, unless otherwise noted on the load
chart. For example, if the load chart states the crane can lift 20 tonnes at a given radius, but the hook and lifting gear have a combined mass of one tonne, the l oad to be lifted cannot be greater than 19 tonnes. T his issue becomes critical for heavier hook blocks and lifting gear (e.g. spreader beams).
2. The need to subtract the mass of the fly jib from the capacity of the main hook when lifting from the main hook on the main boom with a f ly jib attached to the boom head, unless this is allowed for and noted on the load chart. Capacities of the main boom are generally based on the fly jib being removed.
If this issue is ignored, the l ikelihood of the crane overturning can be very high.
16.3
16.3 Sitting Sitting of of Cranes Cranes
1. The ground or foundation, temporary supporting structures, packing or anchor points must be of sufficient strength and stability for t he maximum loading to be imposed.
2. Settlement and deflection of ground support or structures must also be taken into account.
3. Cranes must not be sited on soft or waterlogged ground unless adequate precautions have been taken to provide support to each wheel/outrigger.
4. Dynamic loads, which might arise during operations must be estimated and calculations must include a 25% margin to allow for unpredictable effects.
5. Mobile crane’s shall not be used during wind conditions above 15 m/s or above the crane supplier’s recommendations, whichever is the lower. A wind anemometer shall be
fitted to the boom tip alternatively a hand-held anemometer can be used in the area of the lift.
6. Sitting of cranes on sloping ground must be avoided. Where necessary the crane shall be levelled using outriggers or other means to give a level and stable working platform.
7. Mobile cranes must be positioned so that the risk of injury from collision with other plant is minimised. This issue is particularly important where mobile cranes are set up
on public roads. Another way to minimise the risk of injury from collision with other mobile plant and vehicles is to increase the visibility of mobile cranes. One way to increase the visibility of a crane is to permanently mark the crane’s outriggers with high visibility hazard striping (i.e. ‘zebra striping’). The outrigger beams and/or
hydraulic cylinders shall be marked with the hazard striping.
The striping must:
a. Be at an angle 30-60 degrees to the horizontal;
b. Be 40-150 mm wide; and
c. Consist of two contrasting colours, black and yellow.
8. For cranes sited in flowing water careful investigation must be made of any potential for scouring effect. Constant checks must be made during operations to monitor the
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situation. The possibility of cranes being trapped by rising water must not be overlooked and cranes must be moved to safe position as necessary.
9. Checks must be made to ensure that cranes are not sited above or adjacent to excavations or inadequately compacted ground, which are be liable to subside.
10 Particular care must be taken when cranes are sited in the proximity of hazards including other cranes.
11. Prior to the commencement of any lifting operations, the temporary closure of roads and access required for crane operations must be notified to all parties likely to be affected by the closures.
12. Cranes must not be operated unless all personnel including third parties and members of the public are cleared from the radius of the crane’s boom and loads with a safety margin of 5 metres. The barriers may be made from red/white marking tape.
13. The operation of any crane within 15 metres height or reach from the nearest point of contact (typically the boom, jib or cab) with live overhead electric cables or
conductors is strictly prohibited.
supervisor in accordance with the written lift plan.
15. Where there is a danger of any part of the crane fouling any overhead or nearby obstruction e.g. bridges, gantries, pipe work, scaffolding, buildings or walls, the
operator must work only under the direction of a banksman so positioned as to have a clear view of the crane and the obstruction.
16 Adequate clearance must be allowed between any part of a crane and the nearest obstruction to prevent contact with, and/or the trapping of personnel when the crane is slewed.
17. Where it is not possible to allow such a clearance, no access must be allowed whilst lifting operations are in progress.
16.4 Preparation 16.4 Preparation
1. Preparations for lifting operations must be in accordance with manufacturers recommendations and the lift plan.
2. Load indicators, overload cut-outs, limit switches and all other safety devices must be function tested before operation of a crane.
3. Visual load/radius indicators and rated capacity indicators must be checked after assembly, boom length change or any other factor, which might affect correct and safe operation.
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4. Outriggers must be fully extended properly supported and if required by manufacturers pinned in position.
5. Jacks and outriggers must be correctly fitted with feet to provide a firm base for the crane. Prior to operations, the crane must be jacked in accordance with manufacturer's recommendations.
6. Counterweights of the correct weight must be correctly fitted prior to operation.
A ddi t i o na l co unt e r -w e i g ht i ng m u s t be f i t t e d a s ne ce s s a r y t o s ui t l o ad r e qui r e m e nt s and any boom or jib extension.
7. On wheeled cranes with pneumatic tyres particular care must be taken to ensure tyres are inflated to correct pressures as recommended by the crane manufacturers.
8. Ensure that a pennant of 2 – 3 metres long and correct capacity (refer to Para14.43) is attached to the crane hook and is suitable for the particular lift to be carried out.
W he r e be ca u s e o f t he c r a ne ' s l i m i t e d bo o m l e ngt h a f ul l - l e ngt h pe nna nt ca nno t be deployed, the pennant must be as long as is possible.
CAUTION:
CAUTION:
NEVER WORK OR WALK UNDER A HOISTED OR SUSPENDED LOAD UNLESS IT NEVER WORK OR WALK UNDER A HOISTED OR SUSPENDED LOAD UNLESS IT HAS BEEN ADEQUATELY SUPPORTED FROM BELOW AND ALL CONDITIONS HAS BEEN ADEQUATELY SUPPORTED FROM BELOW AND ALL CONDITIONS HAVE BEEN APPROVED BY THE PIC.
HAVE BEEN APPROVED BY THE PIC.
NOTE:
NOTE: IT IS A REQUIREMEIT IS A REQUIREMENT THAT ALL MOBILE CRANES NT THAT ALL MOBILE CRANES WITH OUTRIGGERS SHALL WITH OUTRIGGERS SHALL USEUSE SOLID SUPPORTING BLOCKING FOR OUTRIGGERS FOR EVERY OPERATION IN SOLID SUPPORTING BLOCKING FOR OUTRIGGERS FOR EVERY OPERATION IN EVERY CIRCUMSTANCE.
EVERY CIRCUMSTANCE.
16.5
16.5 Lift Lift Plans Plans
A l l cr ane o per a t i o n s ha l l be s ui t a bl y pl a nne d as de s cr i be d i n Section 8 Before lifting operations, the person in charge (PIC) of the li ft must ensure:
1. The load is robust and not likely to break up, deform or become damaged during the lifting operation.
2. The load is properly slung and evenly balanced using certified loose lifting tackle with a SWL, adequate for the operation
3. The lifting gear is properly attached to the load and where lifting points are used they are designed for that lifting operation and are in good condition with appropriate
certification stating the WLL and conditions.
16.6
16.6 Environmental Environmental Conditions Conditions
Cranes must not be operated if the visibility of the crane operator or the banksman is significantly impaired by heavy rain, haze etc. Lifting operations must be suspended during heavy rain, except where it would be more hazardous not continuing the lift.
Cranes must not be operated in darkness without adequate lighting to illuminate the crane’s lifting area.
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W i nd i m po s e s a ddi t i o na l s t r e s s e s o n bo t h t he c r ane a nd i t s l o a ds , pa r t i cul ar l y whe n a l o a d starts to swing. Extreme caution must be used during windy conditions and the following
restrictions must apply:
1. Lifting of bulky objects with large surface areas (tubulars, pipes, shipping containers, steel plates etc.) must be stopped when t he wind speed reaches or exceeds 13m/s.
2. All lifting operations must stop when the wind speed exceeds 20.5 m/s.
16.7
16.7 General General Operating Operating Instructions Instructions
Cranes must not be left unattended whilst s uspending a load. When not in use and left unattended, crane cabs and control compartments must be kept closed with controls or power packs locked off.
Cabs and control compartments must be locked and the vehicle parked without obstructing normal access.
Cranes must not be used for any purpose other than for lifting in a vertical plane. Do not use for dragging or fishing a load.
Crane booms must not be used to apply sideways force to an object. For example, during demolition, tree felling or pushing materials and boxes.
Cranes must not be used as winches to drag materials or equipment.
Cranes must not be used if they are not fully rigged or are in a defective condition, e.g. if outriggers do not fully extend, there are hydraulic fluid leaks or controls and safety equipment are defective.
Lifting operations must be conducted cautiously without hoisting, lowering or slewing at excessive speed. Load swinging and snatch loading must be avoided.
On completion of crane operations, the crane boom and hook must be properly secured before the crane operator leaves the crane. The crane boom must be left on any fitt ed rest, with the hoist rope slackened, or pointing downwind with the boom angle lower than 45°.
A ny de f e c t o r da m a ge t o t he cr a ne o r i t s s t r uc t ur e a f f e ct i ng t he s af e t y o f t he cr a ne m us t be reported. The crane must be taken out of service immediately the defect or damage is detected
and not used until it has been rectified, and re-certified if necessary.
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17.0 Mult
17.0 Mult iple Crane iple Crane Lifts Lifts
Lifting a load with two or more cranes requires greater attention to planning and supervision, because the effects of the relative motion between the cranes may create additional loadings on the cranes, the load and the lifting gear in place.
17.1
17.1 Safety Safety Measures Measures for for Multiple Multiple Crane Crane Lifts Lifts
W he r e po s s i bl e, a v o i d ho i s t i ng a l o ad w i t h m o r e t ha n o ne cr a ne . H o we v e r , w he r e i t i s necessary to lift a load using more than one crane, the fol lowing steps must be taken:
1. The person in charge (PIC) of the lift shall be in overall control of the lift.
2. Make an accurate assessment of:
a. The share of the load that is to be carried by each crane.
b. How the load sharing is to be proportioned.
c. How the proportioning is to be maintained.
3. Make sure the instructions to each crane operator and other persons involved are clear, and rehearse the operation wherever possible.
4. Use cranes of equal capacity and similar characteristics, where practicable.
5. Make sure that both cranes are aligned in the same direction when using non-slewing type cranes in the pi ck-and-carry mode.
6. Use luffing up in preference to luffing down.
17.2
17.2 Calculated Calculated Share Share of of the the Load Load
W he r e m ul t i pl e ho i s t i ng o pe r a t i o ns a r e c ar r i e d o ut , t he f ol l o w i ng m i ni m u m ca pa ci ty requirements for each crane will apply:
1. For two cranes—20% greater than the calculated share of the load.
2. For three cranes—33% greater than the calculated share of the load.
3. For four or more cranes— 50% greater than the calculated share of the load.
If it is not possible to comply with the minimum capacity requirements stated above, then an engineer must check and certify the lifting plan.
17.3
17.3 Principles for Multiple Crane Lifting Principles for Multiple Crane Lifting
The following factors are to be considered when planning for multiple crane lifts:
1. Mass of the load.
2. Position of the centre of gravity.
3. Mass of the lifting gear.
4. Safe working capacity of the lifting gear.
5. Synchronisation of crane motions.
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17.4
17.4 Mass Mass of of the the Load Load
Ensure the total mass of the l oad and its distribution is either known or calculated. Where the information is taken from a technical drawing, ensure allowances are made for manufacturing tolerances.
17.5
17.5 Position Position of of the the Centre Centre of of Gravity Gravity
Due to the variable effect of manufacturing tolerances and rolling margins, the position of the centre of gravity may not be accurately known. Accordingly, the proportion of the load being carried by each crane may therefore be uncertain.
17.6
17.6 Mass Mass of of the the Lifting Lifting Gear Gear
Ensure the mass of the lifting gear and its distribution are accurately known and included as part of the calculated load on the cranes. Where heavy or awkwardly shaped loads are
handled, the deduction from the safe working loads of the cranes to allow for the weight of the lifting gear may be quite significant.
17.7
17.7 Safe Safe Working Working Capacity Capacity of of the the Lifting Lifting Gear Gear
Ensure the distribution of the forces within the lif ting gear, which will arise during the lifting operation, is established. The lifting gear must have a s afe working capacity margin in excess of that needed for its proportioned load. Determine whether special lift ing gear is required to suit the maximum variation in distribution and direction of applied loads and forces, which
may occur during multiple lifting.
17.8
17.8 Synchronisation Synchronisation of of Crane Crane Motions Motions
Minimise the variation in the direction and magnitude of forces acting on the cranes by synchronising the cranes’ motions. Where possible, ensure cranes of equal capacity and similar
operating characteristics are used. However, in practice, there will always be some variation due to differences in response to the activation of the motion controller and the setting and efficiency of the braking system.
A s i t i s unl i k e l y t ha t t he m ot i o ns o f t he cr ane s wi l l be acc ur a t e l y s y nchr o ni s e d, e ns ur e t ha t a n assessment of the effect of variation in plumb of the hoist ropes, which may arise from
inequalities of speed, and the means for keeping such inequalities to a minimum, is made. To allow for these inequalities, the lifting operation must be performed at low speeds with extreme care to ensure the hoist ropes are kept as close as possible to vertical.
The rated capacity of a crane is calculated on the assumption that the l oad will be raised and lowered in a vertical plane. The crane boom has limited strength in t he lateral plane.
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18.0
18.0 Precautions when Using Mobile Precautions when Using Mobile Cranes Cranes
18.1
18.1 Lattice Lattice Boom Boom Cranes Cranes
On lattice boom cranes, the top of the ext ended boom must not be lowered to a point below the horizontal line that passes through its boom heel pivot pin. If the boom tips below this plane, the angle of pull of the boom luffing ropes could cause the boom to buckle before the boom
begins to lift.
Lattice boom cranes must not be moved uphill with an unloaded boom in the near vertical position, or operated:
1. With the boom at an angle less than that shown on the load chart.
2. With the boom hard against the boom backstop to avoid serious damage to the structural members of the boom. Regard the boom backstop as a safety device only.
18.2
18.2 Hydraulic Hydraulic Boom Boom Cranes Cranes
W he n e x t e ndi ng t he bo o m o n hy dr a ul i cal l y o pe r a t e d cr ane s , e ns u r e t ha t t he bo o m s e ct i o ns ar e extended or retracted in accordance with the manufacturer’s recommendations.
The crane must not be operated with the boom at an angle less than that shown in the load chart.
18.3
18.3 Precautions Precautions with with Pick-and-Carry Pick-and-Carry Cranes Cranes
W he n m o v i ng a l o a d i n t he pi ck - a nd- ca r r y m o de , t he ba nk s m an m us t r e m ai n i n s i g ht o f t he crane operator, and not walk in the path of the crane. When t ravelling and manoeuvring with a load, the crane operator must ensure that:
1. The slew brake is applied at all times other than when the slew motion is being used.
2. Precautions are taken on uneven road surfaces when loaded or unloaded, as an undulation in the road surface may move the crane into an unstable zone.
3. The slewing brake or lock is applied when travelling with a load.
3. The slewing brake or lock is applied when travelling with a load.