Welcome To Overhead Crane Operator Safety Training

[Audio] Intellitrak Welcome To Overhead Crane Operator Safety Training Intellitrak Welcome To Overhead Crane Operator Safety Training.

[Audio] Goals of This Program Learning safe, professional and efficient operation of Overhead Cranes. Safety review for experienced operators. Create awareness and confidence so that you will WANT to operate safely. Goals of This Program Learning safe, professional and efficient operation of Overhead Cranes. Safety review for experienced operators. Create awareness and confidence so that you will WANT to operate safely..

[Audio] Federal Law Requires That you be trained and authorized by Intellitrak to operate Overhead Cranes. Never allow unqualified, untrained or unauthorized persons to operate your Overhead Crane. Overhead Crane certification is good for 3 years at Intellitrak ONLY Federal Law Requires That you be trained and authorized by Intellitrak to operate Overhead Cranes. Never allow unqualified, untrained or unauthorized persons to operate your Overhead Crane. Overhead Crane certification is good for 3 years at Intellitrak ONLY.

[Audio] Be Familiar With Your Equipment You are responsible for reading and understanding the contents of the operator’s manual for each Crane. If you have questions, get an answer from a qualified person. Know the purpose of all controls. Know the rated workload of hoists, chains and straps. Be Familiar With Your Equipment You are responsible for reading and understanding the contents of the operator's manual for each Crane. If you have questions, get an answer from a qualified person. Know the purpose of all controls. Know the rated workload of hoists, chains and straps..

[Audio] Overhead Cranes Defined A movable bridge carrying a movable or fixed hoisting mechanism and traveling on an overhead fixed runway structure. Overhead Cranes Defined A movable bridge carrying a movable or fixed hoisting mechanism and traveling on an overhead fixed runway structure..

[Audio] Parts of an Overhead Crane Parts of an Overhead Crane.

[Audio] Types of Overhead Cranes Gantry Types of Overhead Cranes Gantry.

[Audio] Types of Overhead Cranes Semi-Gantry Semi-Gantry.

[Audio] Types of Overhead Cranes Cantilever Gantry Cantilever Gantry.

[Audio] Types of Overhead Cranes Storage Bridge Storage Bridge.

[Audio] Types of Overhead Cranes Wall Cranes Wall Cranes.

[Audio] Types of Hoists Manual Electric Pneumatic Types of Hoists Manual Electric Pneumatic.

[Audio] Modifications Cranes can be modified and rerated if the modifications and supports are checked thoroughly for the new rated load by a qualified engineer or the equipment manufacturer. New rated load must be clearly marked on both sides of the crane. If the crane has more than 1 lifting hoist, all hoists should be clearly marked to show their rated load and can be seen from the ground. Modifications Cranes can be modified and rerated if the modifications and supports are checked thoroughly for the new rated load by a qualified engineer or the equipment manufacturer. New rated load must be clearly marked on both sides of the crane. If the crane has more than 1 lifting hoist, all hoists should be clearly marked to show their rated load and can be seen from the ground..

[Audio] Pre-Shift Inspection Crane should be inspected before every shift: Hoisting and lowering Bridge Travel Limit Switches, Locking and Safety Devices Trip setting of hoist limit switches Pre-Shift Inspection Crane should be inspected before every shift: Hoisting and lowering Bridge Travel Limit Switches, Locking and Safety Devices Trip setting of hoist limit switches.

[Audio] Visual Inspection Check for any loose or missing parts Check end stops. End stops prevent trolleys from running off the beam. Know the location of the disconnect that will cut off power only to the hoist or crane. Be sure that it is readily accessible and not blocked. Make sure wire rope is properly seated in its drum and sheave grooves without slack or overlapping Visual Inspection Check for any loose or missing parts Check end stops. End stops prevent trolleys from running off the beam. Know the location of the disconnect that will cut off power only to the hoist or crane. Be sure that it is readily accessible and not blocked. Make sure wire rope is properly seated in its drum and sheave grooves without slack or overlapping.

[Audio] Frequent Inspections cont. Hoist Chains and end connections for wear, twist, or distortion. Running Rope and end connections for wear, broken strands, etc. Hooks with deformation or cracks. Frequent Inspections cont. Hoist Chains and end connections for wear, twist, or distortion. Running Rope and end connections for wear, broken strands, etc. Hooks with deformation or cracks..

[Audio] Periodic Inspections Deformed cracked or corroded members. Loose Bolts or Rivets Cracked or worn sheaves and drums Worn, cracked or distorted parts, such as pins, gears, bearings or rollers. Excessive wear on brake system parts. Excessive wear of chain and chain drive sprockets Deteriorated electrical components, such as push buttons, limit switches or contactors. Periodic Inspections Deformed cracked or corroded members. Loose Bolts or Rivets Cracked or worn sheaves and drums Worn, cracked or distorted parts, such as pins, gears, bearings or rollers. Excessive wear on brake system parts. Excessive wear of chain and chain drive sprockets Deteriorated electrical components, such as push buttons, limit switches or contactors..

[Audio] Written Reports Written reports need to contain any deficiencies or damage to the crane. The report needs to identify the importance of repair and if machine needs to be out of service until repairs are made. Written reports will be kept by someone on the premises and will be available upon request. Written Reports Written reports need to contain any deficiencies or damage to the crane. The report needs to identify the importance of repair and if machine needs to be out of service until repairs are made. Written reports will be kept by someone on the premises and will be available upon request..

[Audio] Rigging Equipment and Slings Synthetic Webbing Natural and synthetic rope Wire rope Chain Rigging Equipment and Slings Synthetic Webbing Natural and synthetic rope Wire rope Chain.

[Audio] Sling Inspections All slings are to be inspected everyday prior to use. This includes all rigging devices, chains, ropes, master links, alligators, clips, hooks, quick alloys etc. A thorough inspection of all facility chains and slings must be done once every 12 months. Sling Inspections All slings are to be inspected everyday prior to use. This includes all rigging devices, chains, ropes, master links, alligators, clips, hooks, quick alloys etc. A thorough inspection of all facility chains and slings must be done once every 12 months..

[Audio] A tag must be present on all slings What is the capacity of this sling if it is choked? Sling Inspections A tag must be present on all slings What is the capacity of this sling if it is choked?.

[Audio] Sling Inspections Look for damage from: Wear, cracks, knots, heat, kinks, melting, snags, tears, chemicals, etc. Sling Inspections Look for damage from: Wear, cracks, knots, heat, kinks, melting, snags, tears, chemicals, etc..

[Audio] Damaged Sling Take it out of service. Tag it. Let supervisors know so that it can get repaired or replaced, as necessary. Damaged Sling Take it out of service. Tag it. Let supervisors know so that it can get repaired or replaced, as necessary..

[Audio] Protecting Slings Slings should be stored hanging off the ground in a clean dry environment. Do Not Drag slings across the floor. Always hook with a “closed hook” with the hooks facing out. Avoid lifting across sharp edges. Protecting Slings Slings should be stored hanging off the ground in a clean dry environment. Do Not Drag slings across the floor. Always hook with a "closed hook" with the hooks facing out. Avoid lifting across sharp edges..

[Audio] Before Moving a Load Ensure all loose parts, materials, blocking and packing have been removed from the load. Remove any slack from hoists. Make sure the lifting device is seated in the saddle of the hook. Before Moving a Load Ensure all loose parts, materials, blocking and packing have been removed from the load. Remove any slack from hoists. Make sure the lifting device is seated in the saddle of the hook..

[Audio] Avoid Swinging/Side Loads Locate the hoist directly above the lifting point of the load before lifting. Keep lifting ropes/straps vertical. Do not pull the load. Maintain two full wraps of cable around the hoisting drum. Avoid Swinging/Side Loads Locate the hoist directly above the lifting point of the load before lifting. Keep lifting ropes/straps vertical. Do not pull the load. Maintain two full wraps of cable around the hoisting drum..

[Audio] Avoid Swinging/Side Loads Dangers of Hoist side Loads: Wire rope misalignment on drum could cause a failure or kink if overlapping rope. Swinging a load into other personnel, product or property. Avoid Swinging/Side Loads Dangers of Hoist side Loads: Wire rope misalignment on drum could cause a failure or kink if overlapping rope. Swinging a load into other personnel, product or property..

[Audio] Pinch Points WATCH OUT FOR PINCH POINTS AND TRIP HAZARDS!!! Inspect your work area and always anticipate load swing. Pinch Points WATCH OUT FOR PINCH POINTS AND TRIP HAZARDS!!! Inspect your work area and always anticipate load swing..

[Audio] Rigging Rigging. Rigging. A picture containing text, scale Description automatically generated.

[Audio] Rigging. Rigging. A picture containing text, sky, outdoor Description automatically generated.

[Audio] Operation Operators must stay focused on their task. No cellphones unless used for communication for task at hand. No horse play or reckless behavior. No food or drink while operating. Keep clear of the load. When workers must be in the fall zone, the load must be handled by a qualified rigger. Lift slowly Check your load stability. Level and secure. Operation Operators must stay focused on their task. No cellphones unless used for communication for task at hand. No horse play or reckless behavior. No food or drink while operating. Keep clear of the load. When workers must be in the fall zone, the load must be handled by a qualified rigger. Lift slowly Check your load stability. Level and secure..

[Audio] An audible warning must sound when the load comes near personnel Loads should not be carried over other personnel. Never leave a suspended load unsupervised. Audible and voice communication system should always be kept with the operator. Operation An audible warning must sound when the load comes near personnel Loads should not be carried over other personnel. Never leave a suspended load unsupervised. Audible and voice communication system should always be kept with the operator..

[Audio] Note: there are 11 safety violations. Safety violations from the drawing that violate code or company policy: 1. Load exceeds maximum rating for the crane. 2. Hook latch not closed. 3. Hook is defective not closed. 4. Lifting load over people. 5. 1 person not wearing a hard hat. 6. Operator distracted and not paying attention to suspended load. 7. Operator working from bed of truck and not ground. 8. Tear in sling. 9. Knot in sling. 10. Load not properly secured and will fall out of the sling. 11. People under load not paying attention..

[Audio] Crane Signals Crane movement should be communicated to others involved or in the vicinity. Hand signals can be useful when verbal communication is impossible. Only one individual should give signals to the operator so that there is no confusion. Crane Signals Crane movement should be communicated to others involved or in the vicinity. Hand signals can be useful when verbal communication is impossible. Only one individual should give signals to the operator so that there is no confusion..

[Audio] Guiding Loads Under what circumstances may employees guide a suspended load by placing their hands on it? Only employees essential to the operation are permitted in the fall zone. Those certain operations are there to: Physically guide the load Closely monitor and give instructions regarding loads movement To attach or detach from structure or components. Guiding Loads Under what circumstances may employees guide a suspended load by placing their hands on it? Only employees essential to the operation are permitted in the fall zone. Those certain operations are there to: Physically guide the load Closely monitor and give instructions regarding loads movement To attach or detach from structure or components..

[Audio] Lifting Loads at or near Capacity Test the hoist brakes by turning “OFF” the master switch with the load just a few inches off the floor. If the brakes do not hold slowly lower the load to the floor. DO NOT OPERATE. Report the situation immediately and DO NOT USE until resolved. Lifting Loads at or near Capacity Test the hoist brakes by turning "OFF" the master switch with the load just a few inches off the floor. If the brakes do not hold slowly lower the load to the floor. DO NOT OPERATE. Report the situation immediately and DO NOT USE until resolved..

[Audio] Leaving An Overhead Crane Never leave controls unattended while a load is suspended. If it becomes necessary to leave the controls, lower the load to the floor. Familiarize yourself with the disconnect switch. If there is an unexpected power loss, put the controllers in the “OFF” position to prevent unexpected movement when power returns. Leaving An Overhead Crane Never leave controls unattended while a load is suspended. If it becomes necessary to leave the controls, lower the load to the floor. Familiarize yourself with the disconnect switch. If there is an unexpected power loss, put the controllers in the "OFF" position to prevent unexpected movement when power returns..

[Audio] Unsafe Overhead Crane Disconnect power to a hoist that is unsafe or in need of repair. Lock out and tag out the power disconnect with “Do Not Operate” or “Out of Order” Never Operate a hoist that is tagged with a sign that says “Do Not Operate” or “Out of Order” or if in your opinion is UNSAFE TO OPERATE… Unsafe Overhead Crane Disconnect power to a hoist that is unsafe or in need of repair. Lock out and tag out the power disconnect with "Do Not Operate" or "Out of Order" Never Operate a hoist that is tagged with a sign that says "Do Not Operate" or "Out of Order" or if in your opinion is UNSAFE TO OPERATE….

[Audio] Load Capacity and Angles The load capacity of the sling is determined by its weakest component. NEVER overload a sling. Remember, the farther the sling “legs” are spread the less the sling can lift. For simplicity remember 45 degrees as 1.5 load factor Leg Angle Load Factor 90° 1.000 85° 1.003 80° 1.015 75° 1.035 70° 1.064 65° 1.103 60° 1.154 55° 1.220 50° 1.305 45° 1.414 *(1.5) 40° 1.555 35° 1.743 30° 2.000 Load Capacity and Angles The load capacity of the sling is determined by its weakest component. NEVER overload a sling. Remember, the farther the sling "legs" are spread the less the sling can lift. For simplicity remember 45 degrees as 1.5 load factor.

[Audio] Load Capacity and Angles Leg Angle Load Factor 90° 1.000 85° 1.003 80° 1.015 75° 1.035 70° 1.064 65° 1.103 60° 1.154 55° 1.220 50° 1.305 45° 1.414 *(1.5) 40° 1.555 35° 1.743 30° 2.000 Load Capacity and Angles.

[Audio] Get your Calculators Out 5ton Overhead Crane 1. What is the strain on the sling if the load weighs 5,000lbs? 2. What is the heaviest load you can lift if you have two slings choked at 90deg on a load and a 5ton crane? 3. Two slings are choked at both points of the load. Can you safely lift a load that weighs 5,000lbs? 1.) 5,000 x 1.5 = 7,500lbs 2.) 5,120 x 2 = 10,240lbs 10,000lb load capacity for the crane is the limiting factor. 3.) Yes; Crane capacity = 10,000lbs (5,000 x 1.5)/ 2 = (7,500lbs)/2slings = 3,750lbs of strain on each sling..

[Audio] 10ton Overhead Crane 1. What is the strain on the sling if the load weighs 8,000lbs? 2. Can you safely lift 22,000lbs with a 10ton crane and 2 lifting straps straddling the load? 3. Can you safely lift 18,000lbs with 4 slings end to end? 1.) 8,000 x 1.5 = 12,000lbs 2.) No, the load capacity is too much for the crane. 3.) No, Crane capacity = 20,000lbs. 6,400 x 4 = 25,600lbs sling capacity 18,000 x 1.5 = 27,000 load on slings.

[Audio] There Is A Difference Between: Someone Who Can Operate An Overhead Crane Vs. A Truly Skilled Operator Great skills take time, patience and effort to develop. Know your abilities and your limits..