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How to Maintain Safety While Operating Crawler Cranes: A Comprehensive Guide
According to industry statistics, an average of 42 worker deaths per year from 2011 to 2017 occurred as a result of accidents related to cranes. Such injuries also relate to mobile crane incidents, which include crawler cranes, among others, that could have been prevented by following specific guidelines.
Knowledge of crawler crane operation and associated dangers
Crawler Cranes also have various techniques of supporting the machine on the ground using tracked chassis systems that provide equal support of the machine's weight on the ground. This is a critical feature making the machine highly stable when placed in land that may not be firm or flat, making such a landscape ideal for such a machine to operate on, contrary to wheeled Mobile Cranes. The ability of the top carriage to rotate with the control cabin, engine, and lifting system of the machine allows it to turn in any direction in 360 degrees without moving the entire machine.
The enhanced lifting capacity of crawler cranes is essentially the central consideration of large construction works, building construction of bridges, industrial plant construction works, and mega projects of various infrastructure facilities. But with enhanced capacity comes increased risk exposure as well. Crawler cranes are generally much heavier than a few hundred tons; they apply immense forces during lifting operations; they function in a challenging and adverse environment wherein different risks tend to come together simultaneously.
The main risks involved in safety risks include tipover of the machine due to its nature or overload, damage to the land or structure from improper maintenance and overload, collision with electric power wires during movement of booms, falling objects resulting from improper rigging or equipment failure, and being squashed by ground personnel inside the working range. From the analysis, 50 percent of accidents that occur in the crane are associated with improper use of outriggers or improper establishment of land, while the remaining percentage is associated with accidents concerning loads, such as overload or poorly rigged loads.
OSHA Regulations and Mandatory Nature of Compliance
Almost all countries have an Occupational Safety & Health Administration that gives safety instructions on the use of equipment such as cranes in the US. For a general industry, there are instructions on the use of a crawler, locomotive, or truck crane in OSHA Standard 1910.180. For construction operations, there is OSHA Standard 1926 Subpart CC on cranes and derricks.
Thus, the operation of the crane was only approved for qualified persons. The certification involves the writing tests for the validation of theoretical skills and the physical tests for the validation of physical skills. They only stand for five years; they are differentiated based on the type of crane.
Besides the aspect of certifying the operator, OSHA has provided certain guidelines concerning inspection requirements for equipment, grounds, and further information concerning regulation to perform the operation. According to OSHA regulation 1926.1402, it is imperative to have grounds that are firm, drained, and textured to perform certain levels depending upon the guidelines provided from the other side through the manufacturers. Though it is the duty of the ruling government to be carried out at the end destination, it is also imperative to be ensured that it is safely situated as far as the operator is concerned.
The details required during the inspection of the equipment are discussed. The inspection of the equipment for a daily shift should be conducted routinely, while the inspection of the equipment for a month should be conducted with supervision from a trained person. The inspection of equipment in writing should be conducted yearly.
Pre-Operational Verifications & Daily Verifications
For each of these operators, there is a list of over forty inspection points that need to be done daily. Among the elements that the operators are supposed to verify before starting up the machine are the condition of the crawler tracks for any damage, levels and leaks of hydraulic fluids, integrity levels of the structure, as well as the safety devices themselves, aside from the charged fire extinguishers.
Once the startup procedure is complete, it then becomes the task of the operating crew to determine whether there are any warnings on the instrument panels and make certain that the hydraulic pressure settles and the controls are placed in their operating position. The anti-two-block system ensures that the load block does not come into contact with the end of the boom in the event of total catastrophic failure. The capacity limiter allows continuous observation of the load with respect to crane capacity.
The ground crew would further ensure that the area where the task would be carried out would be clear of obstructions, including enough space around the power lines and so on. Communication plans would have been verified, lift plans would have been reviewed, and the availability of rigging equipment would also have been verified.
Preparation of Ground & Positioning of Cranes
But in a crawler track, a more even weight distribution can result in instability if the site conditions are not favorable. The operating area must then be evaluated by a competent person for the presence of: underground utilities, Void areas, and Weak soil strata. a The site conditions can be analyzed either by site surveying or by analysis based on site diagrams if available.
Depending on the loads, additional support may also be necessary in order to provide enough space for the distribution of the loads; for example, crane mats/or cribbing. They shall be of a particular manufacturer and with sizes appropriate for particular loads. The ground on which the crawler cranes will work shall either be level or have slope properties, depending on the requirements predetermined by the concerned manufacturer, according to the grades allowed.
The crane operator must position the crane with the tracks standing upright and lowered down the grade to provide a stronger, more rigid setup when operating the crane on a surface with a grade or slope. The crane boom must be positioned up slope during a lift in order for there to be a safe point of gravity.
Weight-Carrying Capability and Cargo Rigging Standards
Each crawler crane has load charts for corresponding loads and boom angles, and these have to be considered before making a lift. The load charts also have factors that can be considered in cases where reduced loads have to be calculated due to operating conditions like operating from rubber tires, presence of a side load, and wind interference.
It is mandatory to inspect all rigging gear prior to use as specified in OSHA standards 1910.184 and 1926.251. Worn-out rigging gear is to be taken out of service. Safe rigging practices depend on understanding hitch configurations as they relate to the overall lacing capacity of a sling. In a vertical hitch, the overall capacity of a sling is estimated; however, in a basket hitch or a choker hitch, the capacity is reduced based on the factor of compression utilized in the hitch process.
OSHA considers all lifts in excess of 75 to 80% of the rated capacity to be critical lifts; therefore, there is greater planning involved. The plan developed for the lift will include: weight of the lift, center of gravity of the lift, configuration of the actual crane, description of the rigging used in lifting, hazard potential that will include electrical power lines, communication plans, and emergency plans.
Communication Protocol and Signal Man Requirement
The hand signals are relatively efficient in a partially noisy situation, as the signals are visual. As per OSHA Standard 1926.1428, there should be a competent signal person overseeing the operation in a situation where the vision of the operator is hindered. It should be a requirement for the signal person to have a visual observation of the operator and the load during the execution of the lift.
Two-way radios will be used in order to complement the use of hand signals wherever the range is not suitable for visual signals. Two-way radios should be adequately used based on an agreed set of methods, such as identifying oneself before calling, speaking with an allocated set of words, acknowledging the reception of the message, and drawing attention to a hazard immediately.
It would be important for all the crew members to realize that the emergency stop may be signaled by anyone when danger has been observed. The stop work authority has been used as a means of facilitating the stoppage of the operation by all the employees.
Prevention of Common Accidents
Tip-overs could be induced by various conditions such as poor site work, overload work, or working within the stability limits. All these would call for a proper analysis of the soil to be carried out in a way that combines proper load management and a higher degree of care while working within the stability limits.
Failures in the boom can occur either due to overload or hidden damage. Observations are carried out periodically in order to check if there is any indication of cracks, deformation, or corrosion that leads to failure before actual damage is caused in the integrity of the boom. The operators should not overload or side load the boom.
Two-block accidents relate to an incident where the load block collides with the tip of the boom. This incident comes with severe damage. There are safety features known as the two-block protection system. It is prudent to note the hook height and the load block to tip-of-boom separation to avoid an incident where the two-block protection system is engaged.
One of the most dangerous situations when it comes to a construction activity related to a crane is when it is closer to an electric power line. Current can travel between the power line and the booms on a crane, an appreciable distance, particularly if it is wet and high voltage. Minimum approach distances, depending on voltage, as outlined by the OSHA, range between ten feet for 50kV or lower to twenty feet or more for voltages greater than 50kV. However, it is always good to have the power line de-energized by the concerned power companies when it comes to a construction activity. Alternatively, when it is not feasible to have the power line de-energized, insulation devices or spotters can be employed to maintain the distance when performing the activity.
Loss of cargo can be due to rigging failure/hook failure or loss of control. For preventing any accident, one needs to make sure that there are good rigging practices with constant checks of the rigging materials in addition to good operation. Never permit cargo to swing over personnel. Also ensure that there are persons on the ground and not in the fall area. Taglines should promote easy rotation/swerve of the material, with the materials needing to be non-conductive in cases of electric hazards.
Maintenance Required Documentation Required
These routine maintenance procedures are still essential for ensuring the crawler crane is operating within safe environmental conditions. Some of the routine procedures that should be followed in the matter at hand include lubrication, replacement, and services. These procedures are all essential for ensuring that none of them poses a threat to health or exacerbates the situation before it becomes a major one.
Hydraulic systems may be of particular interest in this regard because a possible malfunction may easily cause a loss of control or a complete failure of the boom system. Fluid analysis may be a sign of a possible malfunction in the system being considered in this research. The hoses and fittings of the hydraulic system should be inspected not only for any signs of leakage but also for any signs of aging. There should be no drift or jerk in the hydraulic cylinders as they move.
Structural analysis will be useful in establishing fatigue defects, corrosion, and vulnerabilities with respect to the integrity of structures. These regions that need particular emphasis concerning increased loads are at either the joint points of the boom and the remaining base frames or at the rotary machine. Non-destructive testing will involve information for detecting covert defects out of human sight and will entail either ultrasonic inspection or magnetic particle inspection.
The list of requirements for documentation includes records of all inspections performed. Also included is the preparation of statements in the shift inspection checklists. The daily requirements are in addition to the monthly and annual inspection checks in the shift inspection checklists.
Requirements for Training of Cranes Operators
For instance, OSHA has stated that the training, certification, and evaluation of the operator are mandatory before operating a crane. The crane operator should undergo training in relation to both theoretical and technological knowledge in order to equip the individual operating the equipment with the ability not only to operate it but to understand why certain operations are done.
Formal training courses may include such things as parts of the crane, load chart analysis, safe accessories and the purpose of safe accessories, rigging, operation with signal persons, pre-startup checks, operation during normal use, and operation during an emergency.
The training in operations has to begin with simple operations like moving a load through a closed course in a carefully controlled environment.
Apart from the introductory courses, refresher courses can also prove to be an excellent way to inform the operators of new equipment types, experiences gained from incidents in the Industry, and principles that represent the basics of safe operation. Refresher courses become an essential requirement in cases of a change in the kind of cranes used at the workplace, along with a substantial period of time that has passed since the operators last operated the cranes.
It is also the responsibility of the employer to assess the operators of the machine for the various types of machines that they will be working with.
A competence assessment will verify that the operators are able to assemble the crane correctly,interpret the load chart safely, lift safely, and react appropriately during an emergency situation.
All forms of assessment results will also be documented and filed in their respective files at work.
Construction Site Safety Culture
A culture of safety would have to be maintained wherein all employees would feel that safe running is of utmost importance compared to running on schedule. Commitment of management sets the tone of action and decision-making. If management can make their employees feel that safety is of most importance and if their management is with their employees while they try to bring out a certain point, then all of them would take an active interest in hazard identification.
Prior to engaging in working activities, safety speeches are conducted to ensure all employees are aware of the working plan. In safety speeches, potential hazards are addressed, control measures analyzed, as well as emergency measures highlighted. In addition, safety speeches offer employees the opportunity to raise their queries or raise their concerns before working activities take place. In fact, daily safety speeches remain fundamental during a change of working activities as well as the induction of new employees into working crews.
In relation to crawler cranes, it is important to note the intention should be clear with regard to the rentee or contractor in relation to the issue of compliance arising as a consequence of OSHA standards and regulations. There would be a possible likelihood with regard to the ownership of such types of machines in relation to the rental companies but it would be important to note operating control in relation to the contractors.
In relation to operating control being with the contractors and in view of training and experience in relation to crawler cranes, it would be important to note training would be conducted in relation to operating and in relation to appropriate usage with regard to the machine's design and capacity.
In relation to operating control and in relation to training and experience with regard to crawler cranes and safe operating procedures in relation to OSHA standards there necessarily has to be an agency controlling on site which enables the coordination of various activities in relation to crane operation without having any conflicting activities on site. The controlling agency is mandated to ensure site preparation in relation to the execution of the operation by the crane and the visibility of underground utilities prior to their operation by the utility operators in order to avoid any conflict of operation.
Safe Equipment Rental: A Guide on the Utilization of MYCRANE Website
The MYCRANE platform is going to change the current landscape through which a contractor hires a crawler crane rental, as it will be more transparent and efficient in the future. Based on the new platform, the contractor will be able to highlight his requirements in respect of power requirements, boom size, duration of projects, location of projects, among others, for which they will be matched with the prospective suppliers.
"The Crane Selector-tool enables one to establish a correct capacity of a crane for a particular lift with regard to the weight of a lift, a height of a lift, and a radius," this will help contractors in being able to select the appropriate machines for a particular job and thus avoid an overload due to using a particular machine that is not capable of performing a particular task.
The request for quote should also be supported by as many site conditions and special specifications as are being required by the contractors. The responsibility matrix tool in the system describes how the services used in lifting the weight, such as mobilization services, rigging, operation, and maintenance services, do not create any sort of obscurity with regard to safety.
It is well known that the suppliers are aware of the industry standards and laws pertaining to providing equipment that can meet the requirements set out in OSHA. But it would be none too bad if it is checked what the outcome is of their inspection and equipment before its actual use.
Furthermore, it should be added that the other services which are offered by MYCRANE include engineering help as well as method statements that would be of significant use when working with projects that are more complex in nature with less expertise.
Emergency Preparedness and Response
In spite of laying down correct safety measures, there may arise situations that can be classified as an emergency situation. Management of an emergency efficiently helps in averting loss of human resources as well as property. The plan of operations for an emergency may cover drop loads, truck tipping, electricity, medical emergencies, or fires.
Each member of the crew must be made aware of the procedures for contacting the emergency services and the procedures involved concerning them during an emergency. First-aid and CPR skills should be carried out among the crew members who are allocated in the appropriate number, and there should be facilities provided for carrying out the first aid at the site. The contact details of the emergency services should be provided at the site.
However, if actual contact with the power line is to be achieved, all people are to stand back from both the crane and the ground below, since electricity may flow through the earth to make it dangerous for them to walk through. However, he is to attempt to move the crane if he feels that he himself is not in danger. In addition, he is to stay inside the cab until the utility personnel switch off the power line.
An incident has to be investigated so that one can conclude why it happened and what measures have to be taken to ensure that a particular incident does not occur in the future. An incident that could lead to deaths or hospitalizations has to be documented right away, as OSHA states. Matters concerning near misses can also form a subject of investigation since they reveal that there is a system failure that could lead to injuries.
The Future of Crawler Crane Safety
Technology that is constantly improving has also guaranteed that there is a safe operating environment for the crawler crane. This is owing to the perennial improvements being witnessed in monitoring systems, the degree of automation in control commands, and other aspects concerning operational aids. Modern versions of the equipment possess improved load moment indicators that indicate the weight of the load, the radius, and the moment.
The passive collision protection system makes use of sensors as well as the GPS system to identify that the crane is moving towards such things as power wires, other cranes, or structures, thereby sending an alert to the operator that the accident is imminent. The system will automatically halt the movement of the crane as soon as it identifies that there is a possible danger in its path. The remote monitoring system will make it possible to monitor the activities of the crane by the management, and algorithms will be developed to identify that there could be any malfunctions in the systems.
Examples of innovative projects in this field would include assistant systems such as augmented reality displays, automatic weight systems, and precision positioning assistant systems. The construction industry is in the midst of a technological revolution, so it can be expected that new developments in the field of safe crane technology will increase efficiency and safety in the future.
Conclusion
Safely operating a crawler crane is a responsibility that must be shared with all parties in a construction operation, in which a safe level is sought through the involvement of all parties. Extensive safety programs associated with a machine, preparation, operator, inspection, and safety procedures must preclude an event from occurring. Compliance is the minimum standard, while to be great is to comply but strive for excellence through continuous improvement beyond being compliant. The MYCRANE system is intended to incorporate these elements through matchmaking for contractors and equipment suppliers for contractors and equipment, as well as proper utilization of a crane selector as far as communication of requirements is concerned. With the increasing number of projects as well as more complex works in the area of construction, there could never have been a better time than now to capitalize upon the advantages of professionally operated construction equipment. The importance of an expert operator, properly maintained equipment, quality equipment, as well as an environment of openness when it comes to issues of safety, is essential in making successful contractors. Contractors/suppliers interested in creating better environments of safety in addition to accessing the best equipment at a competitive price, have MYCRANE with them in this endeavor.
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