cascadesteeloverheadcrane

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Overhead Crane

Operator Safety Training

a subsidiary of the Schnitzer Corporation

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Cascade Steel recognizes that education, continual learning, skills development, and a successful business go hand-in-hand. To assist in developing essential skills for our personnel this course along with others are being introduced.

We also encourage professional certification and development of skills through recognized organizations.

Overhead Crane Operator Safety Training

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OVERALL COURSE LEARNING OBJECTIVE (CLASSROOM)Upon successful completion of the classroom training the operators will be able to pass a written examination demonstrating comprehension of the safety rules, policies and procedures for the safe operation and use of overhead cranes.

IMPORTANT NOTE: While the federal rules and regulations for operating overhead cranes safely are generic in nature our actual policy and procedures may vary by department. This training program is intended to be an operator training course which can be attended by all personnel in our facility who operate overhead cranes.

There may be special individual departmental and/or crane specific rules and procedures for particular areas of the facility. You will be familiarized with those specific operating rules and procedures at your department in addition to this core curriculum.


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OVERALL COURSE LEARNING OBJECTIVE (PRACTICAL HANDS-ON)Upon successful completion of the hands-on portion of the training program the students will be able to demonstrate the proper skills necessary for the safe operation and use of overhead cranes

IMPORTANT NOTE: While the practical applications and operating procedures for operating overhead cranes safely are generic in nature the actual policy and procedures may vary by department. This training program and practical operating instructions are intended to be an operator training course which can be attended by all personnel in our facility who operate overhead cranes. There may be special individual departmental and/or crane specific practical characteristics, applications and procedures for particular areas of the facility. You will be familiarized with those specific practical operating rules, applications and procedures in addition to this core curriculum.


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• The sources of the rules and regulation for the safe use of overhead cranes

• The training and testing requirements for operators

• The four-step process of the Cascade Steel Rolling Mills Operator Training Program


Learning Objectives Training RequirementsUpon successful completion of this Section you will understand:

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Sources of RegulationsThe rules, regulations and standards governing the maintenance, inspection and operation of overhead cranes are derived from the following sources;


• Federal OSHA 29CFR§1910.179

• ANSI/ASME Industry Standards B30.2, B30.11, B30.17

• Individual State OSHA OAR §1910.179

• Manufacturer’s instructions and CSRM company policy and procedures

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Training RequirementsTo become qualified on overhead cranes at our facility, you must complete a four step process;


1. Core classroom training and pass the written exam

2. Site specific Training

3. Practical instruction on operation and practice time

4. Pass a practical evaluation

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Additional Requirements:


1. At least 18 years old

2. No mental or physical issues that would render you incapable of safe operation

3. Physically able to enter, exit and operate the crane as required

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Learning Objectives Core ProgramUpon successful completion of this Core Training Program you will understand:


1. Any potential hazards and how to respond to them

2. Instructions, warning and precautions for safe operation

3. Rules and techniques for your crane

4. Proper loading, elevating, movement and set down

5. Steps for securing the crane

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Worksite HazardsPrior to operating you must be aware of all potential hazards that will effect the safe operation of the crane, specifically;


1. Poor or slippery surface conditions

2. Obstacles in the load’s path

3. Obstacles in the cranes path

4. Obstacles in your walking path

5. Other equipment in the work area

6. Pedestrian traffic aisles and walkways

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Prior to Operating an Unfamiliar CranePrior to operating an unfamiliar crane within your classification you are authorized and qualified in, you must;


1. Locate the emergency power panel

2. Become familiar with all control functions and safety devices

3. Operate the hoisting and traveling functions for a sufficient amount of time prior to lifting a load

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Core Operator CertificationUpon sucessful completion of the core training program and practical operator training and evaluation you will be issued a laminated operators ID card.


1. ID card shows the issue date, evauation date, evaluators name, types of cranes authorized to operate

2. We will retain all the training records and documentation of initial training in our HR files.

3. To maintain certification you must be trained and evaluated if you are assigned to operate a totally different type of crane, involved in an accident or if you are assigned a new job with different skill set requirements.

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• Identification of the different classifications of overhead cranes in our facility

• Identification of the basic overhead crane parts and components.


Learning Objectives Types and ComponentsUpon successful completion of this Section you will understand:

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Cab Operated Overhead Crane


A crane whose movements are controlled by an operator through the use of controllers located in a cab that is attached to the crane.

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Outdoor Crane


An overhead or gantry crane that operates outdoors and for which provisions are to available for storage in an area that provides protection to the crane from weather conditions, An indoor crane that may operate outdoors on a periodic basis is not classified as an outdoor crane.

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Remote-Operated Overhead Crane


A crane with a single or multiple girder movable bridge carrying a movable or fixed hoisting mechanism and traveling on an overhead fixed runway structure.

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Hot Metal Handling Crane


An overhead crane used for transporting or pouring hot molten material.

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Wall Crane


A crane having a jib with or without trolley, and supported from a side wall or line of columns of a building, It is a traveling type and operates on a runway attached to the side wall or columns.

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Free Standing Pedestal/Jib Crane


A crane having a frame with or without trolley and supported with free-standing base secured to the floor.

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Underhung Bridge Crane Basic Components


Stops

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Wall or Jib Crane Basic Components


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Cab Operated Bridge Crane Basic Components


Stops

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Top Running Bridge Crane Basic Components


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Mechanical Upper Limit Switch

Rail Stops or End Stops


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Examples of hand held and waist type remote controllers you may see on our overhead cranes.


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Examples of the basic lower load blocks you will see on some of our cranes.

Examples of the hoisting chains you may find on some overhead cranes.


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Examples of hoisting wire rope you will find on our overhead cranes. Multipart reeved for two or four parts.

Examples of hoisting wire rope you will find on our overhead cranes multi part reeved for 10 parts.


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D

E

B

C

A

F

H

G

I

Identify the basic components.

J

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• Definitions and frequency requirements for inspections

• Pre shift inspection requirments and rejection criteria.

• Operator responsibilities and the checklist


Learning Objectives InspectionsUpon successful completion of this Section you will understand:

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1. Initial Inspection (after initial installation by the installer).

2. Frequent (daily to monthly intervals). Normally performed by the operator or other assigned person. (Pre-Op or Pre-Shift)

3. Periodic (1 to 12 month intervals). Normally performed by trained maintenance inspector.


InspectionsInspections for Overhead Cranes are comprised of three general classification or types. In our program we will be addressing the Frequent Inspection. It is referred to as the Pre-Operational or Pre-Shift Inspection.

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1. Overhead obstructions in your path of travel.

2. Other overhead cranes on the same rails, or in the same proximity.

3. Mobile crane or aerial lifts where the boom is elevated into your path.

4. Tall equipment or machinery which may be an obstacle.

5. Pedestrian aisles or doorways. Use extreme caution around doors.

6. Obstacles, slippery surfaces or problems in your walking path.


Work and Travel Area CheckPrior to using your crane, your canes immediate working and traveling area must be visually checked and inspected for the following hazards.

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A

G

A

F

C

D E

B

Identify the work area hazards.

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1. No apparent damage, excessive wear, or deformation on any load bearing part.

2. All safety devices, braking devices, limit switches, load indicators, controls and other operating parts must be in proper working order.

3. Any condition found by inspection that is determined to be a hazard to continued operation shall be corrected before continued use of the crane.


General Rule for Rejection Criteria

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1. Ensure controller and all controls function properly.

2. Must have a legible safety label on remotes.

3. Pendent controller has support cable.

4. Inspect wire rope or hoisting chain for visible damage.

5. Check load block, hook and latch for proper operation and visible damage.

6. Check upper limit switches for proper operation.

7. Listen for unusual sounds when verifying all crane functions.

8. Inspect all rigging or engineered below the hook devices.


Pre-Operational InspectionPrior to each shift the crane must be inspected by someone trained to identify unsafe operating conditions that may have arisen during use of the equipment. Be sure to check with your individual departments to verify the checklist.

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This is a sample of a typical overhead crane checklist.

Be sure to utilize the cranes checklist specific to the cranes in your departement.

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• The main parts of wire rope

• Multiple parts of line advantage

• The external issues that effect wire rope longevity and life

• How to perform the required daily inspection for wire and chain

• The external issues that effect the hoisting chain’s longevity and life

• The parameters and rejection crieria for wire rope and chain


Learning Objectives Hoisting Wire Rope & ChainUpon successful completion of this Section you will understand:

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1. Sufficient length to reach the intended load.

2. Sufficient rated load capacity per part of line.

3. Sufficient parts of line.

4. Appropriate condition to ensure full rated load.


Hoisting Wire RopeThe majority of our overhead cranes are equipped with a wire rope hoisting cable. In order for the mechanical hoisting winch to safely and successfully hoist a load off the ground, the wire rope spooled on the cranes drum must provide the following:

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1. Wire Rope has 4 basic parts: The Core, Strands, Wires and a Center Wire.

2. Rope lay length: The distance or length it takes one strand to fully rotate one-time around the core and come back to the same side (for 6x19 wire rope it would be the distance between every seventh strand). This measurement is used in determining broken wire rejection criteria.


Wire Rope Components

Lay

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1. Consists of core and 1 strand layer.

2. 6x19 has 6 strands and 19 wires per strand.

3. Overhead crane hoisting lines are IWRC (Independent Wire Rope Core (steel core)


Standard Wire Rope

Lay

NOTE: Overhead cranes used in our Hot Metal work utilize a specialized heavy duty 8x19 or 7x19 IWRC wire rope

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1. BS is the absolute factory pull test strength.

2. You do not get to use this.

3. You must still apply the industry safety margins or design factors.


Breaking Strength & Safe Working Load

Standard 6 x 19 Wire Rope (IPS) Improved Plow Steel

Breaking Strength (BS) of 9/16” IPS IWRC is_________ tons x 2000 lbs/ton =____________ lbs.

Steel Steel

TONSTONS Lbs/Foot Lbs/Foot

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PART(S) OF LINE (POL): One or more length's of rope from trolley or equalizer sheaves to load block or ball.

SAFE WORKING LOAD: The rated load that the wire rope can hoist

with one part of line. DESIGN FACTOR (DF): This is what you divide the Breaking Strength

by to get your capacity (SWL) per part of line. (safety margin) Rope Use or Type Design Factor (DF)Standard 3.5



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Calculate the SWL for one part of 9/16” IWRC from the chart, using a DF of 3.5. = ________ ? lbs Using the SWL for the 9/16 IWRC rope listed above, what is the total

capacity for the wire on each of these two blocks? A: __________________ B. ______________



4 parts 8 parts

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Better Cable with Better Grade of Steel

Standard 6 x 19 Wire Rope (IPS) Improved Plow Steel

Breaking strength (BS) of 9/16” RRL IPS IWRC is _________ tons x 2000 lbs/ton =____________ lbs. ÷ ______ = SWL ________ PPL

Breaking Strength

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1. Steel core (IWRC) is stronger than fiber core (FC).

2. (XIPS or EIPS) steel is stronger than (IPS).


Rope Facts

1. Avoid dragging the hoisting rope.

2. Ensure hoisting rope is running in the sheave grooves.

3. Never bend the hoisting rope around anything but the sheaves.

4. Ropes require lubrication.

Wire Rope Use

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1. Visually inspect (parts you can see) to ensure capacity is still valid.

2. Document on departments daily inspection log.

3. Do not use if reject criteria has been met or exceeded. Notify maintenance to conduct further examination.


Daily or Pre-Shift Inspection

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1. Broken Wires: 4 broken wires in 1 strand or 12 broken wires in all strands of 1 rope lay length. (Hot Metal Cranes rejection is 3 in 1 strand or 6 in all strands). 2 or more broken wires in an end socket.

2. Flat Spots: On outerwires where wires are less than 2/3 normal thickness.

3. Decrease in Diameter: Indicating core break or failure

4. Distortion: Kinking, crushing, bird caging, displaced wires

5. Heat Damage: From any cause

6. Reduction in Overall Diameter: Significant reduction (varies by rope size)

7. Broken Wires Protruding: Coming from between strands (valley break or fishhooks) usually from the core.


Rejection Criteria

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Identify the applicable wire rope rejection criteria for the pictures above.


Rejection Criteria

A B C D E

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A. Solid welded link chain to be used in a sheave for two or more parts of chain.


Hoisting ChainSome overhead cranes utilize a hoisting chain instead of wire rope. There are two basic types of this hoisting chain.

B. Formed link chain which attached directly to load hook usually on smaller cranes with one part of chain.

A B

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1. Never exceed the load rating.

2. Ensure the load is uniformly applied ina direct vertical tension to a straight length of chain.


Hoisting Chain Rules

CautionCertain conditions will decrease the rated capacity of the chain.

1. Twisting or angle loading.

2. Deterioration by straining.

3. Weathering and corrosion.

4. Rapid application of load or jerking.

5. Applied excessive force.

6. Prolonged exposure to extreme heat (cobbles)

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Hoisting Chain InspectionHoisting Chain is made of grade 8, 80 or better Alloyed Steel. It will deform or disfigure to give you a visual warning of overloading or abuse.

Use the departmental checklist and visually check the hoisting chain at the intervals noted and recommended for your particular area or crane.

Look for:1. Wear between links

2. Nicks

3. Cracks

4. Breaks

5. Gouges

6. Bending of links

7. Weld splatter

8. Discoloration from temperature.

9. Signs of lengthening or stretching

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Identify the applicable chain rejection criteria for the pictures above.


Chain Rejection Criteria

A CB

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• The main components of hook;

• The load ratings for hooks;• The external issues that

affect the hook’s longevity and life;

• How to perform the required daily inspection and the rejection criteria for overhead crane hoisting hooks;

• How to properly seat the rigging or engineered lifting devices into the load hook for overhead hoisting.


Learning Objectives Blocks & HooksUpon successful completion of this Section you will understand:

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1. Actually supports the rigging or lifting device.

2. Made to deform before losting ability.

3. Latches are designed to retain rigging.


Load Hook

Operating Practices

1. Never exceed rating

2. Know load weight

3. Use hook as mfg intended

4. Never shock, point, side or backload the hook

5. Center the load in the bowl

6. Never carry load on latches

7. Keep body parts from between the load and hook

8. Verify proper engagement and latches are closed

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1. Deformation: Bending or twisting exceeding 10 degrees.

2. Throat Opening: Distortion exceeding 15%

3. Cracks, Nicks or Wear: Any wear exceeding 10%

4. Non functioning Latch: If originally equipped with one


Rejection Criteria Inspecting load hooks is part of our daily pre-op checklist. Use the appropriate checklist for your particular area or department.

Hooks showing any of the following will be immediately removed from service for futher evaluation.

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Identify the applicable hook rejection criteria for the pictures above.


Hook Rejection Criteria

A B

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1. Visually inspect prior to using the crane for your shift.

2. Remove from service if visual evidence of excessive wear, corrosion or deformation.

3. Sheaves must be free to rotate with no visible deformation, wear or cracks that would damage the rope.

4. Remove from service if sheaves are not functioning properly or meet rejection critieria.


Blocks An assembly of the hook, swivel, bearings, frame and sheaves. Increases the ability of the winch and cable to do work by mechanical advantage. Changes the direction of the wire rope.

Block Inspection Points.

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• The safe procedures for securing and using the crane when perfoming maintenance, inspection or service.


Learning Objectives MaintenanceUpon successful completion of this Section you will understand:

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Securing the Crane

1. Only designated persons work on our cranes.

2. Land, remove load or rigging.

3. Move crane to designated area.

4. All controllers in neutral or off.

5. Follow lock-out, tag-out procedure.


Preventative Maintenance Whenever we perform any preventive maintenance or repairs on our overhead cranes we must follow the recommended procedures by the crane manufacturer and/or the industry for safely securing the crane prior to working on it.

6. Place warning signs, barriers on floor under the crane.

7. Use spotter for active cranes in area.

8. Prevent contact with active cranes.

9. Remove loose material, maintenance equipment, install guards and reactivate safety devices before restoring for use.

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1. All conditions deemed as a hazard will be repaired before use.

2. De-energize and lock-out the main switch prior to repairs.

3. Repairs by maintenance staff only.

4. Function, instruction, caution and warning labels or plates on pendants or remotes must be kept legible.


Adjustments Repairs or Replacements We only allow our trained maintenance staff to perform repairs or adjustments on our overhead cranes. If you are assisting them in this repair, the follow rules apply:

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NOTE:

In the event the operator finds a safety problem or hazardous condition which affects the safe option of an overhead crane, he/she shall install a locked-out tag on the machines on/off switch, even if there is an existing locked-out tag on the machine.


Lubrication Part of the operator’s responsibility is to continually watch and listen for signs that components are not turning properly and may need lubrication. Immediately report and visual or audible signs that the crane may be in need of lubrication. Do not take chances, report the unusual crane noise!

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• The rules and regulations for attaching, elevating, moving and placing a load with an overhead crane.

• Lift planning to include critical lifts and planned engineered lifts.


Learning Objectives Load HandlingUpon successful completion of this Section you will understand:

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1. No horseplay, keep your focus.

2. Do not operate when unfit.

3. When safety is in question consult with a supervisor.

4. Be familiar with your crane, report any dangerous issues immediately.

5. Contact bridge or rails stops slowly.

6. Operate with care and safety of others in mind.

7. Respect all lock-outs and tag-outs.


Operator Conduct Your mental concentration and attitude plays a very important part in operating the overhead cranes at our facilities in a safe manner.

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1. Do not exceed the rating of the (1) crane, (2) hook, (3) wire or chain, or (4) rigging being used.

2. Move the block with minimal swing.

3. Ensure rope is not kinked, never wrap hoist rope around the load.

4. Verify rope is properly seated in sheaves and on drum.

5. Ensure load is attached properly with slings or other approved engineered devices.


Attaching the Load

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1. Avoid carrying loads over people.

2. Conduct a dry run first where clearance is limited.

3. Avoid collisions.

4. Verify personnel are clear prior to lifting or moving the load.

5. Ensure load is secure and balanced before lifting more than a few inches.

6. Lift slowly until load clears ground.

7. Never suddenly accelerate or decelerate with a moving load.

8. Never use the crane for side pulls unless authorized to do so.


Moving the Load

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9. Do not lift, lower or travel while someone is on the load or hook.

10.Check your hoist brake occasionally. Any slippage is unacceptable.

11.Sound a warning when your hook or load approaches personnel.

12.Use tag lines as necessary.

13.Diagonal movement across an area is best accomplished by simultaneously moving both the bridge and the trolley.


Moving the Load (cont.)

“Rough” crane travel may be a sign of a broken wheel, flat spot on track, misaligned track or foreign objects on the track or rail. Report rough crane travel to the appropriate maintenance personnel.

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1. Never leave a load suspended.

2. When leaving the crane, position the block high out of reach and out of any main path of travel.

3. Never allow the crane to coast to a stop, use plugging (control reversal) or the braking system to stop (loaded or unloaded).


Landing the Load

NOTE: Avoid sudden stops as the load may swing outward and possibly could injure others. Sudden stops also will result in uneven wear on the wheels.

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1. Use only approve signals to avoid confusion.

2. Communicate any special signal requirements in advance.

3. Follow signals from one person, except the stop signal which you will obey from any person.


Signals and SignalpersonIt is vital that both the signaler and the operator completely understand the task that is being asked of them. There can be no room for miscommunication.

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Lift TypesOur overhead crane lifts can be divided into two types, they are:1. Repetitive or Simple Lift (the majority of our lifts)2. Critical or Engineered Lift

Plan specifics will change based on your load weight, environment, capacity of rigging and crane, complexity of lift or nature of the lift. Critical or Engineered Lifts will require more than just a mental review of the safe operating procedures for overhead lifting.

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Repetitive or Simple LiftsThese are the bulk of our lifts. The same lift(s) are done by a particular craneover and over, load weight is well within the cranes and rigging ratings, nounforeseen hazards to account for, no documentation or approval is required.A mental review of the lift is required by the operator.

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Critical or Engineered LiftDue to the nature of the lift it must be accurately planned, to include a writtenlift plan approved by a Supervisor or Engineer prior to the lift actually takingplace.

1. Lifting personnel. ASME B30.2 rules.

2. Using two cranes on the same load.

3. Leaving the load elevated for an extended period of time.

4. Hoisting a costly or critical item.

5. Exceeding 75% of the cranes rated capacity.

6. Engineering a lift which exceeds the cranes rated capacity. ASME B30.2 rules.

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• General safe use of basic rigging hardware.

• How angle loading affects rating.• How to perform the daily inspection and

understand the rejection criteria for hardware.

• The general safe use of slings.• How horizontal sling angle affects rated

capacity of slings.• How to inspect the slings and

understand the rejection criteria.


Learning Objectives Basic RiggingUpon successful completion of this Section you will understand:

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Safe Working Load (SWL)Every piece of hardware that we use for overhead lifting has a rated capacity.Here are a few basic rules about theses ratings.

1. Maximum allowed, do not exceed rating.

2. Referred to as SWL, WLL, MWL or MLL

3. Identified on each piece of rigging.

4. Rated for in-line loading.

5. Side or angle loading will reduce capacity rating.

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IdentificationSince the hardware we use all has rated load limits, we must ensure that thecomponents we select will handle the load weight we are imposing on it. You must verify the rating by the identification markings prior to using thehardware or sling.

1. All rigging shall have the rated capacity noted on it. (you need to know what the rating is).

2. Some specific hardware (eyebolts and master links) will have only the size denoted on it. You will have to refer to rating charts and mfr information.

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IdentificationNote: If any piece of rigging or hardware does not have the SWL or WLLlegibly marked on it, you cannot verify the rated capacity.

It must be removed from service and:

1. Retagged with the appropriate SWL noted on it.

2. Retested if the SWL is not known and retagged with SWL immediately after testing by the testing agency.

3. Removed from service and destroyed if SWL cannot be found or attached.

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Rigging Hardware BasicsAll rigging must be visually inspected prior to use to verify it has not met orexceeded the rejection criteria. Here are some basic rigging rules and therejection criteria for the basic hardware and slings. Shackles

1. Pull in-line for 100% rated WLL.

@ 45˚ you have 70% of WLL

@ 90˚ you have 50% of WLL

2. Visually inspect prior to use.

* Full thread engagement of pin* Ears not pulled open* Excessive wear* Markings and ratings

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Shackles

A B C

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Sling Use Basics

1. Inspect prior to use.

2. Type of Hitch can affect rated capacity.

3. Horizontal sling angle affects load rating.

4. All require legible sling tags (ASME B30.9)

5. Some environments can damage slings.

6. Do not make sling eyes with knots.

7. Never exceed the rating.

8. Never shorten or lengthen by knotting.

9. Damaged slings shall not be used.

10.Use the proper hitch for control, rig to center of gravity.

11.Store them properly when not in use.

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Wire Rope Sling Rejection Criteria

1. Broken Wires: 5 broken wires in one strand or 10 broken wires in all strands in one rope lay.

2. Metal Loss: one third the original diameter of outside individual wires.

3. Distortion: Kinking, crushing, bird caging or other damage which distorts the rope.

4. Heat damage: Metallic discoloration or loss of internal lubricant.

5. Bad end attachments: Cracked, bent or broken fittings.

6. Bent Hooks: 15 percent throat opening or more, or twisting of more than 10 degrees.

7. Metal corrosion: Severe corrosion of the rope or end attachments, pitting or binding of wires. Light rust usually does not affect sling strength.

8. Missing or illegible sling identification (ASME B30.9).

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Wire Rope Sling Rejection Criteria

A B

Identify the applicable hook rejection criteria for the pictures above.

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Chain Sling Rejection Criteria

1. Wear, nicks, cracks, breaks, gouges, stretch, bends, weld splatter, discoloration from excessive temperature.

2. Links and attachments should hinge freely.

3. Latches on hook should hinge freely and seat properly without evidence of permanent distortion.

4. Missing or illegible sling ID tag.

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Synthetic Sling Rejection Criteria

1. Acid or caustic burns.

2. Melting or charring of any part of the sling.

3. Holes, tears, cuts or snags.

4. Broken or worn stitching in splices.

5. Excessive abrasive wear.

6. Knots in any part of the sling.

7. Excessive pitting or corrosion, or cracked, distorted or broken fittings.

8. Other visible damage that caused doubt as to the strength of the sling.

9. Missing sling tags (ASME B30.9)

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Basic Sling Hitch Types

CHOKER BASKET BRIDLE

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Basic Sling Hitches

Pro’s Con’sChoker: Good load control 75% capacity of vertical

Easy to apply Difficult to removeVersatile for shapes 60° minimum angle of choke

Basket: Twice rated capacity Poor load controlEasy to apply Requires twice the length

Bridle: Good load control Load isn't always sharedEasy to apply Must use hardwareUsed down to 30° Must calculate sling angle

stress

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Other things to consider when using slings:

1. Wire rope should never be bent around any object equal to or less than it’s own diameter. When this occurs this “D/d ratio” or curvature of the rope affects the rated capacity of the wire rope. Most slings are rated at a 25:1 curve ratio (1/2” sling curved around a 12” load)

2. Various sling materials may grip various load materials differently. Be sure your sling selected grips your load material well.

3. Soften edges of objects when using any type of sling. All slings can be affected by sharp edges and abrupt corners.

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Sling Charts: To understand the correct reductions for the various hitches it is important that

you understand the basic components of a sling chart. 1 3 4 5 6 72 1

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Horizontal Sling Angle Horizontal angle is the angle created between the load and the sling leg. Both the Basket Hitch and the Bridle Hitch create horizontal sling angles.There are a few basic rules to follow when selecting your slings andconsidering the horizontal angles.

1. You must take that angle into account when selecting your sling and hardware.

2. Sling and hardware have to work harder when the horizontal angle is below 90 degrees.

3. The lower the angle, the greater the stress on the sling.

4. 30° is the recommended minimum horizontal sling angle.

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Horizontal Sling Angle

Horizontal Sling Angle

Sling Angle Increase due to sling stress

Total Sling Stress

90° +0% 1000 lbs

85° +.4% 1004 lbs

80° +1.5% 1015 lbs

75° +3.5% 1035 lbs

70° +6.4 1064 lbs

65° +10.4% 1104 lbs

60° +15.5% 1155 lbs

55° +22.1% 1221 lbs

50° +30.5% 1305 lbs

45° +41.4% 1414 lbs

40° +55.5% 1555 lbs

35° +74.2% 1742 lbs

30° +100% 2000 lbs

25° +136.4% 2364 lbs

20° +192.4% 2924 lbs

15° +286.1% 3861 lbs

10° +474.7% 5747 lbs

5° +1049% 10490 lbs

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• Types of magnets used in overhead lifting;

• Daily preoperational inspection requirements and rejection criteria;

• Application of lifting magnets when lifting;

• Failure factors and how to avoid them.


Learning Objectives MAGNETSUpon successful completion of this Section you will understand:

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MagnetsMagnets used as a below the hook lifting device on overhead cranes at ourfacility come in two basic types.

Type 1 Close Proximity Operated Magnets: These must be manually positioned on the load and manually guided during the lift.

1. Battery powered: Requires continuous current from a battery to maintain holding force.

2. Electrically controlled: Contains permanent magnet material that requires current only for attachment and release of the load.

3. Manually controlled: Contains permanent magnet material and requires a manual effort during attachment or release of the load.

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Magnets

Type 2 Remote Operated Magnets: These do not require the operator or other person to be in close proximity while using the magnet.

These types of magnets are not broken down into any particular classifications but can come in different shapes and sizes according to task requirements.

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Safety StandardsWhile magnets are an integral part of handling our materials as we do in manyareas of our facility, there are some basic safety facts you should know aboutthe design, use, inspection and care of the magnet to ensure safe and properapplication. Identification All magnets at our facility have ID tagsembossed or attached to them.

These tags will show:1. Manufacturers’ name and address2. Model or identification number3. Magnet weight and Duty cycle 4. Primary supply voltage5. Load rating & Legible safety labels

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Duty CyclePut very simply, the duty cycle is the amount of time the magnet is energizedvs the amount of time it is de-energized in an average time period. So a 75% duty rating would mean for every 45 seconds it is on, it will be de-energized for at least 15 seconds or a 3:1 ratio.

1. Your magnet should have the duty cycle rating clearly marked on it

2. Exceeding the duty rating cycle could potentially cause the magnet to lose power or grip on the load

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Safety LabelsAll of our magnets have safety caution labels affixed or attached. You must follow the information provided on this label. Typically these labels say, DO NOT:

1. Exceed capacity rating or alter 2. Exceed duty cycle rating3. Operate if damaged or missing parts4. Lift people or lift loads over people5. Remove or obscure warning labels6. Operate without first understanding the manual7. Position yourself under suspended loads8. Lift loads higher than necessary to clear

obstacles.9. Disconnect magnet with power on10. Lift without the control handle latch fully in the “lift”

position (manual type)

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Status PanelMany of our Cab operated cranes have a magnet status panel in the cab nextto or behind the operator. A sample panelsample panel might include:

1. Voltmeter: Indicates voltage on the buss system, (not battery).

2. Ammeter: Indicates flow to and from the batteries only. Needle pointing right indicates charging (current flowing to the batteries to charge). Needle pointing left indicates draining (current flowing to the magnets). Needle in the middle indicates ready, fully charged batteries.

3. Magnet on Batteries Light: Indicates backup batteries are supplying power to magnet on the load. Set down load immediately.

4. Rapid Charge Light: Indicates the batteries do not have a sufficient charge to operate properly and are being quick charged. Do not operate until this light is off.

5. Horn Reset: Disables the horn when the loss of power results in the warning horn sounding

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Visual Magnet InspectionAll magnets are required to undergo a visual check prior to using them for theshift. Utilize the inspection checklist provided by your department. You will be asked to check:

1. Surface face is clear of foreign materials.

2. All control handles (manual type).3. Visible electrical conductors for loose

connections, corrosion, insulation damage.

4. All wires and connectors.5. Indicators and/or meters. (manual)6. Housing for cracks, bad welds, and

loose bolts.7. All labels and markings for legibility.8. Al attachments, hardware, slings and

hooks.

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Premature FailureMagnets fail or lose the ability to hold onto the load for these reasons.

1. Excessive duty cycle: Magnet is energized too long with not enough de-energized time.

2. External Heat: Either by the heat of the material being hoisted or by the external ambient temperature in the immediate area. Allow for adequate time for the magnet to dissipate the heat.

3. Shorted or Grounded Coils: Insulating shorts in coil create hot spots adding additional heat to the coil. The magnet can also be grounded by excessive moisture causing the coil to heat up.

4. Gaps in Engagement: Without full contact with the load (foreign substance on magnet) the load may fall. Load surface must be free of debris. Always ensure maximum magnet contact with the load. Remember that too long of a load can “peel off” the magnet. Be sure to spread and position magnets accordingly.

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Magnets and WaterMoisture and water can dramatically effect the magnets’ ability to hold.As an operator you must observe the following safety rules with regards tomoisture and water when using magnets:

1. Check the case, welds, bottom plate, center pole for cracks where moisture could enter.

2. Keep magnets away from water.

3. Do not dip or spray magnets with water to cool them.

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Attaching the Load

1. Only use for designed tasks. 2. Follow the manufacturer’s instructions.3. Distribute the load weight evenly. 4. Contact area is clean of debris and the

magnet has full contact with the load.5. Do not prematurely energize the magnet.6. Lift the load only a few inches and verify the

load is secure.7. Ensure any input control should be switched

to “full on” or “full power” and remain in that position until the load is ready to be removed from the magnet.

8. Continually check the battery indicators during use.

9. Prior to hoisting, audibly warn all personnel near the lift.

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Lifting

1. Center the load. 2. When using two magnets and one is off

center or too low, set down load and reposition.

3. Energize magnets while on the load. 4. Lift straight up and keep load away from

cab.5. Travel load as low as possible to clear

obstacles.6. Do not carry loads over people.7. Center load over target set down area.8. Do not leave any load suspended by a

magnet unattended.

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Set Down

1. Position squarely and completely lower load into the desired area.

2. When the load is down, de-energize magnets.

3. Pause and wait for the magnets to de-energize (may take a moment).

4. Lift straight up using the hoist control.

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Storing

1. Store (if removed) in a dry location clear of potential contact with other items.

2. Separate magnets when storing, do not stack.

3. Do not store them directly on the ground, set them on wooden pallets or blocks.

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Power LossIn the event of a loss of power to the magnets or crane while operating thethese steps must be followed:

1. Immediately, get all ground personnel or vehicles out of the way.

2. Try to set the load down (if able.3. Secure area, prevent personnel

entrance, alert supervisor.4. Do not use equipment again until

properly repaired and tested.

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Handling Scrap MaterialSome of our cranes are used to handle scrap metals. This may involve loadingand unloading of trailers and railcars. There are specific rules for eachdepartment in this regard. DO NOT TWIST hoisting cables or magnet lineswhen loading or unloading.Listed below are some general safety rules for scrap material handling.

Unloading Trucks or Trailers1. Truck driver must not be in the cab, make sure

he/she is clear. 2. Position magnet in the bed taking care not to

damage the sides of the bed of the truck.3. Use your horn to alert driver when it is safe to

return to his/her truck cab.

Unloading Railcars1. Empty railcars at the ends first and then move to the middle. Uneven

loading or unloading can result in the pin of the railcar to fall out. Reinstalling the pin can put fellow workers at risk.

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Hand Signal for Magnet Off

It would now be safe to approach the magnet and the load.

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• The additional hazards of operating an overhead crane in this environment.

• The additional personal protective equipment that may be required.

• How your use of the crane may affect the safety of other workers.


Learning Objectives HOT METAL Upon successful completion of this Section you will understand:

There will be additional area and crane specific training required in addition to this core safety training. This will include rules and procedures, operating techniques and skill-sets, and a more in-depth explaination of the actual processes at work.

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HOT METAL Additional HazardSince the work with hot metal usually involves temperatures of around 3000degrees F, it is imperative that you understand all of the company proceduresprior to operating in this environment.

PRIOR TO USING ONE OF OUR CRANES IN THIS ENVIRONMENT YOU WILL REQUIRE ADDITIONAL

TRAINING ON ALL COMPANY SAFETY RULES AND

PROCEDURES PRIOR TO OPERATING OR HOISTING LOADS IN THIS TYPE OF

ENVIRONMENT!

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Operator QualificationDue to the specific nature of this equipment and the extreme hazardsassociated with its operation, this equipment can be operated only by speciallytrained, qualified and designated persons.

Specialized Training shall include: 1. Actual use of crane itself.2. Performance related tasks.3. All special procedures and cautions.4. Manufacturer’s procedures.5. Required condition of loads.6. Storage, shutdown.7. Limits and capacities.8. Indicators, meters and alarms.

Operator must demonstrate ability to operate thehot metal bucket or ladle as prescribed by thecompany procedures and the operator’s manuals.

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Personal Protective Equipment (PPE)Additional Personal Protective Equipment (PPE) is required for operating in thistype of environment (extreme heat). Requirements may vary by job and task inthis environment. The following list is provided as a guideline for training, butoperators are to follow their individual departmental policy and procedures.

Additional PPE : (remote control cranes)• All standard PPE items PLUS• High Heat version of Hard Hat• Cotton Mill Gloves• Hot Coat (by task)• Hat Flap (by task)• Hot Pants (by task)• Face shield (by task)• Dust mask (by task)• Anti-vibration gloves (by task)

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Additional Cab FeaturesOur hot metal crane cabs have been fitted with additional safety featuresincluding:

1. Totally enclosed for outdoor protection.2. Have windows, metal sash and

heat-resistant glazing material.3. Floor has been insulated with heat

resistant material.4. A metal shield has been installed

below the cab floor.

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Auxiliary or Secondary HoistBecause our hot metal crane tasks require the use of both the main and theauxiliary (OX) hoist the operator must understand the dangers of running bothload hoists in tandem and be adept at this task.

1. Understand the limitations of the auxiliary hoist.

2. Understand that many tasks will require simultaneous use of both hoists.

3. Understand that use of one hoist may effect the cable or chain of the other.

4. Watch out for hoisted material coming in contact with the auxiliary lifting line or vice-versa.

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Attaching and Moving the LoadThis is a very specialized task and a specific skill set is required by ouroperators. Due to the special nature of the lifts, the operating procedures willbe very site and crane specific.

1. Follow all attachment and hoisting rules as previously covered in the load handling section of the overhead crane operator training program. PLUS

2. Any and all department safety rules and work related procedures for hot metal work.

.

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Inspection of Buckets or LadlesDivided into two intervals or types of inspections. Done by a quailfied person.

Frequent inspection: Performed as per duty rating. May be daily to weekly.

Periodic inspection: Indepth inspection performed as permfr’s requirements.

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Frequent Inspection:Both the manufacturer and our company policy and procedure outlines thevisual examination criteria for these cranes in this working environment.Employees with specialized training perform the inspections on these cranes and all below the hook lifting devices which are utilized as per the duty ratingschedule. These types of inspection may include but are not limited to:

1. Visual check per the dept checklist.2. Special attention to the hoisting cable.3. Check all attachment points.4. Check ladle and/or bucket.5. Verify no components show signs of

potential failure or hazard..

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Safety of other WorkersAs a qualified operator, you must understand your actions have the potential togreatly affect the personnel on the floor of the facility, potentially damageequipment and cause equipment down time or repair due to impact or misuse. 1. Communication must be

maintained.2. No misunderstanding or

miscommunication.3. Perform your crane movements,

hoisting or other tasks only when signaled that it is safe.

4. Do not allow non-essential personnel inside your danger zone.

5. Be constantly aware and keep a keen eye on all movements of your load and surrounding area.

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CASCADE STEEL is firmly committed to provide you with the necessary training, materials and processes to become proficient at your job and skill set. Thank you for your undivided attention today during this training program.

Today’s classroom training portion of our operator training and qualification program is now completed.

The next step in our four step process is the verification of comprehension of the curriculum we just covered

by passing a written exam.

Please carefully tear out the last page in your student handbooks, I will pass out the written exam questions.

Date post:	14-Dec-2014
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