DOE HOISTING AND RIGGING
ADVISORY COMMITTEE
&
FALL ZONE DANGER ZONE
AU-11 Learning Topic September 16, 2020
Bill Schleyer, Sr. Safety Professional & Chairperson, HRAC
NA-513
AGENDA
Introduction to the HRAC
Issues HRAC will tackle
Fall Zone/ Danger Zone Overview
History of accidents confirms is a real risk that need control
WHAT IS THE HRAC?
DOE Hoisting and Rigging Advisory Committee is the long standing community of practice offering
• Chartered by AU-10 Office of EHSS
• Advice to the DOE through our AU-11 Sponsor, Maurice Haygood
• Helps Maintain the DOE-STD-1090-2020, Hosting and Rigging [Update just published in July!!!]
• Recommends safe performance methods for DOE
• Technical Standards provide non-mandatory best practices and acceptable methods for meeting requirements
HRAC GENERAL• History of accidents confirms H&R is a real risk
• 60+ participants representing DOE sites --not all sites
• Private sector support and participation – learn with private sector
• Meet every 2-3 months
• Working a list of issues and opportunities
• Collaborate to improve safe hoisting and rigging performance
• While not HRAC function, some members sit on Consensus Standards Committees
• --ASME B30.2 - Overhead and Gantries sub-committee
• --ASME B30.17 - Cranes and Monorails Sub-committee
WHERE ARE WE?
ISSUES—WHAT HRAC IS WORKING
Prioritized by HRAC members
Can do a few well. Try keeping up with others.
Divide and conquer using working groups
Issues:
Training
Improve Operations
HRAC management
o Sustainability and mentoring
o Sling protection
o Fall Zone and Danger Zone
o Safe by Design
o New Technology integration
o Common training
o Site methods operations shared
o Subcontracting includes safety
o Standards and our role
DO YOU KNOW THE H&R EXPERTS AT
YOUR SITE?
Reach out and connect.
How can you participate?
FALL ZONE AND
DANGER ZONEThanks to the many DOE and Private Sector Contributors for the content.
55 -110
We lift frequently in tight spaces with ordinary, special, production and critical lifts.
Workers and Materials are always at risk.
WHY IS FALL ZONE/
DANGER ZONE
IMPORTANT?
Real world. People are dying from lifting accidents and at
greater numbers than most hazards!!
.
REAL HAZARDS – REAL ACCIDENTS
An Accident Investigation Board was appointed to investigate the December 19, 2018, construction lifting accident that resulted in serious injuries.
Worker using forklift to hold elevated metal HVAC frame dropped it ~12 feet—near miss
2020- Reactor 15-Element Rack Separation During Critical Lift bottom portion of the rack separated from the upper grid plate. The bottom of the rack tipped over.
Fatal Occupational Injuries Involving Cranes-- From 2011 to 2015, the Census of Fatal Occupational Injuries reported 220 total crane-related deaths, an average of 44 per year over this 5-year period. (BLS)
Failure of Lifting Points during Lift of Batch Plant Silo
2017-Girder Dropped During Lift by Mobile Crane
Lift fixture slipped from the end of telehandler tines and conveyor to the floor
FALL ZONE -- DEFINED
OSHA defines- in 1926.1401- Fall zone means the area (including
but not limited to the area directly beneath the load) in which it is
reasonably foreseeable that partially or completely suspended
materials could fall in the event of an accident.
Danger Zone not defined specifically in standards. It exists in the
“not limited to” and addresses reasonably foreseeable fall or
energy release. “Danger” is a warning term.
DANGER ZONE -- DEFINED
Danger is a Warning word that seeks to get emotional awareness
Hazard is a condition including a scenario where harm is possible
Danger Zone is NOT an OSHA defined term for Fall zone and associated hazards
Dangerous areas is OSHA defined for some crane operations, e.g. 1926.1435
Concept of DANGER ZONE is to capture workers attention, emotional connection, so each is aware and consider hazards and risks
Sites often have different warning terms. Teach and apply to site practices
Danger Zone is ANY area or location potentially impacted by failures or events during the life-cycle process of the lift
Control hazards and warn of danger
CONCEPT – NOT A MATH EQUATION
Fall Zone is SET by risk owners with
technical support of Qualified HR Workers
Hazards are lift dependent and varying
Danger zone around Fall Zone
Expect the unexpected
Danger Zone
Fall Zone
FALL ZONE / DANGER ZONE IS NOT AN EXACT
MEASURED SPACE
PLAN TO ADDRESS FALL ZONE /
DANGER ZONE
ISMS and Work Planning and Control
MINDSET OF DANGER ZONE HAZARDS
Untrained users may be unaware of the subtlety of “but not
limited to, directly below the load”.
Erroneously the focus may be placed solely on the “directly
below the load” without regard to “but not limited to”.
Key point -- awareness of the potentially deadly consequences
of the fall zone must involve more than falling loads. The release
of tension in any attitude, i.e., vertical (up and down), and/or
horizontal (to and from), at any angle can result in severe injury or
death.
LIFT PLAN TO
CONTROL FALL ZONE
Processes defined in Site Practices
Apply ISMS
Work planning and control process applies
Lift planning process
Evaluate the Sphere of Influence
Energy Trace Barrier Analysis tool
ALARP- no reasonable lower risk alternative
COMMUNICATE
Pre-Job= increase understanding of risk/control using diagrams, signs, and instructions to workers.
Authorize the lift activity
PRINCIPLES OF INTEGRATED SAFETY MANAGEMENT
• LINE MANAGEMENT RESPONSIBILITY FOR SAFETY. Line management is directly responsible for the protection of the workers, the public, and the environment.
• CLEAR ROLES AND RESPONSIBILITIES. Clear and unambiguous lines of authority and responsibility for ensuring safety are established and maintained at all organizational levels within the Department and its contractors.
• COMPETENCE COMMENSURATE WITH RESPONSIBILITIES. Personnel possess the experience, knowledge, skills, and abilities that are necessary to discharge their responsibilities
• BALANCED PRIORITIES. Resources are effectively allocated to address safety, programmatic, and operational considerations. Protecting the workers, the public, and the environment is a priority whenever activities are planned and performed.
• IDENTIFICATION OF SAFETY STANDARDS AND REQUIREMENTS. Before work is performed, the associated hazards are evaluated and an agreed-upon set of safety standards and requirements is established which, if properly implemented, will provide adequate assurance that the workers, the public, and the environment are protected from adverse consequences.
• HAZARD CONTROLS TAILORED TO WORK BEING PERFORMED. Administrative and engineering controls to prevent and mitigate hazards are tailored to the work being performed and associated hazards.
• OPERATIONS AUTHORIZATION. The conditions and requirements to be satisfied for operations to be initiated and conducted are clearly established and agreed upon.
“
”
FACTORS IN EVALUATING FALL ZONE/
DANGER ZONE
If you don’t recognize the hazard, you can’t control the load,
potential fall, or released energy
FACTORS IN
DEFINING
FALL ZONE /
DANGER ZONE
Predict, analyze where load can fall
Load shape, Center Gravity, size
Rigging
Attachment points and order of attachment
Attaching and unhooking steps
Height above surface
Route and range of Motion
Swinging
Projectile/Recoil/Released tension
Load control precision
Working Slopes, walking conditions
Weather
Sphere of Influence
Every Direction
Many options for
energy release
USN Synthetic Line Snapback
20©2020 Lift-It Manufacturing Co., Inc.
Visualize Danger Zone
21
EVALUATE THE SPHERE OF INFLUENCE
As an example, consider a scenario in which a spreader bar is
used to lift a load and it is connected to the crane with a two-leg
bridle sling. Imagine the sphere of influence if during use, just one
of bridle legs were to break. The load may fall “directly below”,
but the spreader bar, while still connected to the crane with the
remaining bride leg may be propelled into the “but not limited
to” zone.
DEFINE THE CONTROLS
Keep Everyone out of the Fall Zone
DEFINE clearly in plan when qualified person is allowed in Fall Zone
-Assigned workers with competencies
-Specific functions and scope of action
-Temporary worker exposure to hazard-shortest time
The better the hoisting and rigging, unexpected energy release is much less likely. Thus hazards in Fall Zone and Danger Zone are more controlled
Personnel shall not pass under orstand under a suspended load.[ASME B30.9 (2018) 9-5.10.2 (c)]
Personnel should not stand in line or next to slings under tension.[ASME B30.9 (2018) 9-5.10.2 (b)]
SET THE CONTROLS
--
DEFINE THE SAFETY
EXPECTATIONS
“
”OSHA 1926.1425 for Cranes and Derricks in Construction
Hoisting routes minimize employee exposure
No employee in Fall Zone unless hooking or guiding, attaching load, receiving, tilt-up, ...
OSHA specifics apply-
rigged by qualified rigger
self closing hooks or equivalent
NEVER UNDER – NEVER ON – NEVER IN-LINE.
Graphics from Mike Gelskey, Sr.
OSHA 1926.1425 “Keeping Clear of the Load” regulations detail the requirements and provide
good guidance. A summary includes:
Avoid carrying loads over people. Plan the load travel path to minimize exposure to
individuals on the site.
When a suspended load is not moving, it is only permissible to have an employee in the fall
zone if they are:
hooking, unhooking or guiding the load
doing the initial attaching of the load to a component or structure; or
operating a concrete bucket.
The load must be rigged to prevent unintentional displacement.
Hooks with self-closing latches or their equivalent must be used.
The load must be rigged by a qualified rigger.
When a load is being landed, only employees needed to receive a load are permitted to be
within the fall zone.
During a tilt-up or tilt-down operation, no employee must be directly under the load and only
employees essential to the operation are permitted in the fall zone if it is not feasible for the
employee to perform that operation from outside the fall zone.
OSHA 1926.1425 “KEEPING CLEAR OF THE LOAD”
MINIMUM FALL ZONE AND DANGER ZONE CONTROLS
SAFETY CONTROLS TO
MEET OSHA COULD
INCLUDE
Define rigging material and process considering danger zone
Set Engineered controls – fixtures, tables, lifting beams
Erect and maintain control lines, warning lines, railings or similar barriers areas. (1926.1424(a)(2)(ii))
Alignment guides
Use Precise load control devices improve operator control
Tag lines, pike poles, boat hooks, and gripping reaching devices
Control lateral loads and forces
Control swinging
Eliminate rapidly released energy
Control Fall impact area as if it WILL fall
PLANNING IS
DETAILED
PLANNING IS
DETAILED
SPHERE OF
INFLUENCE AND
ROUTE
Hoisting and Rigging is hazardous
Hoisting and Rigging done well has controlled
risk and pre-conditions safe performance
Work the lift plan...
PLEASE ASK QUESTIONS!
HOISTING AND RIGGING ADVISORY
COMMITTEE
FALL ZONE AND DANGER ZONE
Thank you for being engaged and seeking organizational learning.