Vishnu

1. KNOWLEDGE INSTITUTE OF TECHNOLOGY
DEPARTMENT OF MECHANICAL ENGINEERING
M.E. (Industrial Safety Engineering)
TECHNICAL SEMINAR - I
Safe Operation of Crane and Lifting activities
Presented by
Vishnuraj G
611221423024
PG INCHARGE:
Dr.N.PANNEERSELVAM, M.E, Ph.D
Associate Professor ,
Knowledge Institute of Technology,
Salem
FACULTY INCHARGE:
Mr.G.THANGARAJ M.E,
Assistant Professor ,
Knowledge Institute of Technology,
Salem

2. CONTENT
• INTRODUCTION
• LITERATURE REVIEW
• OBJECTIVE
• LIFTING OPERATION & RIGGING
• LIFTING EQUIPMENT'S
• LIFTING TOOLS AND TACKELS
• LIFTING PRINCIPLES
• HAZARDS ASSOCIATED WITH
CRANE ACTIVITIES
• ELECTRICAL HAZARDS
• OVERLOADING OF CRANE
• MATERIAL FALLING HAZARD
• SAFETY DEVICES IN MOBILE
CRANE
• CRANE OPERATION SAFE
PRACTICES
• BEST RIGGING PRACTICES
• RIGGING SELECTION
• SIMPLE RULES FOR LIFTING
• CONCUSION
• REFERENCES
2
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3. INTRODUCTION
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Myself Vishnuraj G, pursuing M.E in Industrial safety Engineering in Knowledge
Institute of Technology.
I am doing this Technical seminar as a part of second semester, I have chosen the
topic as “Safe Operation of Crane and Lifting Activities”. The seminar is based on
the Crane Hazards and Risk associated in Lifting, Safe Working Procedure During
Lifting, Rigging.
I am doing this technical seminar, as I am very much interested working in
construction site. So I am carrying out this seminar based upon the activities
involved in lifting and rigging.

4. LITERATURE REVIEW
S.N
O
Title AUTHOR YEAR DESCRIPTION
1 An investigation of
lifting operations on
UK construction
sites
Begum
Sertyesilisik,
Ashley Tunstall,
John McLouglin.
2010 Investigation and case studies were carried out about Lifting
Operations, the surrounding area was surveyed according to
Lifting Operation and Lifting Equipment Regulations (LOLER)
1998, the results were obtained by General site staff, Managerial
Staff are Interviewed. 24% of incidents are due to Hazardous
weather condition as working near seashore. The investigation
also states that the incidents happened due to improper
communication between the workers and operators.
Recommendations were obtained from the managerial staff
interview to provide better training.
2 Preventing human
error in crane
operations: a case
Study of
organizational and
design elements
Jiun-Yin Jiani,
Gerry E. Milleri,
and Sahil Shahii
2017 The Case Study was conducted between 2009 to 2016, 57
offshore crane-related incidents in the construction industry
resulted in numerous injuries and fatalities in the Gulf of Mexico
region. Even though this case study has indicated compliance
with the standard’s recommended design method, the review and
outcome illustrate possible flaws if a design recommendation
does not account for fundamental human factors design
principles which are not always covered by industry standards.
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5. LITERATURE REVIEW
3
Determination of the
Hazard Area of Crane
and Hurdle-using
Method for Accident
Prevention
Xuan Nam Chu,
Ha Dinh Thi
2018
In this paper, Hazardous areas on the crane are
mainly located near the drive mechanisms and
the swing radius the area between the cables,
the rollers in the winch or pulley, the pulley,
between the chain. The hazardous areas are
isolated with the use of Hurdles as barricading.
Structural barrier can be fixed or removable and
movable. If the danger area is temporary for a
short period of time, the pile can be pivoted.
4 Safety Practices during
Lifting Operations in
Metro Projects
Rambabu Pitani,
Dr. S. P. Venkatesan,
Mr. S. Karthikeyan
2020 In metro construction industries it is necessity to
give importance to safety of lifting operations as
these activities having interface with public
vehicle and to ensure road safety. In recent
years fatal accidents related to lifting are
reduced in the metro industries as compared to
previous times, it is because of companies are
giving highest priority to safety of the people.
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6. OBJECTIVE
• To study about the Lifting Equipment's and Lifting tools and tackles.
• To understand about the major principles in lifting and working of
Crane.
• To find out the major hazards involved in Crane Activities.
• To analyze the Control Measure for the Hazards
• To study about the Crane Accident Case study
• To Describe and suggest the best safe operating practices in crane
operation and rigging.
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7. LIFTING OPERATION
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 Lifting operations in construction occur during transportation
of material from the storage place to the place where it is
being processed, and during the processing of materials. A
load includes any material that are lifted or lowered by lifting
equipment.
 Lifting equipment is any work equipment for lifting and
lowering loads, Heavier objects.
 Crane is a type of Lifting Equipment, generally equipped with a
hoist rope, wire ropes or chains, and sheaves, that can be used
both to lift and lower materials and to move them horizontally.
It is mainly used for lifting heavy objects and transporting
them to other places.
 Rigging is part of the lifting operation which forms the link
between the crane and the load.

8. LIFTING PRINCIPLE
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• Centre of gravity
• Leverage
• Stability
• Structural Integrity

9. • 1. Electrical Hazards.
• 2. Overloading.
• 3. Material Fallings.
• 4. Crane collapsing.
• 5. Hazardous Weather.
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Major Hazards During Crane Operations

10. Major Hazards During Crane Operations
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• 1. Electrical Hazards
Cranes typically operate at high heights, which
means they may be in the same area as electrical
lines and hazards. If the operator is not careful,
the crane could come into contact with the
electrical lines, which is very dangerous.
Effects:
This could lead to fatal accident of crane operator
or any individual working under crane.
High voltage (More than 33kv) causes Electrical
Arcing and Fatal injury from exposure due to
Electrical Arcing.

11. Control measure for Electrical Hazards
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• Operator and Supervisors shall ensure that overhead
power lines are de-energized or separated from the
crane and its load by implementing one or more of the
following procedures:
1.De-energize and visibly ground electrical
distribution and transmission lines.
2.Use independent insulated barriers to prevent
physical contact with the power lines.
3.Maintain minimum clearance between energized
power lines, the crane and its load.
• Risk assessment in the particular should be conducted
and proper safe working procedure should be
developed in workplace.
• Conduct an on-site planning meeting.
• Arrange for insulated barriers to be installed.

12. Major Hazards During Crane Operations
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• 2. Struck by Crane Loads
• Falling of materials is a major hazards while using
• overhead cranes. If materials are not properly secured,
• for instance, the load can slip and land on workers in the
• vicinity or cause major damage to property.
• Causes of Material falling are due to:
• Improper rigging of loads
• Inadequate inspection and maintenance of equipment's and tackles.
• Lack of proper receptacles for loose loads
• Defective or damaged lifting tackles such as slings, hooks, inserts, eyes, shackles.
• Structural failure of crane component such as the boom, jib, hydraulic rams or wire
rope due to the crane being loaded beyond its loading capacity.
Effects:
Falling objects from height can strike persons on the head and cause serious or even
fatal injuries.

13. Control measure for Material Fallings
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• The lifting equipment's and Tackles should be inspected prior Lifting and the
load does not exceed the SWL of the equipment. Report any damage to your
supervisor and take it out of use.
• Ensure the correct type of lifting equipment is selected for the lift.
• Rigging should be done by a competent rigger and supervised by lifting
Supervisor
• Rigging angle or Operating angle should be according to the Lifting Plan and
should be communicated with all the employees on-site.
• Warning signage should be installed in any areas where the risk is present and
No one should be Under the suspended load.
• To arrest the swinging of load, The tag liners should be appointed to control the
load from a safe distance.
• Lifting Tackles shall be Provided with Rubbers and wooden block to protect from
sharp edges.
• Do not lift outside of the cranes safe working radius
• Ensure that all equipment certification is in date.

14. Major Hazards During Crane Operations
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• 3. Crane Collapse
By exceeding the operating capacity or operating radii or by
failure of Safety devices. Crane overload is strictly prohibited.
Effects:
• Overloading causes the tipping of crane as well as Structural
failure of Crane which may lead to Major / Fatal Accident to
the workers and Property and Lifting Equipment damage.
Control measures:
• 1) Crane operators should be trained on planning and load
measuring.
• 2) All the safety Devices should be followed while operating.
• 3) On job-training is necessary to crane operators even if
they are all qualified.

15. Load Chart of Crane
Different load lifting capacity at
different angles & length.
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• Safe Load Indicator
• A Safe Load Indicator (SLI) or an
Automatic Safe Load Indicator (ASLI) is a
device which is installed on mobile or
portal Cranes to alert the operator if the
lift is exceeding the safe operating range
of the machinery. In some cases, the
device will physically lock the machinery
in circumstances it determines to be
unsafe.
Control Measure for Overloading of Crane

16. SAFE WORKING LOAD( SWL)
• Safe Working Load (SWL) sometimes stated as
the Normal Working Load (NWL) is the
maximum safe force that a piece of lifting
equipment, lifting device or accessory can
exert to lift, suspend, or lower, a given mass
without fear of breaking. Usually marked on
the equipment by the manufacturer.
• In no circumstances must the load exceed the
safe working load (SWL), except when under
test by an authorized competent person.
• When lifting near to the maximum SWL, the
load should be raised a short distance only
and the operation stopped to check stability
and safety before continuing.
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Calculation for
percentage of object
Control Measure for Overloading of Crane

17. Documentation required For Crane Operation
• For Crane Operators
Operator must have heavy Motor Vehicle HMV
License, as per Motor Vehicle Act, 1996.
Operator must be physically able to operate a crane.
Operators are required to complete medical
examination which includes audiometric testing and
eye sight testing and Physical fitness certificate.
• Documentation required prior lifting
Risk assessment
Lifting plan
Lifting Permit to work
Pre-Operational Crane Checklist
Soil Test certification
Crane Maintenance Repot
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• Statutory Inspection of Lifting equipment
 Lifting Equipment & Lifting Tools & Tackles, Govt.
Approved / Authorized Competent Person carry out
Inspection and testing of the products and certify to
use them, according to factory Act Section 28.
Safety devices and Emergency Shut down devices
should be Calibrated by TPI approved by NABL
Certification.
Properly maintained, and shall be thoroughly
examined by a competent person at least once in
every period of six months, and a register shall be
kept containing the prescribed particulars of very
such examination.
Color coding and tag should be given to all the
equipment's and tackles according to the condition,
which is revised for every month.
Control Measure for Overloading of Crane

18. Other Common Hazards Related to Crane
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• Bypassing safety devices
• Excessive speeds
• Moving the crane too quickly
and jerking the Hoist
• No hand signals (Banksman)
• Under capacity of lifting gears
• Poor ground conditions
(unstable ground)
• Operating in Hazardous Weather
such as High Wind condition.
• Unauthorized person entering
into lifting area
• Unguarded parts
• Unguarded swing radius
• No barricading in the Lifting Area
• No steps/guardrails walkways
• Failure to use or fully extend
outriggers or stabilizers
• failure to level the crane
• Lifting in Uneven or Slope Surface,
Back filled areas, near excavation.

19. Safety Devices in Mobile Crane
Emergency Stop Button.
Load Movement Indicator LMI.
Boom Angle Indicator
Crane Inclinometer.
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20. • Automatic Safe Working Load
indicator.
Safety Devices in Mobile Crane
Outrigger/ Stabilizer position Sensor/Monitor.
Hoist Drum Rotation Indicator.
Luffing Jib Limiting Devices.
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21. Safety Devices in Mobile Crane
Lowering Limiter
Hoisting Limiter
• Anemometer.
Typical maximum in-service wind speeds
Tower cranes 20 m/s (45 mph / 72 kph)
Crawler cranes 14 m/s (31 mph / 50 kph)
Mobile cranes 9.8 m/s (22 mph / 35 kph)
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22. Crane Operation Safe Practices
• Only trained, qualified and specifically designated persons shall operate a mobile crane.
• Crane operator shall not engage in any practice that will divert their attention while
operating the equipment.
• Prior to operating a mobile crane, the operator must make a complete walk around the
equipment to ensure that people are clear of the equipment, and that all equipment is in
a safe condition.
• Barricades, warning signs or other methods must be used to prevent entry into a lift area
or turn radius of the crane.
• All controls must be tested by the operator prior to operating the equipment. Any
malfunctions must be corrected or repaired before operating the crane.
• Operators will respond to signals only from a trained signal person.
• When there is any doubt as to the safety of rigging and hoisting activity, the operator has
the authority and responsibility to refuse to handle loads.
• At no time shall persons work under a suspended load and suspended loads shall not be
left unattended without proper safeguards.
6. .
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23. Whenever any sling is used, the following practices shall be observed!
Slings that are damaged or defective shall not be used.
Slings shall not be shortened with knots or bolts or other makeshift devices.
Sling legs shall not be kinked.
Slings shall not be loaded in excess of their rated capacity.
Slings used in a Basket Hitch shall have the load balanced to prevent slippage.
Slings shall be padded or protected from the sharp edges of their loads.
Suspended loads shall be kept free of obstructions.
All employees shall be kept clear of loads about to be lifted and of suspended loads.
Hands or fingers shall not be placed between the sling and it’s load while the sling is being tightened
around the load.
Shock loading, Jerk Loading is prohibited.
A sling shall not be pulled from under a load when the load is resting on the slings.
Best Rigging Practices
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24. Rigging Selection
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3. Are the Working Load Limits
Adequate?
a. What is the weight of the load?
b. Where is the center of gravity?
c. What is the sling angle?
d. Will there be side loading?
e. Capacity of the gear?
4. Will the Load be Under Control?
a. Tag Line available?
b. Is there any possibility of
fouling?
c. Clear of Personnel?
1. Are there any Unusual Loading or
Environmental Conditions?
a. Wind?
b. Temperature?
c. Surfaces?
d. Unstable Objects?
2. Is the Equipment in Acceptable
Condition?
a. Appropriate Type?
b. Proper Identification?
C. Properly Inspected?

25. Case study
• Three persons including the crane
operator were severely injured after a
crane toppled at a construction site and
the iron rods it was carrying fell onto an
MTC bus on Mount Poonamallee Road in
Ramapuram. This crane accident
happened during 4.30 am Approx. on
27th of October.
• The crane which was transporting Metal
Caging used on a Metrorail construction
site. The crane toppled suddenly and the
cage fell onto an MTC bus approaching
from Kundrathur on Mount Poonamallee
Road.
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26. Finding from the CASE STUDY
• The Crane was lifting heavy load
(more than 5 Tons), and length of the
cage is 20 meters. The Barricades
were removed for the free movement
and swinging of the crane. Since,
there was an opening the Local MTC
bus entered Under the suspended
Load.
• Due to less illumination, the bus
Driver could not able to recognize the
cage which is being lifted and the cage
collided with the bus, as it pulled the
crane which as well leads to collapse
of the crane.
• This accident caused three major
injuries in the construction site.
Recommendations
• Proper Illumination has to be
provided by the management.
• Banksman and Traffic marshal
should be provided by the
management to stoop traffic as
well as to communicate with the
operator to control the lifting
loads.
• IPV (Impact Protection Vehicle)
has to be present available in the
road side, which indicate a danger
sign, to Stop or slow down the
running vehicles.
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27. 1. Know the WEIGHT of the load
2. Use the right LIFTING EQUIPEMENT for the Job.
3. Attach it Correctly, to the Load, ensuring that the hook is over THE
CENTRE OF GRAVITY of the Load.
4. Before Lifting Ensure that the HANDS are clear of the slings.
5. Lift Slowly and Carefully, ensure that all the persons are CLEAR from the
SUSPENDED LOADS.
6. Use of Personal Protective Equipment(PPE), i.e. safety boots, safety nets,
safety helmets etc.
Simple Rule for Lifting
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28. CONCLUSION
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In any industry for execution of safe lifting operations, lifting equipment
and lifting accessories should be fit to use and with competency of the lifting
team, each high-risk lifting activity must have dedicated lifting plan, never
overload cranes and slings than its safe working load, a proper communication
needs to setup with defined signals to avoid confusion.
Accidents involving cranes can severely damage people and companies.
Unfortunately these show a constant trend in term of number of fatalities over
the years. By analysing the causes of accidents, major number of accidents are
caused by Electrical hazards, Crane Collapsing and Struck by Loads.
For the above major accidents, the Control Measures and Safety Precautions
were discussed in this presentation.

29. REFERENCES
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• Factories Act 1948, Section 28
• Building and Other Construction Works Act ( BOCW) Act 1948.
• The Tamil Nadu Building and other Construction Workers (Regulation of
Employment and Conditions of Service) Rules, 2006
• National Safety Council, Lifting Operations books and films.
• RRTS Metro Project Lifting Operation Requirements
• Metro Projects - Safety Health & Environment condition of contract.
• OSHA (Occupational Safety , Health Administration); Cranes and Derricks in
Construction
• OSHA (Occupational Safety and Health Administration); Qualifications of
machinery operators and supervisory training.
• General Requirements of Mechanical Handling – KU Mistry Book.