PAGE 1 OF 5 HEALTH, SAFETY & ENVIRONMENTAL MANUAL PROCEDURE: S360 Overhead Cranes & Lifts Procedure REV 4.0 8/14/2012

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1 PAGE 1 OF 5 PURPOSE: OVERHEAD CRANES AND LIFTS PROCEDURE The purpose of this procedure is to define the safety and training requirements for use of overhead cranes and lifts. Procedure: Definitions Designated Person is a person designated to perform a task and who is recognized as having the responsibility to assure that the task is properly performed. Qualified Employee is a person who by possession of a recognized degree, certificate or professional standing or by sufficient knowledge, training and experience has proven their ability to solve problems relating to the job in question. General Requirements 1. All overhead cranes installed after August 31, 1971 must meet the specifications of the American National Standard Safety Code for Overhead and Gantry Cranes, ANSI B Cranes can be modified and load capacity re-rated as long as the modifications and associated structure is thoroughly checked for the new rated load by a qualified engineer or the equipment manufacturer. After these modifications and certification are complete the modified crane must be inspected according to the requirements listed below. 3. The rated load of the crane shall be plainly marked on each side of the crane. If more than one hoist is present, each hoist will have its rating shown. 4. Clearance must be maintained above and to the side of cranes. Walkways cannot be placed in a crane operating zone that would compromise employee safety when the crane is in operation. Parallel cranes must have adequate clearance between the two bridges if no walls or structures are between them. 5. Only designated personnel will be permitted to operate a crane. Inspection Requirements Due to the large and heavy objects often being transported by overhead cranes, routine inspections are necessary to ensure continued operation of the crane and the safety of the employees around the crane. An initial inspection of the crane prior to initial use of new and altered cranes is necessary. Once placed into service, overhead cranes will require two different types of inspections. Frequent inspections are done at daily to monthly intervals, while periodic inspections are completed at annual intervals. The purpose of the two

2 PAGE 2 OF 5 inspection types is to detect damage critical components of the crane before they fail and to determine the extent of wear, deterioration or malfunction. Initial Inspection New cranes must be constructed in a manner that meets the requirements of OSHA They must be inspected before they enter operation. Initial inspections must include: 1. Operational testing including hoisting and lowering, trolley travel, bridge travel, and the operation of limit switches and other locking and safety devices. 2. A rated load test not exceeding 125 percent of the rated load. 3. Inspection per the Frequent Inspection standards. 4. Inspection per the Periodic Inspection standards. Any crane that has been dormant for more than one month must have it s rope inspected by a qualified person. This inspection must be documented, and the record kept with the crane maintenance records. Any crane that has been dormant for more than six months must receive a full Periodic Inspection before it is returned to service. Frequent Inspections Daily items are to be checked by the operator before operation of the crane begins each day: 1. The adjustment and proper function of operating mechanisms. 2. Excessive wear of any operating mechanism. 3. Any deterioration or leaks in air or hydraulic systems servicing the crane. 4. Visual inspection of hooks for deformation or cracks per the Company policy S Visual inspection of the lift chain or rope including its end connections for damage or excessive wear. 6. Visual inspection of all lifting chains and tackle to be used during the shift per The Company policy S350. All lifting devices must be of suitable capacity for the loads to be lifted, must not exhibit excessive wear or damage and must be removed from service if determined to be out of compliance. 7. Visual inspection of the rope routing through the blocks and on the spool. 8. Proper operation of the limit switch: with no load attached to the block slowly inch the block up until the switch is triggered. Monthly items must be inspected by a qualified employee. This employee is to be designated by the shop manager. These inspections are to be documented including the name of the inspector, the serial number or unique identifier of the crane or part in question and the date. The shop manager will retain control of these records and file them with the equipment maintenance logs for audit availability. Items included in this category are to include: 1. Deformation or cracking of hooks per the Company policy S350. Hooks with cracks, a throat opening of more than 15% over nominal or a twist of more than 10 degrees are to be removed from service.

3 PAGE 3 OF 5 2. Hoist chains or ropes and their end connections must be checked for unusual or excessive wear, distortion, proper function and stretch according to the manufacturer s specifications. 3. Rope reeving for compliance to the manufacturer s specifications. 4. Operating mechanisms for proper function and excessive wear: limit switches, hook latches, loose bolts, proper lubrication etc Periodic Inspections Periodic Inspection items are to be inspected annually by a qualified outside certification company. A record of the inspection is to be documented including the name of the inspector, the serial number or unique identifier of each crane and component item, and the date of the inspection. This inspection is to be a thorough check of the crane s function and must include: 1. All of the items listed in the Frequent Inspections section. 2. Any deformed corroded or cracked structural members. 3. Any loose rivets bolts or other fasteners. 4. Cracked, worn or otherwise damaged sheaves or drums. 5. Pins, bearings, shafts, gears, rollers, clamps and locking devices for cracks or excessive wear. 6. Brake system function and wear. 7. Wind, load or other operation indicators for proper function throughout their operating range. 8. The condition and proper operation of the crane power source. 9. Drive sprocket wear and chain or rope stretch exceeding the manufacturer s specifications. 10. Pitting or other deterioration of the controller contacts, limit switches or other control electronics. Maintenance Requirements A preventive maintenance program based on the crane manufacturer's recommendations must be implemented. If any deteriorated components or unsafe conditions are detected during the required inspections they must be repaired before the crane reenters service. Only designated personnel may perform the required maintenance and repairs. Maintenance records are to be tracked by the shop manager for a minimum of one year. The requirements of 29 CFR , The Control of Hazardous Energy or lockout/tagout (the Company policy S230), shall be used to de-energize the crane. Operation 1. The manufacturer's instructions must be followed when operating the crane. Pay attention to the crane s load rating and the rating of the rigging used to assure that it is appropriate to the weigh of the load lifted. No crane shall be used to lift a load greater than the manufacturer s listed load limit.

4 PAGE 4 OF 5 2. Ensure that the hoist rope or chain is free of kinks and twists and that it is not wrapped around the load. 3. Attach the load to the block hook by means of slings or other approved devices, making sure the sling is clear of all obstacles. Once the load is properly secured and balanced in the untwisted sling, slowly raise the load. Horizontal movement must also begin slowly to prevent the load from swinging or coming into contact with other obstacles. 4. Take care not to accelerate or decelerate the load suddenly. Always move the load in a smooth and controlled fashion to prevent excessive strain on the rigging and crane and to maintain the stability of the load. Keep loads as low as practicable to minimize drop hazards. 5. When a load is large or likely to be unstable tag lines must be used to control the load. 6. When a load is large enough to obstruct the visibility of the crane operator a spotter must be used to flag from the blind spot. The spotter s command to stop MUST be observed immediately. 7. Never use the crane to pull sideways on a load. Pick loads up with the hoist rope or chain perpendicular to the ground. If the rope or chain is not hanging straight down it may be sheared by the spool or bind up in the block and break. 8. Never pick up a load upon which any employee is standing. Take special care when picking up a load that all employees are clear of the area in case the load shifts or swings unexpectedly. 9. NEVER carry a suspended load over any employee. 10. Make sure that there are always at least two wraps of cable around the spool. Lowering the crane below this point may cause the cable to be over stressed and break loose. 11. When more than one crane is used to lift a load one person must be designated to take charge of all the rigging and movement of the load. 12. Do not leave a suspended load unattended. 13. The crane warning signal or horn must be sounded when the load or hook comes near personnel. 14. Audible and discernible voice communication should be kept with the operator at all times. If this cannot be accomplished, a signal system should be used. However, it may be necessary to create special signals in certain circumstances. In these circumstances, the signals must be understood and agreed upon by all individuals using the crane. 15. All operators must be familiar with the signals for directing overhead cranes. These signals are defined in the Company s policy number S111, basic safety rules. Chain Hoists 1. Inspect the hoist for any evidence of damage or loose parts. 2. The supporting structure and load attaching devices should have a load rating at least equal to that of the hoist. 3. This hoist is not suitable for use in uncovered outdoor locations or areas containing explosive dust, vapors or gasses. 4. The installation area must provide safe operating conditions for the operator, including sufficient room for the operator and other personnel to stand clear of the load at all times.

5 PAGE 5 OF 5 5. In areas where a slack chain hanging from the hoist may create a hazard, use a chain container. 6. Inspect the hoist for any signs of loose, broken, or malfunctioning parts. Any malfunctioning hoist must be tagged as out of order and removed from service until the defect is corrected. 7. Before starting the hoist, the operator shall be certain all personnel are clear. 8. Do not lift more than the rated load of the hoist. 9. Do not lift people or loads over people. 10. Avoid jogging controls or quick reversals of suspended loads. 11. Do not leave a suspended load unattended. 12. The operator should have a clear view of the load any time it is moving, and should be certain that the load does not contact any obstructions. Training: Before any employee is allowed to operate an overhead crane they must complete the Company s overhead crane training program. This program will be conducted by a qualified person with sufficient experience and technical understanding of crane operation to instruct others in their use. This training is to be repeated or expanded upon if an employee demonstrates a deficiency in operating ability or in the event of an accident. The overhead crane training curriculum shall include completion of training in the following order: 1. A formal training session to familiarize operators with the risks and special considerations inherent in operating their machines. This session shall include: a. A basic overview of how overhead cranes function. b. Operating instructions for the specific types of crane that the employee will use. c. How to determine load capacity of the cranes and the rigging they may use as well as how to determine the weight of any load they will move. d. Standard hand signals for directing crane operation. e. The proper methods for safely moving a load: using a spotter for large loads that limit visibility, moving employees and equipment out of the path of travel, setting up barricades to warn employees of a transit hazard etc. f. Specific hazards posed by the site: narrow runways, hidden corners, areas that contain sensitive or reactive materials, power lines, transit between floors. g. The frequent and periodic maintenance requirements of the cranes they are trained to operate: what needs to be done and by whom, the records that must be kept of these operations, and what to do if they encounter a fault or defect in their crane. 2. A practical training session during which the instructor demonstrates proper operating technique then monitors the student as they learn to perform those operations safely. This stage of the training shall terminate with a documented practical skills test administered by the designated qualified trainer. 3. A work environment evaluation in which the instructor monitors the performance of the student in operation on the job. This monitoring must continue for a period sufficient to demonstrate that the student has the skills needed to safely operate an overhead crane.