512 EM 385-1-1 Chapters 16-22

Sections

16-8. General Requirements.

Operational Aids

Operations may only start when operational aids are functional. If aids fail, the operator must halt operations until they are fixed or temporary measures are in place.
Category I aids must be repaired within seven days of malfunction, or within seven days of part receipt if parts are ordered promptly.
Temporary measures for malfunctioning Category I aids include using alternative devices or markings to ensure safe operation.

Category II Operational Aids

Malfunctioning Category II aids must be repaired within 30 days, or within seven days of part receipt if parts are ordered within seven days of malfunction.
Use temporary measures, such as alternative devices or measuring methods, until the aids are fixed.
Ensure all equipment like outriggers are correctly positioned as per the manufacturer’s instructions before beginning operations.

Determining Load

Operators must know the load weight before lifting, determined by a recognized device or calculation method.
Specific exceptions apply to permanently installed cranes lifting gates, but load cells are recommended to determine capacities and overload conditions.

General Testing Requirements

A Qualified Person (QP) must conduct operational tests following ANSI/ASME standards and the manufacturer's instructions.
Operational testing is required before first use, after significant repairs or alterations, and during annual inspections.
Keep all test reports with the crane/hoisting equipment or at the onsite project office.

Knowledge Check Choose the best answer for the question.

16-10. When must a qualified person (QP) conduct operational tests of LHE?

Before first use, after repairs, and annually

Daily, quarterly, and annually

After significant repairs and daily thereafter

Before and after each use as directed by the KO/COR

You forgot to answer the question!

EM 385-1-1 Paragraph 16-8 (q.–s.).

16-8. General Requirements. (q.–s.).

q.  Operational Aids.  Operations may not begin until the listed operational aids are in proper working order, except where the employer meets the specified temporary alternative measures (see exception paragraphs below).  More protective alternative measures specified by the crane manufacturer, if any, must be followed.  If a listed operational aid stops working properly during operations, the operator must safely stop operations until the temporary alternative measures are implemented, or the device is again working properly.  If a replacement part is no longer available, the use of a substitute device that performs the same type of function is permitted and is not considered a modification.  (16-8.q)

(1)  Category I Operational Aids and Alternative Measures.  Repair all malfunctioning operational aids listed in this paragraph no later than seven days after the deficiency occurs.

Note. Exception. If the employer documents that it has ordered the necessary parts within seven days of the occurrence of the deficiency, the repair must be completed within seven days of receipt of the parts.

(a)  Boom hoist limiting device.  Temporary alternative measures must include at least one of the following:

(a-1)  Use a boom angle indicator.

(a-2)  Clearly mark the boom hoist cable at a spot that it is visible to the operator and that gives the operator sufficient time to stop the hoist so that the boom stays within the minimum allowable radius.  If the operator cannot see the mark, then install mirrors or remote video cameras and displays.

(a-3)  Clearly mark the boom hoist cable at a location that is visible to the spotter and that gives the spotter sufficient time to signal the operator to stop the hoist so that the boom stays within the minimum allowable radius.

(b)  Luffing jib limiting device.  Install a luffing jib limiting device on all equipment with a luffing jib.

(c-1)  Equip cranes and derricks with an A2B/Hoist-limit device that disengages the function that is causing the two-blocking or install an A2B damage prevention feature (except as noted).  A CP must test and certify that the devices are functioning properly prior to operating the crane.

(c-2)  Equip lattice boom cranes with an A2B device to stop the load hoisting and boom-down functions before the load block or load contacts the boom tip.

(c-3)  Duty Cycle Exception.  Lattice boom cranes used exclusively for duty cycle operations are exempt from A2B equipment requirements.  When a lattice boom crane engaged in duty cycle work is required to make a non-duty cycle lift (for example, to lift a piece of equipment), it will be exempt from the A2B equipment requirements if the following procedures are implemented:

1) An international orange colored warning
                device (for example, flag, tape, ball) is properly secured to the hoist line at a distance of
                8 feet to 10 feet (2.4 m to 3 m) above the rigging;

2) The signal person acts as a spotter to alert the crane operator with a “STOP” signal when the warning device approaches the boom tip and the crane operator immediately stops the hoisting functions;

3) During a non-duty cycle lift, the signal person does not stand under the load, has no duties other than as a signal person, and complies with the signaling requirements of this manual; and

4) A2B warning devices may be used in lieu of A2B prevention devices for lattice boom crane and hoisting equipment with manually activated friction brakes.

(d)  Telescopic boom cranes.

(d-1)  Equip telescopic boom cranes with an A2B device to stop the load hoisting function before the load block or load contacts the boom tip, and to prevent damage to the hoist rope or other machine components when extending the boom.

(d-2)  Equip telescopic boom cranes used exclusively for duty cycle operations with a two-blocking damage prevention feature or warning device to prevent damage to the hoist rope or other machine components when extending the boom.

(e)  Floating cranes.  Floating cranes may use an A2B alarm system in lieu of a disengaging device unless they are hoisting personnel.

(f)  Other cranes used in duty cycle operations, to include clamshell (grapple), magnet, drop ball, container handling, concrete bucket, pile driving and extracting operations, drilled shaft operations (except telescopic boom cranes), dynamic compaction, and continuous flight auger drilling are exempt from the requirements for A2B devices.
        (g)  Temporary alternative measure.  Clearly mark the cable where it can be easily seen by the operator and that gives the operator sufficient time to stop the hoist to prevent two-blocking. Use a spotter when extending the boom.

(h)  Locate the crane mounted wind speed indicating devices where the maximum wind speed can be measured for the lifting activity.  Where wind speed and gusts can be effectively measured, a hand-held anemometer may be used.

(2)  Category II Operational Aids and Alternative Measures.  Repair malfunctioning operational aids listed in this paragraph no later than 30 days after the deficiency
occurs.

Note. Exception. If the employer documents that it has ordered the necessary parts within seven days of the occurrence of the deficiency, and the parts are not received in time to complete the repair in 30 days, the repair must be completed with seven days of receipt of the parts.

(a)  Boom angle or radius indicator.  The equipment must have a boom angle or radius indicator readable from the operator’s station unless it is an articulating boom crane or digger derrick manufactured before November 8, 2011.  Calibrate and test the indicators following the manufacturer's instructions.  An acceptable temporary alternative measure for figuring out the radii or boom angles is to use a measuring device.

(b)  Jib angle indicator.  Not applicable to articulating boom cranes.  Required if the equipment has a luffing jib.  An acceptable temporary alternative measure for figuring out the radii or jib angle is to first determine the main boom angle and to then use a measuring device.

(c)  Boom length indicator.  Not applicable to articulating boom cranes.  Required if the equipment has a telescopic boom, except where the load rating is independent of the boom length. An acceptable temporary alternative measure to determine boom length is to use at least one of the following:

(c-1)  Mark the boom with measured marks to calculate boom length.

(c-2)  Calculate boom length from boom angle and radius measurements. (c-3)  Measure the boom with a measuring device.

(d)  Load weighing and similar devices.  Not applicable to digger derricks manufactured prior to November 8, 2011.  Required if the equipment has any of the following: load weighing device, LMI, rated capacity indicator or rated capacity limiter. Acceptable temporary alternative measures to determine the load weight are to: use a reliable source (that is, load manufacturer), use a reliable calculation method (that is,
calculating a steel beam from measured dimensions and a known unit weight), or use other equally reliable means.  Provide the operator with the load weight prior to the lift.

Note. Exception. Overhead and mobile LHE used in duty cycle operations are exempt from the requirements for load indicating devices and LMI devices.

(e)  Hoist drum rotation indicator if the drum is not visible from the operator’s station.  Temporary alternative measures: mark the drum and if needed, install mirrors or remote video cameras and displays if necessary for the operator to see the mark.

(f)  Outrigger position (horizontal beam extension) sensor/monitor if the equipment has outriggers (required on equipment manufactured after January 1, 2008).
        Temporary alternative measure: the operator must verify that the position of the outriggers is correct according to the manufacturer’s instructions before beginning operations requiring outrigger deployment.

r.  Determining Load. Ensure that the operator has the load information prior to the lift. Determine all loads from one of the following devices or methods:  (16-8.r)

(1)  Load weighing device.

(2)  LMI (or rated capacity).

(3)  Load moment (or rated capacity) limiter.

(4)  The weight of the load must be determined either from a source recognized by the industry (such as the load manufacturer) or by a calculation method recognized by industry (that is, calculating a steel beam from measured dimensions and a known per foot weight as determine by a QP).

Note. Exception. Permanently installed overhead, gantry, or other cranes that are used to lift gates (for example, spillway, intake, discharge) from slots, have been designed with a reserve capacity and are factory proof tested at 125% of WLL.  Load cells are highly recommended, but not required, to determine rigging capacities and overload conditions.

s.  General Testing Requirements.  The reports must include the test procedures and confirm the adequacy of the repairs or alterations.  Keep the test reports with the crane and hoisting equipment or at the onsite project office. (16-8.s)

(1)  A QP must conduct operational tests following the applicable ANSI/ASME standard and the manufacturer's instructions.  If the manufacturer has no procedures, follow requirements included in this chapter.

(2)  Perform operational testing at the following frequencies:

(a)  Before the first use of a new or reinstalled crane or hoisting equipment.

(b)  Before using a crane or hoisting equipment after altering, replacing or
repairing a load bearing or load controlling part or component, brake, travel component, or clutch (to include securing devices, skids, and barges for floating cranes).

Note. Adding/removing counterweights is not a load controlling/load bearing.

(d)  Every time a crane and/or hoisting equipment is brought onto a USACE
        project.

(e)  During annual inspections.

Note. When wire rope is replaced, full operational testing of the equipment is not required, but a limited operational test is required prior to putting the equipment back into service.