LIFTING MATTERS - Published in the interest of promoting safety in the crane industry...

1. Fatality costs crane firm $150,000.
November 28, 2009
Ian Roebuck Crane Hire Ltd of Taranaki, New Zealand, has been fined
$100,000 following the death of employee Allan Robert Peacock, 38, last
year and ordered to pay $50,000 to his partner.
Peacock died at the premises of McCurdy Engineering on November 17,
2008 after he was struck in the head by a metal shackle attached to a
web type lifting sling which was later found to be frayed. The sling was
being used in conjunction with a 10 tonne loader crane..
The company was cited for failing to take all practicable steps to ensure
the safety of an employee while at work and for failing to ensure the
LIFTING MATTERS
employee was adequately trained and supervised in the safe use of the
crane.
Company director, Ian Roebuck was also convicted but discharged,
thanks to his guilty plea, his co-operation with the investigation, remedial Published in the interest of promoting safety in the crane industry
activity and willingness to offer reparation.
In his judgment, Judge Roberts said Peacock had been attempting to lift a trailer utilising a Hiab
loader crane. Peacock was operating the controls at the side of the crane when one of the eye loops
on the nylon slings under the trailer broke. Peacock, who was wearing a hard hat, was struck in the
head by the shackle.
Sharing and Learning
Judge Roberts added that the company had failed to ensure that the slings were in a safe condition,
failed to ascertain the weight of the object to be lifted before selecting the crane to be used, failed to
ensure the crane had a load chart and failed to provide Peacock with an operator's manual. The last
three omissions were acknowledged by the company.
The judge also found that Roebuck ran a well established business, having operated in Taranaki for
close to 35 years without an incident, but said that he found the company's „buddy training‟ process
was "simply inadequate".
He added that because Roebuck did not have the funds to pay and that any fines would have to be
borrowed, there was little point in imposing a fine on him personally.
"Regrettably, the deceased - an employee of four months - lacked the skills to make the appropriate
decisions about the intended lift. He had not been provided with the appropriate training."
www.vertikal.net/en/news/story/9157
HSE Guidance for the festive season
While Shepherds Watched
While shepherds watched
Their flocks by night
All seated on the ground
The angel of the Lord came down
And glory shone around
The union of Shepherd's has complained that it breaches health and safety regulations to insist that shep-
herds watch their flocks without appropriate seating arrangements being provided, therefore benches, stools
and orthopaedic chairs are now available. Shepherds have also requested that due to the inclement weather
DECEMBER 2009
conditions at this time of year that they should watch their flocks via cctv cameras from centrally heated
shepherd observation huts.
Please note, the angel of the lord is reminded that before shining his / her glory all around she / he must
ascertain that all shepherds have been issued with glasses capable of filtering out the harmful effects of UVA,
UVB and Glory.
Thank you to Mike.M.ODonnell@stos.co.nz
12 LIFTING MATTERS December 2009 LIFTING MATTERS December 2009 1

2. EDITORIAL Loss of Crane Hook from mobile crane
Can you believe that it‟s the end of the year already and also the end of the decade? While times 6th November 2009
are still currently hard in the crane hire and construction industries there are definite signs that Incident
things have bottomed out from the current recessionary economic climate. Hopefully 2010 and be-
yond will see a recovery that surpasses levels of the past decade.  Grove GMK3055 All Terrain crane
Looking back on this year from a Lifting Matters perspective, the readership of the newsletter has
 Crane was setting up for the day’s work
grown in popularity and I believe is fulfilling a need in highlighting the real causes of incidents and  Hook block has contacted the boom head sheaves causing the hoist
accidents in the workplace. wire to part
A big thank you to those that have contributed to this months issue. There‟s a balanced mix of initia-  Hook fell approx 18m
tives, alerts and incidents. Something for all of you.  Hook block – 250 kg
There is a very good instruction on „Working in a Safety Harness‟ (on page 08) with guidance on the  No persons directly underneath – no injury
correct use and care of safety harnesses. Harnesses save lives (as shown on page 03) with the Immediate Actions
potential of being called into action, (see „photo of the month‟ on page 05).
 Operator taken away from scene for interview
We always need to be on the lookout for dodgy shackles that are being peddled ‟out there‟ (page  Scene secured and photographed
07). In this case it is only the ‘capitals’ stamped on the shackles that give them away. Authorized
distributors and manufacturers should be the rule and lets face it, you get what you pay for.  HSE contacted under RIDDOR reporting guidelines
„Time to clear the air‟ is an alert produced by the HSE in the UK on the safe use of cut-off saws or  Incident investigation team mobilised
disc cutters (page 06). Exposure to stone dust can have very serious consequences to the health of Incident Findings
those workers that use them.  As boom telescopes, hoist rope path length increases (hook becomes close to boom tip)
The „Loss of Crane Hook‟ alert on (page 11), was as a result of the manual override being used and  Hook block activates anti-two block, stopping the crane
the operator failing to adhere to the cranes‟ alarm systems. Operators do not always realise the  Audible alarm sounds but the operator chooses to continue without identifying its cause (CF2)
financial cost and damage to the company reputation that is incurred when such incidents take
place.  Operator turns safety system override key to continue (CF1)
Your opinion and any queries and wishes you may have are extremely important to us! Let us know
 Hook block falls into an open, unguarded area where personnel could have been (CF3)
what's on your mind. Please send your contributions to ricky@universalcranes.com or contact us  History of a computer problem relating to the setting
by phone on +61 7 3907 5800.
Root Cause Analysis
Wishing you a wonderful Christmas and a prosperous new year. (RDP)
CF1 – Crane Operator overrode the Crane’s Safety Systems
IN THIS ISSUE ON THE COVER  Use of equipment with known effect
A Universal  Incorrect behaviour not confronted
Editorial 02
Harness saves life 03 Cranes DEMAG  Lack of SPP for the task
TRAM height safety system 03 AC-80 lifting 28m CF2 –Crane Operator didn’t identify the cause of the alarm and contin-
Heavy lift foundation failure 04 long roofing iron ued to telescope
Tower crane fatal fall 04 sections to a 45°  Violation (by individual)
pitch for Intebuild
Crane tips in Basel 05
at Grain Corp,  Use of equipment with known effect
Photo of the month 05 CF3 – Possibility for personnel to be under the falling hook up operation
Port of Brisbane,
Working in a safety harness 06 QLD.  Lack of SPP for the task
Time to clear the air 08
Counterfeit Crosby shackles 09 The fly and nee-
San Diego Special 10 dle were used so Actions to Prevent Recurrence
that the two
Condolences 10  Check all crane check logs to ensure that there are no safety critical faults or those requiring regular use of
lines could be
Harbour crane collapse 10 well spread. Two overrides
Confused by dating terms 10 rigging sheeves
Loss of crane hook by mobile crane 11  Procedure to be developed to have crane logs countersigned by formally assigned responsible person
were utilized
Fatality costs firm $150 000 12 which enabled  Develop a SSoW for when it is acceptable to override crane safety systems
HSE guidance for festive season 12 the operator to rotate the roof iron sections to  Time out for safety session with operators to discuss incident and potential consequences
the appropriate roof angle.  Develop Risk Assessment to cover setting up mobile cranes
Four attachment points, which were tied back  Implement system to communicate SLP RA/MS to hired in crane operators
to the ends of the sheets, were used to pre-
vent any sliding of the roofing iron. Alert submitted by jason.taylor@tf-fpm.com
2 LIFTING MATTERS December 2009 LIFTING MATTERS December 2009 11

3. San Diego special Harness saves life
November 26, 2009 November 25, 2009
Spotted in California a team of men with crane, plat- Two men were rescued in Atlanta, Georgia, after
form ladders and make-do working methods on a one end of a suspended platform they were using
gave way. Dumping them from the platform.
large billboard in San Diego…Death Wish?
The two men were caulking windows around 12
One man is
metres from the ground, on the construction of the
working
48 storey Duke Energy Center, one of them man-
from a self aged to scramble to safety on a ledge, while the
propelled
other was left dangling in his safety harness.
boom lift,
guiding the A self propelled boom lift was brought in to rescue
load in or the men who are both reported to be unhurt by the
out of the billboard. The boom lift levelled up with rough sites main contractor, locally based Batson-Cook.
wood packing
The boom is levelled The incident is under investigation, and the com-
up on small rough stacks of wood. However another man pany will file an incident report with the Occupa-
is casually sitting astride the top of the board while another tional Health and Safety Administration, first indi-
is hanging on the side and a third seems to be doing cations suggest that a brake on one of the winch One of the men is rescued
something on the top of a ladder. motors failed.
Meanwhile others or bystanders are directly below. www.vertikal.net/en/news/story/9140
How many safety defects can you spot?
Check out the number of people hanging TRAM (Total Restraint Access Module)
off of this billboard www.vertikal.net/en/news/story/9146
A family of fail-safe fall prevention safety sys-
CONDOLENCES tem products.
The management and staff of Universal Cranes extend their deepest sympathies to the management, TRAM is a unique height safety system that is simple to use,
family and workmates of the John Holland employee that died on the 05th December 2009 following a provides the wearer with full mobility and yet completely
workplace incident. He was involved in the construction of a high voltage transmission line using a high prevents the user from falling to another level
level elevated man platform West of Townsville in Queensland. While other height safety systems will arrest a free fall,
More information will be available in future issues after investigations have been completed. RDP they can expose the user to suspension trauma or the risk
of hitting obstacles while falling. TRAM overcomes this
Harbour crane collapse safety issue while also reducing the likelihood and conse- Demag CC2800 – Approx 60 Metres of 2724 boom
18 November 2009 quence of a fall on the same level. sections
A 200 tonne mobile harbour crane collapsed at a boat There have been no fatalities and no injuries reported by
yard owned by Elevated Boats LLC in Houma Louisiana, organisations using TRAM. The system has prevented falls that would have
killing one person. otherwise resulted in serious injury or death.
Local reports say that the crane’s superstructure broke The TRAM safety system is designed so that the user is firmly attached to the
free from its base while lifting a 30 ton load from a unit at all times and cannot fall. The safety system includes a mechanical
truck. The crane’s mast and jib then crashed through component that slides along a rail fixed to the tanker and a specially designed
the yards fabrication building, landing on an employee. restraint belt attached by two lanyards. The TRAM provides a handhold that
moves with the operator (vertically and horizontally) and is also a moveable
He was taken to a local hospital where he later died The crane went through the fabrication
anchor point for the restraint belt.
from his injuries. The 60 year old crane operator, suf-
fered serious injuries and remains in hospital. TRAM is the world's best safety system for preventing falls from height when
www.vertikal.net/en/news/story/9104
inspecting and servicing mobile cranes and other heavy equipment.
Confused by Dating Terms TRAM is currently being used in the mining industry to allow riggers safe
access to mobile crane booms, to protect maintenance workers on gantry
Two elderly gentlemen were talking over a cup of coffee.
and bridge cranes and to provide safe access to equipment mounted on the
"I guess you're never too old," the first one boasted. "Why just yesterday a pretty college girl said she'd be
interested in dating me. But to be perfectly honest, I don't quite understand it." cab roofs of mobile plant machinery. Extended Arm, Rotating
In all of these applications, TRAM prevents operators falling from height and Arm TRAM.
"Well," said his friend, "you have to remember that nowadays women are more aggressive. They don't mind
being the one to ask." therefore avoids the risk of serious injury or a fatality.
"No, I don't think it's that." In the photos shown on the right a TRAM system is fitted to the boom sections of a Universal Cranes Demag
"Well, maybe you remind her of her father." CC2800 600T crawler crane for use on the wind farms in South Australia.
"No, it's not that either. It's just that she also mentioned something about carbon 14." For more information www.Tramaustralia.com.au
10 LIFTING MATTERS December 2009 LIFTING MATTERS December 2009 3

4. HEAVY LIFT CRANE FOUNDATION FAILURE RWE npower Safety Information Notice
Sunday 8th November 2009
Accident Description Date: 11/11/2009
A heavy lift crawler crane had a foundation failure with
subsequent over-turning while operating on a Construc-
tion Yard in the U.A.E.
Lessons to be learned
The main lessons to be learned could be summarized
as follows:
1. Always know the weight of the object before a lift Scope
is made. All EAF locations
2. Assess the Lift Plan - boom angle / radius / weight / Purpose
size of crane required / number of cranes required - To raise awareness of potential counterfeit Crosby shackles and the consequence of their use.
built-in safety margin. Description
3. Select the appropriate Lift Crane/s - size - type / Counterfeit Crosby Shackles have been found at locations in Europe. These shackles are NOT up to
mobile / crawler- confined space - type of foundation - required standards and it is mandatory that they be immediately removed from service. The counter-
swing area - walk with the load. feit shackles can fail at as low as just 40% of their stated rating, causing a potentially catastrophic
4. Verify that Foundation is firm and capable of outcome. The most obvious difference is that the counterfeit shackle has the word “CROSBY” all in
supporting the load being generated by the Planned capital (Upper Case) lettering. The genuine shackle only has the “C” of “Crosby” capitalized.
Lift – requirement for soil compaction test - need of See description below, which shows the key differences between a genuine shackle and a counter-
crane mats / plates to be assessed. feit one.
5. First initial Lift made and held a half meter off the
ground - thorough check of all foundation support,
rigging, lift radius / plan, crane stability / track-outrigger
movement.
www.big5pmv.com/buildsafe/20091108-369-BSUSafety Alert-HEAVY LIFT CRANE FOUNDATION FAILURE
Tower Crane Fatal fall incident climbing from the turntable to the cabin. While he
was ascending the turntable ladder, he slipped
Attention all Project Managers, Engineers
and fell onto the mast platform 6m below.
and Supervisors!
This Safety Alert relates to a recent incident
outside of Australia where a crane operator fell
to his death while climbing the turntable ladder to
the cabin of a tower crane.
The points to look for in deciding whether you have a Crosby Shackle or a copy are:
· On the face, (a) the Crosby Name should be embossed as per the Crosby Logo, (b) The CE mark
should appear along with (c) markings of the 45 degree angles
· On the rear of the shackle should appear 2 different groupings of IDs (3 for Belgium manufacture)
Fig 2. The turntable ladder to the cabin providing full traceability of the shackle.
· The pin should also be stamped (d) on the head with a traceable ID number.
From the information provided, it appears clear Responsibility for Action
that the fall protection equipment was removed
· All QHSE Staff to coordinate and document a complete inspection of shackles in their locations
prematurely, leaving the operator unprotected.
and destroy any suspected counterfeit shackles. Liaise with your Lifting Equipment Specialists.
Additionally there may be opportunity to improve
Figure 1: Height of worker’s fall
the fall arrest system as installed. · Add the requirement to sample a selection of shackles to your Yard Planned General Inspection
checklists to ensure on-going vigilance.
The lifeline was terminated at the top mast and Safety Alert supplied by Frank Horky, Safety Manager
the worker had removed his safety harness when of LBBJV, Brisbane, QLD
Article submitted by Mike.M.ODonnell@stos.co.nz
4 LIFTING MATTERS December 2009 LIFTING MATTERS December 2009 9

5. TIME TO CLEAR THE AIR! Water suppression is your first line of defence. All Crane tips in Basel
modern cut-off saws have an attachment for a water
Protect your lungs when using cut-off saws hose. The water can be supplied from a mains feed November 26, 2009
If you are working in highway paving construction or (the best option) or a pressurised water bottle. You An All Terrain crane went over in Basel, Switzer-
maintenance work, it is highly likely that you use a need a minimum flow rate of 0.5 litres per minute to
cut-off saw (also known as a disc cutter, a con-saw or damp down dust effectively. land, while erecting a tower crane, injuring one
a ‘whizzer’). Cutting kerbs, paving or blocks can Wear a suitable dust mask person.
produce enormous amounts of dust (stone dust). The Even with water suppression you will need to wear a The accident occurred on the site of a children's
stone dust will contain some very fine dust called suitable dust mask (respirator). Nuisance-grade dust
respirable crystalline silica (RCS). Exposure to RCS hospital where the six axle crane, a Grove GMK,
masks do not protect your lungs. Use one with an
dust can cause serious health problems and may even- assigned protection factor of at least 10, even when was erecting or dismantling a large tower crane.
tually kill you. your water suppression equipment is working effec- The crane appears to have lost control of the tower
tively. Use either FFP3 filtering face pieces or orina- crane jib causing the crane to tip. The boom struck
sal respirators with P3 filters.
the top edge of a building causing the it to buckle. The upturned crane
Maintain equipment
Meanwhile the short heavy duty jib also buckled
 Check your machinery and safety equipment over the top of the building sending an object, possibly a hook smashing into an apartment window,
regularly.
injuring a woman standing inside.
 Make sure the water jets are working properly.
Maintaining an adequate water flow by cleaning The operator escaped without injuries. The building was evacuated for inspection. The cause of the
the water jets is essential and should be done at accident is not yet known, although local reports are suggesting that wind which was gusting over
least every time the blades are changed. 61kph, may have been a factor.
 Replace worn cutting discs to reduce the cutting
Vertikal Comment
This alert has been produced to explain how stone time.
dust exposure can affect your health and what you can  Maintain hoses and bottles. The crane hire company has a first class safety record over
do to control the risks. a long period, to the point where it is possible that this is its
Health effects  Inspect and maintain masks.
Stones, rocks, sands and clays may contain large first accident in what must be almost 50 years in crane
amounts of crystalline silica. They are used to make rental.
kerbs, flags, bricks, tiles and concrete. Even plastic
kerbs can contain a silica-based filler. Cutting these Strong winds would certainly have had a major effect on
materials produces very fine RCS particles in the such a long load, but the company would normally have
airborne stone dust. These particles are small and you been well aware of this and have taken it into consideration.
can’t always see dust given out by cutting. If you The fact that the crane appears to be operating in a partial
breathe in too much RCS you could develop the fol- counterweight configuration may also have been a factor?
lowing lung diseases.
Silicosis The jib buckled and sent something - a
hook block?- crashing into the building www.vertikal.net/en/news/story/9147
Silicosis makes breathing more difficult and increases
the risk of lung infections. It usually follows many Other risks
years of exposure. But exceptionally high exposures Make sure you deal with other risks, eg: PHOTO OF THE MONTH
over a few months or years can cause these symptoms.
Lung cancer  noise; Somewhere in Vancouver is a worker
Heavy and prolonged exposure to RCS can cause lung  flying debris; who is concerned that some passers-by
cancer.  water spray; may never have a chance to attend
Chronic obstructive pulmonary disease (COPD) Cirque de Soleil, much less a regular old
COPD is a group of lung diseases like bronchitis and  hand-arm vibration;
circus, so he offers an impromptu side-
emphysema that may also be caused by RCS, result-  manual handling. show/preview for them to enjoy as they
ing in severe breathlessness and prolonged coughing. Consider the safety of yourself and others when you
The disease is slow to develop and rarely seen in
drive past.
operate a cut-off saw. Use suitable personal protective
people under 40. It can be very disabling and is a equipment, such as hard hats, safety glasses and ear “The sidewalk was closed, the telehan-
leading cause of death. defenders. Make sure these items are worn correctly dler was running, the harness was con-
Be aware! and are suitable for use together. nected, everything was going fine until
 You can’t always see dust from cutting. Remember! the guy switched off his brain!”
• Always damp down dust.
 Dust could harm workmates and other people
standing near you. • Wear a suitable dust mask.
Managing or reducing the risk Article from the HSE and Highways Agency in the UK http://safetycentre.navy.mil/PHOTO/archive_351-
sent by Chris Gunn from K Home International Ltd 400/photo354.asp
Damp down the dust
8 LIFTING MATTERS December 2009 LIFTING MATTERS December 2009 5

6. SAFETY INSTRUCTION 4. Use
Working in a Safety Harness  Equipment must be used in accordance with manufacturers instructions;
 Anchor points must be designed/inspected by an engineer/competent person before initial use;
1. Purpose and scope  If one person is using the system the anchor point must have a minimum breaking strength of
This safety instruction provides guidance and instruction on the correct use and care of safety har- 15kN (1.5t). This is equivalent to hanging a small family car on it;
nesses and associated fall protection equipment and applies to all workplaces on the North South  If two people are using the system (e.g. temporary horizontal lifeline rated for 2 persons) your
Bypass Tunnel Project. This instruction incorporates key requirements of the QLD WHS Regulation anchor points must have a capacity of at least 21kN (2.1t);
2008 and AS/NZS 1891.1.  DO NOT attach shock absorbers to scaffolding handrails etc, or wrap it back around itself
2. Training (commonly referred to as “back-latching”);
All personnel who work at height and require the use of height related equipment must be trained in  Depending on the fall distance and your body weight, the load imparted on the anchor point and
the correct use, inspection and care of such equipment; and Training provided must also include the harness can be up to 1100kg. Shock absorbing lanyards/inertia reels and harnesses are de-
safe recovery of persons suspended in a safety harness. signed to reduce this to a maximum force applied to the body of ~600kg. To help ensure this
3. Inspection occurs it is important that all harness straps are fastened as tight as comfortably possible;
 You must ensure there is sufficient clearance below you so that if you fall (refer illustration below)
 The same colour scheme for electrical and lifting gear inspections apply to mandatory harness you will not hit any other object, surface or the ground;
inspections in use on the project:
 In the event of a fall, all equipment that is
RED : January-March
January- BLUE : July-September
July- involved must be tagged out of service
immediately until inspected by a competent
GREEN : April-June
April- YELLOW : October -December authority to determine serviceability;
 Adjustable shock absorbing lanyards
 Personnel required to use height related equipment must inspect such equipment, each time (reduced in length for minimal slack) or
prior to use; inertia reel blocks are to be used whilst
working in EWPs due to the possibility of
 Items that are out of date or are missing the quarterly tag must be taken to the store and ex- limited ground clearances;
changed for gear that has the current inspection tag; and
 The JSA / Prestart Card for your work at
 Any of the following examples of damage during equipment inspection must be tagged out of height must include the rescue method for
service immediately and returned to the store for re-certification or destruction: a worker who has fallen, without placing
the personnel retrieving the worker at risk;
and
 No person is permitted to work at height Illustration of clearance required below worker when equipment has
whilst alone. deployed
5. Care
 Ensure all equipment is stored correctly and not
Markings with highlighter Markings with spray Corroded safety hooks / left on the ground or on the floor of EWP baskets;
(acetone based) markers paint or similar seized latches
 All textile products should be kept clean – warm
soapy water is recommended for cleaning – DO
NOT use harsh cleaning products or chemicals;
 All Inertia Reel devices must be returned to the
manufacturer annually for inspection, service and
tagging; and Adjustable Lanyard
Corroded fittings, excessive Illegible markings on Unacceptable / prohibited ad-hoc
 All textile products (Harnesses, Lanyards etc) have Twin Tail Lanyard
build up of dirt attached labels repairs / modifications a ten year life from the date of manufacture and Inertia Reel with Recovery
do not need to be returned to the manufacturer for in-
spection.
6. Relief straps
At least one relief strap device (as shown left & right),
must be fitted to all harnesses in use to reduce the risk of
suspension trauma.
Straps exposed to chemicals, Straps exposed to chemicals, Physical damage to webbing
Article supplied by Frank Horky
Safety Manager
can effect webbing strength can effect webbing strength and fittings
LBBJV
Relief strap Brisbane , QLD Relief strap deployed
6 LIFTING MATTERS December 2009 LIFTING MATTERS December 2009 7