Operate a Gantry or Overhead Crane PDF

Operate a Gantry or Overhead Crane OPERATE A GANTRY OR OVERHEAD CRANE Learner Guide Operate a Gantry or Overhead Crane Table of Contents 1. Introduction......................................................................................................................... 4 1.1 You will learn about:.......................................................................................................... 4 1.2 Overhead and Gantry Cranes.............................................................................................. 4 The Hook Block............................................................................................................................ 5 The Hoist....................................................................................................................................... 5 The Carriage.................................................................................................................................. 6 The Bridge..................................................................................................................................... 6 The Runway................................................................................................................................... 6 The Main Isolator Switch.............................................................................................................. 6 Safety Devices............................................................................................................................... 7 Remote Controls............................................................................................................................ 7 1.3 Doggers and Riggers........................................................................................................... 7 What is a Dogger........................................................................................................................... 7 Dogging Duty of Care................................................................................................................... 8 Crane Operating and Dogging....................................................................................................... 8 2. Policies and Procedures...................................................................................................... 9 3. Hazard Identification and Control.................................................................................... 10 Identify Hazards.......................................................................................................................... 10 Control Hazards........................................................................................................................... 10 Personal Protective Equipment.................................................................................................... 11 Environmental Hazards............................................................................................................... 12 Reporting Hazards....................................................................................................................... 12 4. Confirm Job Feasibility..................................................................................................... 13 5. Finalise and Confirm Lifting Plan.................................................................................... 13 6. Choose and Check Equipment.......................................................................................... 14 Select and Check Attachments.................................................................................................... 14 Lifting beams............................................................................................................................... 15 Spreader Beams........................................................................................................................... 15 Other Lifting Attachments........................................................................................................... 16 Choose Lifting gear..................................................................................................................... 16 7. Inspections........................................................................................................................ 20 Conduct Routine Checks............................................................................................................. 20 Pre-start checks............................................................................................................................ 21 Check the Service Log Book....................................................................................................... 21 Operational Checks..................................................................................................................... 21 Crane Movements........................................................................................................................ 22 Safety Devices............................................................................................................................. 22 Page 2 of 27 Operate a Gantry or Overhead Crane Recording and Reporting Faults.................................................................................................. 23 8. Prepare the Load............................................................................................................... 23 Prepare the Load Placement Area............................................................................................... 23 Crane Safe Working Load Limits................................................................................................ 24 Load Calculations........................................................................................................................ 24 Attaching Lifting Gear to the Crane Hook.................................................................................. 25 Position the Crane Hook above the Load.................................................................................... 25 Attach Lifting Gear to the Load.................................................................................................. 25 Check the Work Are Before Lifting............................................................................................ 26 Conduct a Test Lift...................................................................................................................... 26 Transfer The Load....................................................................................................................... 27 Safe Load Transfer Techniques................................................................................................... 27 Protect Personnel......................................................................................................................... 28 Lift The Load............................................................................................................................... 28 Using the Remote Control........................................................................................................... 29 Move the Load............................................................................................................................. 29 Dual Hoists.................................................................................................................................. 31 Follow Directions and Signals..................................................................................................... 31 Steadying a Load......................................................................................................................... 32 Lower and Place the Load........................................................................................................... 33 Remove Lifting Gear from the Load........................................................................................... 34 Load Destination......................................................................................................................... 34 Restraining Loads on Vehicles.................................................................................................... 34 Shut Down the Crane................................................................................................................... 35 Partial Shut Down........................................................................................................................ 35 Full Shut Down............................................................................................................................ 35 Conduct Post Operational Checks............................................................................................... 36 Reporting Faults.......................................................................................................................... 36 9. Carry Out Routine Maintenance....................................................................................... 37 Carry Out Lubrication Tasks....................................................................................................... 38 Carry Out Housekeeping Tasks................................................................................................... 38 Dispose of Environmentally Sensitive Fluids and Materials...................................................... 38 Process Records........................................................................................................................... 39 Practical Assessment Instructions............................................................................................... 40 Page 3 of 27 Operate a Gantry or Overhead Crane 1. Introduction These training materials are based on the national units of competency RIIHAN305D Operate a Gantry or Overhead Crane 1.1 You will learn about: Planning and preparing for operations. Preparing for lifting. Operating the crane to move loads. Carrying out maintenance. Cleaning up. This training qualifies you to Operate a gantry or overhead crane with 3 or less powered operations, where hoist/raise and lower is one operation. A national High Risk Work Licence is required to operate a bridge or gantry crane if it is: Controlled from a permanent cabin or control station on the crane, or Remotely controlled and has more than 3 powered operations. 1.2 Overhead and Gantry Cranes An Overhead Crane (also called a Bridge Crane) is a crane comprising of a bridge beam mounted at each end to an end carriage, capable of travelling along elevated runways and having one or more hoisting mechanisms arranged to traverse across the bridge. A Gantry Crane is a crane comprising a bridge beam, supported at each end by legs, mounted on end carriages, capable of travelling along runways at surface or deck level, and which has a crab with one or more hoisting units arranged to travel across the bridge. Gantry cranes may have fixed runways with or without rails. Page 4 of 27 Operate a Gantry or Overhead Crane Overhead and gantry cranes commonly include the following components: The hook block The hoist The carriage The bridge The runway The main isolator switch Safety devices Remote controls To make sure you know the specific details for the crane you are operating you should access the technical information. This will be found in the operator's manual or manufacturers' specifications The Hook Block The hook block is used to raise and lower the hook. It consists of: Sheaves or pulley wheels. A hook. A safety latch. Running through the pulley of the hook block is the hoist rope. The hoist rope consists of many small wires formed into a flexible and strong rope. To reduce wear on the hoist rope it should be kept lubricated. The Hoist The hoist rope is wound up and down by the hoist. The hoist consists of: The hoist travels on the crane bridge. The motor that drives the hoist from one side of the bridge to the other called the cross travel motor. The cross travel brakes are part of the cross travel motor. A serial hoist is an all in one hoist and cross travel unit. The other kind of cross travel unit is the crab hoist where the hoist is mounted onto a trolley with wheels. On a crab hoist, the cross travel brakes may be separate from the cross travel motor. The hoist brake operates when the hoist is not being raised or lowered. Page 5 of 27 is Operate a Gantry or Overhead Crane When you press the "raise" or "lower" button, the brake is released. The hoist drum is usually grooved so that the rope does not wear quickly or become tangled. The over-hoisting limit switch stops the hook block from being raised too high by stopping the power. Do not use the over hoisting limit switch as a convenient method of stopping the hoisting motion. Continual over-hoisting will wear the limit switch and cause the hoist drum and rope guide to be damaged. The Carriage The carriage is the main unit of the crane comprising the hook block, hoist, bridge and motors. The Bridge The bridge extends across the crane structure from rail to rail. It sits on an end carriage that has track wheels. The bridge of the crane should show the Safe Working Load (SWL). This tells you the maximum load that the crane can lift. DO NOT operate a crane without a Safe Working Load notice The Runway When the carriage travels the length of an area it is called long travelling. For this a crane needs a runway. On a gantry crane the runway would be the concrete floor. On an overhead crane the runway is two strong steel beams supported from the columns of the building. The long travel motors drive the crane along the long travel rails. They usually have internal brakes. There are usually two long travel motors, one for each end carriage. Older cranes may have only one motor with long shafts that drive the wheels on both sides of the crane. Once a crane has reached the limit switch position, it will automatically shut off. It can be reactivated at a slow speed. Electricity is supplied through bus bars and contact is made through collector shoes. Only maintenance personnel are authorised to work in this area. The Main Isolator Switch The main isolator switch controls the electric power to the bus bars and any crane using them. There may be one switch to each crane or a number of cranes may share a switch. Page 6 of 27 Operate a Gantry or Overhead Crane Some switches have a key lock so that the bus bars and crane can be made safe when they are not being used, or when they are being worked on. Safety Devices Most cranes are fitted with emergency stop buttons, which are provided so that other people can stop the crane if they see any danger. Usually, the crane operator presses the stop button on the remote control in an emergency situation. A warning device warns people away from the crane while it is working. The warning device fitted to your crane could be a bell, buzzer, or siren. Remote Controls Remote controls can be pendant, infrared or radio controlled. Both infrared and radiocontrolled remote controls have a limited range. Infrared controls must be pointed towards the crane during operation, or the crane will stop. Pendant controls are connected directly to the crane and the operator must walk with the crane as it travels. When using a remote control, it is important to be in a position to review the load and the travel path. A direction notice tells you which way the crane will move when you push each remotecontrol button. 1.3 Doggers and Riggers You will often need to work with doggers (or riggers) during your crane operations. It is important to know what daggers are responsible for and what you need to do to assist them so that you can safely carry our lifting operations. What is a Dogger A dogger (or rigger) is someone who is qualified and holds a High Risk Work Licence to carry out dogging work. Dogging work includes: Assessing the weight of a load. The selection and/or inspection of lifting gear. The application of slinging techniques. The directing of a crane/hoist operator in the movement of a load when the load is out of the operator's view. Communicating with the crane operator in regards to the capabilities of the crane. Page 7 of 27 Operate a Gantry or Overhead Crane Dogging Duty of Care It is the Duty of Care of a person who is involved with the slinging of a load to ensure they have their dogging licence in the following situations: When selecting/inspecting slings and the selection of a slinging technique. When directing the crane operator in the movement of the load, particularly when the load is out of view of the crane operator. It is the responsibility of the person who can legally sling the load, generally the dagger, to determine the weight of the load to be lifted. Crane Operating and Dogging In some situations you may be able to sling the load without a dogging licence. This is only in cases where there is no decision required specific to any of the following: The selection of slinging equipment. The inspection of slinging equipment. The lift points (as they are clearly defined). Directing the crane operator in the movement of the load. Determining the weight of the load. For example, you may move the same type of load regularly that always has the same weight, shape and size. In some workplaces crane operators will be instructed on the correct equipment and technique to use with that particular by a dagger, and must always sling the load as instructed. You must have a dogging licence, or be supervised by a person with a dogging/rigging licence, as soon as you need to do ANY of the following: The crane operator is responsible for communicating with the person who is slinging the load (the dagger) and providing information on the crane capacity. If you are not sure if you are allowed to sling a load or not, speak to your supervisor. Page 8 of 27 Operate a Gantry or Overhead Crane 2. Policies and Procedures You must follow all safety rules and instructions when performing any work. If you are not sure about what you should do, ask your boss or supervisor. They will tell you what you need to do and how to do it in a safe way. Before starting your work, you need to make sure you have access to all load handling and crane operation documentation for the job. This will help you to do your work in the safest way and make sure all work is compliant. Load handling and crane operation documentation may include: Your worksite will also have instructions for working safely including: Emergency procedures, including using firefighting equipment, first aid and evacuation. Handling hazardous materials. Safe operating procedures. Personal protective clothing and equipment. Safe use of tools and equipment. Page 9 of 27 Operate a Gantry or Overhead Crane 3. Hazard Identification and Control Before you start work, you need to check for any hazards or dangers in the area. If you find a hazard or danger you need to do something to control it. This will help to make the workplace safer. Identify Hazards Part of your job is to look around to see if you can find any hazards before you start any work. A hazard is the thing or situation with the potential to cause injury, harm or damage. When you start checking for hazards, make sure you look everywhere. A good way to do this is to check: Up high above your head. All around you at eye level. Down low on the ground (and also think about what is under the ground). Some hazards you should check for in the work area: Control Hazards Alter you have found hazards or dangers you need to work out how bad they are: Thinking about these things will help you to choose how to control the hazards. Hazards controls need to follow: Legislation Australian Standards Codes of Practice Manufacturers Specifications Industry Standards The best way to control hazards is to use the Hierarchy of Hazard Control. The Hierarchy of Hazard Control is the name given to a range of control methods used to eliminate or control hazards and risks in the workplace. Page 10 of 27 Operate a Gantry or Overhead Crane You start at the top of the list and see if you can take away (eliminate) the hazard or danger. If you can't take it away you move down the list to see if you can swap it for something safer (substitution). Keep working through the list until you find something that controls that hazard or danger. This table shows you the 6 different types of controls in order from best to worst: Hazard control measures need to be put in place before you start your work, or as soon as you see a hazard while you are doing your work. Hazard controls can sometimes be listed in your work instructions, or you can ask your boss or supervisor for help. Once a hazard control is in place you will need to check to make sure it is working well to control the hazard or danger. Talk to your supervisor or safety officer if you are not sure if it is safe enough to carry out your work. If you think the hazard is still too dangerous you should not try to do the work. Personal Protective Equipment Personal Protective Equipment (PPE) is clothing and equipment designed to lower the chance of you being hurt on the job. It is required to enter most work sites. It includes: Head protection - hard hats and helmets. Foot protection - non-slip work boots. Page 11 of 27 Operate a Gantry or Overhead Crane Hand protection - gloves. Eye protection - goggles, visors or glasses. Ear protection - plugs or muffs. Breathing protection - masks or respirators. Hi-visibility clothing - clothing that makes you stand out and lets other people know where you are. Weather protection - clothing that protects you from the sun or from the cold. Make sure any PPE you are wearing is in good condition, fits well and is right for the job. If you find any PPE that is not in good condition, tag it and remove it from service. Then tell your supervisor about the problem and they will organise to repair or replace the PPE. Environmental Hazards Environmental protection requirements are part of every worksite. Make sure you check with your supervisor about what environmental issues need to be managed during your work. All environmental details should be listed in an 'Environmental Management Plan' for the site. It can include details for: Waste Management Water Quality Noise Control Vibration Control Dust Management Reporting Hazards Any hazard or environmental issue that you identify will need to be reported. If you have taken any action you will also need to report those details. This could include written or verbal reports. Your worksite may have standard paperwork that needs to be filled out, for example: ♦ Hazard report forms. ♦ Work method statements. ♦ Other documents. Your report may need to be given to a safety officer or a member of the management team. Page 12 of 27 Operate a Gantry or Overhead Crane 4. Confirm Job Feasibility Once you have completed your preliminary lifting plan in accordance with procedures and site requirements you will need to confirm that the job can be carried out the way you have planned. This is called confirming the job feasibility. Confirming the job feasibility includes: Checking with any other personnel involved in the work to make sure they are: o Available. o Experienced, competent and qualified. o Aware of the requirements of the job. Organising to contact: o o o The load designer. Site management. Suppliers. The load designer is the person who determines the best way to pack and unpack items from a pallet or container. They work out how items will fit together in the best way, as well as making sure the pallet or container is properly balanced. You may need to speak to the load designer to make sure you: Unload items in the correct order. Load items correctly. The load designer may also have information about: The load weight or size. The weight distribution for the load. Speak with your supervisor once you have completed your plan to make sure it is achievable in the timeframe available to you. 5. Finalise and Confirm Lifting Plan Once you have confirmed the feasibility of the lifting plan you will need to finalise and confirm this plan including the organisation and scheduling of resources. Speak with, or organise contact to be made with all parties involved in the work including supervisors, contractors, personnel and suppliers. A major part of confirming the lifting plan is to make sure all parts of the job meet the site and project quality requirements and relevant codes and standards. If you are unsure, speak with your supervisor before signing off on the plan. Page 13 of 27 Operate a Gantry or Overhead Crane 6. Choose and Check Equipment Once you have confirmed your job requirements you need to choose the right equipment and attachments to get the job done. When choosing equipment and attachments you need to think about: The task requirements, specifications, and goals. The appropriateness of the equipment for the completion of the task. The characteristics, correct use, operating capacity and limitations of each item. The potential risks to yourself and others in the intended use of the equipment. As overhead and gantry cranes are fixed items you will usually not have any choice as to the crane you use. You will still need to check the crane and select any other equipment you will use to make sure they are safe and able to move the loads involved in the work. Information about technical capabilities and limits can be found in the operator manuals supplied by the manufacturer of each item. It is not safe to operate plant, equipment or attachments outside site procedures and the manufacturer's specifications. This may cause the machinery to break and could also cause an accident or injury. Select and Check Attachments When selecting an attachment you have to work out if it is suitable for the tasks you need to complete by confirming: You will find this information in the operator's manual for the crane and the operator's manual for the attachment. Otherwise, you may need to check the workplace equipment procedures for your site Once you have decided that the attachment is right, you need to attach it securely using approved methods. Once again, the operator's manual for the specific crane you are operating will have exact instructions on the connection process which must be always followed. Page 14 of 27 Operate a Gantry or Overhead Crane Inspect all lifting attachments for damage including: Deformations. Weld fractures. Worn lifting points. The most common attachments used are: Lifting beams Spreader Beams Lifting beams Lifting beams are devices that spread the load evenly for a given lift. They are generally made to suit a particular job. Most have a central lifting point for the crane or lifting medium, and have two or more lugs underneath to take the load slings. Lifting beams have a centre lifting lug at the top to accommodate a crane hook and has a bottom lug at each end for connecting slings. Headroom for the lift is reduced as no top slings are required. All lifting beams must be suitable to lift the particular load and must be branded with the Working Load Limit. The Working Load Limit must include the weight of the load plus all lifting gear (slings, shackles etc.) Spreader Beams Spreader beams literally "spread" a two-legged top sling. A spreader beam has better stability than a lifting beam and a higher potential capacity for a given size of steel section used. Spreader beams require more headroom than lifting beams due to the two-legged sling arrangement at the top. Check that spreader and lifting beams display the following details: Tare weight of the beam. Safe Working Load/Working Load Limit. Approval plate. Registration number Page 15 of 27 Operate a Gantry or Overhead Crane Other Lifting Attachments Other lifting attachments include: ‘H’ Frames Pallet Lifters ‘C’ Hooks Inspect all lifting attachments for damage including: Choose Lifting gear Lifting gear needs to be selected based on the type, size, weight and shape of the load to be lifted. Remember: Only a licensed dagger or rigger is authorised to select and inspect lifting gear, determine the weight of loads and select and apply slinging techniques. Each piece of lifting gear is rated to a specific capacity known as a Working Load Limit (WLL). This WLL can change depending on how the lifting gear is connected and arranged. This is why a licensed dagger or rigger needs to decide what lifting gear is being used and how it will be used. Page 16 of 27 Bucket and Kibbles Operate a Gantry or Overhead Crane Lifting gear that may be used with the crane includes: Lifting Gear Description and Use Fibre Rope Fibre rope is used extensively for taglines, whips, tackles and lashings. Natural Fibre Rope Natural or vegetable fibre ropes are grouped into those made from hard fibres and those made from soft fibres. Manila and sisal are the only types of natural fibre rope that can be used for dogging and rigging purposes. Other natural fibre ropes such as cotton, jute, flax and hemp can only be used for lashing and tying. A 16mm dry natural fibre rope is usually used as a tagline as it is nonconductive. Generally made from filaments twisted into yarns, the yarns twisted into a strand then three strands into the rope like natural fibre ropes. Synthetic Fibre Rope Synthetic ropes can be much thinner and yet have a greater WLL than natural fibre rope because they do not have overlapping fibres and because some filaments are stronger than natural fibres of the same thickness. Synthetic fibre ropes have a smooth slippery surface which can cause slip and failure of most bends and hitches and are not suitable for hand haulage. Prevent this with additional half hitches or seize the tail with yarn, twine or marline. Under some conditions synthetic fibre rope can conduct electricity and therefore should not be used as taglines near powerlines. Flexible Steel Wire Rope (FSWR) Rope constructed of steel wires and strands laid around a central core. The core of a FSWR can be: ♦ Fibre Core (FC). ♦ Independent Wire Rope Core (IWRC). ♦ Plastic Core (PC). FSWR Lays Left Hand Ordinary Lay FSWR Uses Right hand Ordinary Lay Left Hand Langs Lay Right Hand Langs Lay FSWR has many uses, including: Slings for lifting. For hoist drum ropes. For excavator, dragline, and pile driving ropes. Page 17 of 27 Operate a Gantry or Overhead Crane Chain Lifting chain is proof tested short link chain. The barrel of short link chain requires a greater force to bend, provides greater strength, reduces the tendency to twist and provides better reeving performance. There are various grades of lifting chains, with Grade 80 (or T grade chain) used extensively for all load lifting tasks. Chain Shorteners There are 2 main types of chain shorteners: Grab Hooks - Look like normal sling hooks but are designed so that the throat of the hook will securely hold a link of the chain without twisting the chain. Clutch Hooks - Are designed to hold a chain link without damaging the link. When using clutch hooks to shorten chain the Safe Working Load (SWL) is not reduced. Chain Joiners or Hammerlock A chain joiner or hammerlock is very much like a chain link that can be taken apart. Chain joiners may be used: To join pieces of chain together to make a longer chain. To hold different parts of a chain together. To connect the chain to the master link. Slings Slings are used to connect loads to the crane hook. They can be connected in different arrangements and may use hooks and shackles as part of the connection and slinging arrangement Synthetic Webbing Slings Flat webbing and round synthetic slings are used for lifting where it is necessary to protect the load from damage and for protection from electrical hazards. They are made from nylon, polyester, polypropylene or aramid polyamide. Each sling must be labelled with the Working Load Limit. Flexible Steel Wire Rope Slings Flexible Steel Wire Rope slings are available in several different configurations including: Soft eye 4 Leg sling 2-leg sling Open swage socket Closed swage socket Master link captive Hook captive Thimble eye Page 18 of 27 Operate a Gantry or Overhead Crane Chain Slings Chain slings should be made up to AS 3775 Chain slings Grade as per manufacturer's recommendations. The working load limit tag must be fixed on all chain assemblies. The tag must detail the SWL under all conditions of loading. If a tag is missing the sling should be taken out of service unless the necessary information is marked on the master link. Once the tag is replaced, the sling can immediately be returned to service. A competent person should replace the tag. Shackles Shackles are a portable link, used for joining various pieces of lifting equipment. The two main shapes for load lifting are the 'Dee' and 'Bow' shackles. Hooks There are many different shapes and sizes of hooks. They range from mild steel to very high grade alloy steel. Safety hooks are fitted with a safety latch or device across the mouth of the hook. Some hooks come with a swivel fitting which prevents a chain, rope or tackle from twisting and will allow any twists to unwind. DO NOT use a hook without a safety latch. Hooks used with chain to make chain assemblies are usually Grade T or Grade 80 strength. The lifting capacity of a hook should be stamped or marked on the hook. Do not use a hook if the Safe Working Load is not marked, or has worn away and is unreadable. Eyebolts Often used as lifting lugs on set pieces of equipment. The safest eyebolt is a collared eyebolt. Uncollared eyebolts should only be used where the pull on the eyebolt is vertical. Only collared eyebolts should be used where the pull is at an angle. The eyebolt should be tightened so that both faces meet in a neat tight fit. If both faces are apart the collar is of no use. Where two eyebolts are used to lift a load, a pair of slings should be shackled into them. Do not reeve a single sling through two eyebolts and then put both eyes on the hook. Loads can spin when lifted with a single eyebolt, causing the eyebolt to unscrew from the load. Mouse or lash the eyebolt to the load to stop it unscrewing. Lifting Gear Description and Use Fibre Rope Natural or vegetable fibre ropes are grouped into those made from hard fibres and those made from soft fibres. ♦ ♦ Other natural fibre ropes such as cotton, jute, flax and hemp can only be used for lashing and tying. ♦ A 16mm dry natural fibre rope is usually used as a tagline as it is non-conductive. Manila and sisal are the only types of natural fibre rope that can be used for dogging and rigging purposes. Page 19 of 27 Operate a Gantry or Overhead Crane 7. Inspections The dogger/rigger will inspect and check the lifting gear before it is used to make sure that it is safe to use. DO NOT use any lifting gear that is damaged or in poor condition. Any equipment that is not safe to use should be labelled, rejected and segregated from other equipment. If you notice any lifting gear that appears to be damaged or in poor condition speak to the dagger or your supervisor, so the defective equipment can be disposed of, repaired or replaced. Conduct Routine Checks Before starting work you will need to make sure all equipment is in safe working order. Before you use any piece of plant or equipment, you need to conduct routine checks to make sure it is safe to use. Check the machine logbook before you start your inspection to see if there are any faults that still need to be fixed before you can use the crane. Also make sure you are wearing the correct PPE before you start checking the machine. Routine checks are made up of: Generally, routine checks are performed at the start of each day or shift. You may be required to use an inspection checklist to make sure all parts and components have been checked and to record the results for the checks. Page 20 of 27 Operate a Gantry or Overhead Crane Pre-start checks Pre-start checks are done before the engine is started. Walk around the crane and look for anything that is out of the ordinary. All crane equipment should be checked for damage and defects before any operations are carried out. Part or Component What to Check ♦ Crane Structure ♦ ♦ ♦ Crane Runways. Bridge, End Carriage, Crab/ Hoist Unit, Bus Bars Hook Block Any approved modifications and/or attachments are fitted in accordance with manufacturer's specifications. Check for adaptions/modifications outside of the manufacturer's specifications. Clear of obstacles. Signs of damage or wear. ♦ ♦ ♦ ♦ Sheave covers showing signs of excessive wear. ♦ Making sure the hook or "bight" is rounded so that it does not cut into or damage Crane Hook Hook Safety Latch Visible signs of damage such as evidence of structural weaknesses, paint separation and stressed welds. The Safe Working Load (SWL) and directional compass is displayed on the crane. Sheaves are worn, damaged or stiff to turn. Hook does not have excessive wear, cracks, nicks and isn't twisted. Hoist rope free of abrasion, wear or damage. slings and fittings. ♦ Turning the crane hook to check that it freely rotates at all times. ♦ ♦ Serviceable. Not bent or broken. For exact details on the components for the crane you are operating, check the operator's manual as different makes and models may have different requirements. Check the Service Log Book The service logbook is used to record any service maintenance carried out on the crane as well as any reported faults and actions taken to return the crane to service. Make sure any recorded faults have been addressed and fixed and the crane is fit for use. There should also be a history record system where the service and maintenance history is kept. Operational Checks Operational checks are made once the crane is started. Before you start the crane you will need to locate the remote control. Before you begin using the crane or at the start of the shift you may need to change the battery and put the used battery in the charger. Check that the remote control device is working properly, the casing is intact and that the control buttons are operational and clearly labelled. Start up the crane according to manufacturer's specifications and operating requirements. Page 21 of 27 Operate a Gantry or Overhead Crane Check that the following are functioning properly: Also check for any abnormal noises or movements. Crane Movements The hoist of the crane moves the hook block and crane hook UP or DOWN (raising and lowering). The brake is released when raising or lowering the hook block. The Limit Switch will prevent the hook block being raised too high. The crane can also travel in a North, South, East or West direction. Check the cross travel by moving the hoist across the bridge. Check the long travel by moving the carriage along the rails. Safety Devices Check that all safety devices are located, identified and tested in accordance with manufacturer's specifications. Make sure all safety and limiting devices are functioning correctly including: The upper hoist limit switch. The lower hoist limit switch. The anti-collision device (where fitted). Emergency stop button. Isolation pin (test the remote control does not function with the pin removed). Hazards warning systems such as lights and horns. Audible reversing alarms (where applicable). Beacon light (where fitted). Check the movement of attachments (e.g. external lifters) are smooth and comply with operating requirements. Check the emergency stop by pressing the red cap key on the remote control. To restart the crane, turn the red cap key to the left (cap will spring up) and press the horn to activate the lifting functions. Report and record all defects and damage according to site procedures. Page 22 of 27 Operate a Gantry or Overhead Crane Recording and Reporting Faults Once all routine checks are finished, you will need to report any problems, faults, defects and damage that you found during the inspection so that they can be reported, repaired and the crane and equipment are safe for you or the next operator to use. If you find any faults during the routine checks you must: 1. Immediately stop. 2. Isolate the equipment and attach an out of service tag to it so that nobody uses it by mistake. 3. Record the fault in the service logbook. 4. Report the fault to an authorised person for corrective action. Do not use any faulty equipment until it has been fixed and returned to service. 8. Prepare the Load Before you move the load, you need to ensure that everything is ready and it is safe to carry out the load movement. To do this you should: Prepare the area where the load will be placed, including positioning trucks to be loaded. Make sure you are working within the limits of the crane. Position the crane hook above the load. Attach lifting gear to the crane hook. Prepare the Load Placement Area Check the necessary documentation (e.g. job sheet, delivery docket, load tag) to check where the load needs to be transported. Check the placement area is an appropriate location, clear of obstacles, and the correct amount of dunnage is positioned as needed. Dunnage, such as blocks or packing, is used to protect loads and to enable lifting gear to be removed easily from the load. Chocks should be put in place for round loads to prevent the load from rolling or shifting once the lifting gear is removed. Check dunnage is strong enough to support the weight of the load. Page 23 of 27 Operate a Gantry or Overhead Crane Crane Safe Working Load Limits It is important to ensure that you do not lift a load that is above the capacity of the crane you are operating. You will need to work with the dogger (or rigger) to ensure the load is within the crane capacity. The dogger is qualified to assess and determine the weight of the load. You must assist the dagger by providing information on the crane capacity and they will work out if it is safe to lift the load and the best lifting equipment and slinging arrangement to use. The crane capacity will often be labelled on the crane, or you can find this information in the operator's manual, manufacturer's specifications, or crane load charts. You should always access and confirm the information so that you do not exceed the capacity of the crane. If the dogger determines that the load is too heavy for the crane another crane or piece of equipment will need to be used, or if possible, the load could be broken up into smaller parts which the crane can then safely move. Load Calculations While the dogger will work out the weight of the load it is helpful to know some basic calculations relating to safe working loads. Two common calculations relate to working out the volume and weight of a load. Volume: Volume is the space that something takes up and is calculated using the formula: Weight: It is important to know how to convert measurements of weight (e.g. kilograms to tonnes) and volume (litres to megalitres) when preparing to lift loads. This will help you to work out the weight of a load if it is in a different measurement to what the specifications or work instructions tell you. There are conversion tables available for converting non-metric measurements (e.g. feet, inches, miles) and some calculators will do it for you. Page 24 of 27 Operate a Gantry or Overhead Crane Attaching Lifting Gear to the Crane Hook After consulting with the dogger the lifting gear will need to be attached to the crane hook. It is essential to the safety of everyone in the work area that lifting gear is correctly attached to the crane hook. This is to minimise the risk of equipment failure. Inspect the crane hook for damage, wear, stretching or cracks. Make sure the safety latch is in place and working properly. If you suspect that the hook is not in a serviceable condition, report the defect to your supervisor. Attach the lifting ring to the crane hook block and make sure the safety latch is correctly in place. If you are using a spreader beam you will need to move the crane so that the hook is over the centre of the beam before attaching the beam lifting ring to the crane hook. If you are using dual hoists you should attach the lifting beam rings to the crane hooks and check the safety latches are firmly engaged. Position the Crane Hook above the Load Once the lifting gear has been attached to the crane hook you will need to position the hook and lifting gear above the load. The crane hook should be positioned above the centre of gravity of the load to keep the load from swinging when it is lifted. The dogger will help you in determining the centre of gravity. Sometimes the only way of finding the centre of gravity of the load is by performing a test lift. Lower the crane hook until it is low enough for the lifting gear to be attached to the load. There should be enough of the lifting gear to connect it safely and effectively to the load. Attach Lifting Gear to the Load The dogger is responsible for the application of slinging techniques, which means that they will be the one to attach lifting gear to the load. You might be required to assist the dogger. Some things to remember in relation to connecting loads include: Make sure that any sharp corners are packed to prevent any unnecessary damage to slings or the load. Check the manufacturer's specifications for special loads to locate specially designed lifting points. DO NOT attach the load directly to the crane hook. The safety hook can be used to directly attach a load where a suitable shackle can be fitted, or a lug is available. Page 25 of 27 Operate a Gantry or Overhead Crane When using a pallet lifter attachment make sure that you: Always check the location of the lifting ring on the forks to maintain a balanced load. Without a load the lifting ring should be towards the back of the forks. With a load the lifting ring should be towards the front of the forks. Check that the forks are inserted properly before commencing the lift. Check the Work Are Before Lifting Before you commence with the lift you should check the work area and the path of movement to make sure that any hazards have been removed or controlled. This will help to ensure that there are no new hazards that have occurred while getting the load and lifting gear ready. Things you should check for before lifting a load may include: Oil leaks from the crane or equipment. Position of barriers and work area isolations. Position of other cranes if sharing the runway. If loading onto a truck, make sure it is in position and can safely leave the site or area once loaded. Other hazard controls are still in place. You need to make sure that any hazard controls are in place before starting to lift the load. If you find a hazard that requires a control, do not commence the lift. Stop your work, speak with your supervisor and organise for controls to be put into place. Conduct a Test Lift Before moving the load it is important to conduct a test lift. A test lift is done by lifting the load just slightly off the lifting plane (e.g. ground) and is conducted to determine if the load is safe to move. Test lifts can be used to ensure that: The load has been correctly slung. The load's centre of gravity has been correctly determined. Loads of unusual shape or weight distribution are correctly slung. Near capacity loads do not overload the crane. Load measuring equipment can be used to verify the calculated weight of the load. All crane equipment is functioning properly. Hydraulic or pneumatic systems (where relevant) are at the required operating pressure. Adjustments to the slinging can be made in a safe manner. Page 26 of 27 Operate a Gantry or Overhead Crane Conduct the test lift according to the following procedures: Where load measuring devices are fitted, the estimated weight should be verified and load calculations revised as required. You should only proceed with the load movement if the test lift indicates the load is stable and safe to proceed. Transfer The Load Once the load has been prepared and connected and any adjustments made after the test lift you can transfer the load. Make sure you follow the lifting plan for the task and continue to monitor the work area for any hazards that may arise. This includes making sure that any required hazard controls are in place. Safe Load Transfer Techniques There are a number of important points to consider to make sure that the load transfer is safe. These points and techniques include: To operate a remote bridge or gantry crane the person must be competent and qualified. Only use appropriate load shifting techniques and methods, including following relevant standards and workplace procedures. Take into account specific terrain, weather conditions and time of day or night when transferring loads. Consult with associated personnel, such as the dogger, to determine if a tagline or other method for controlling the load is required to prevent load swing or twisting during transfer. Make sure all required signals are correctly given and interpreted in Page 27 of 27 Operate a Gantry or Overhead Crane accordance with the appropriate Australian Standard. Make sure all planned hazard controls are implemented including PPE. Avoid damage to product and the crane during handling. Sound warning devices prior to lifting and moving a load to let others know that a load is being moved. Before moving the load, check that there are no warning signs along the load path which indicate that cranes cannot be used in the area or at that time. When a maintenance technician or contractor has been brought in to perform maintenance on the crane, you MUST NOT operate the overhead crane until it has been formally handed back to you (returned to service). Protect Personnel Make sure that you and other personnel are not put in danger while carrying out your work. Never wear loose clothing or jewellery that could be drawn into a machine and button long sleeves and tuck in your shirt to prevent such injuries. People can be seriously injured by falling loads. Never stand under a suspended load or lift a load over another person. If approaching another person or a person is in your path, stop and sound the horn. Proceed when the person is out of your path. Do not place yourself or any part of your body into an area where there is any likelihood of being caught or struck if things go wrong. Be careful of slip and trip hazards that may be present when operating the crane. Inspect the floor surface for oils, lubricants or other debris. Lift The Load When lifting a load you should: Stand clear of the load (in a designated position) and use the crane controls to raise the load up. Lift the load slowly. Check for any obstructions and people while lifting. Never lift a load over machinery or people. Stop the vertical lift of the crane before reaching the limit switch. Do not use the over hoisting limit switch as a convenient method of stopping the hoisting motion. Page 28 of 27 Operate a Gantry or Overhead Crane Using the Remote Control All crane controls and movements should have been checked during the operational checks. However, it is a good idea to double check the direction of the crane against the direction indicated on the remote control. The operator may depress the Down, Up, West, East, South and North buttons to the first position for slow operation and into the second position for faster operation. The operator then has to lift pressure from the buttons completely to stop the operation. All crane movements should be as smooth as possible to prevent the load form swinging or twisting. If the remote control will not respond check battery supply as the light will flash if the supply is low. Contact maintenance for a new battery if needed. If the remote control fails to operate correctly in any way: 1. Press the emergency stop. 2. Remove the red key cap. 3. Hand in the control and report the incident. The remote control is not to be used if it is not working correctly. For an Emergency Stop press the Red Button. Move the Load When moving a load you should keep the following safe operating techniques in mind: Continue to monitor the area and load: Check for obstructions and pedestrian traffic as you move the load. o Ensure pedestrians are kept well clear of the load while it is moving. If someone is in the path of the load, stop and sound the horn. o Only proceed once the person is out of your path. Check the load remains stable. Control the load balance and stability to avoid damage or potential injury. Keep the load under control by using a speed appropriate for the load. weight. Avoid sudden stops or speed starts. DO NOT drag the load. Walk behind the load when moving. If the overload light or indicator comes on you should stop operating immediately - lower the load to the ground, report the incident to an authorised person and await instructions. Page 29 of 27 Operate a Gantry or Overhead Crane If the load swings while the load has been moving, the operator may have to 'Chase the Hook': o Stop the horizontal movement of the hook before the destination. This will cause the load to swing forward. o Move the Bridge or Crab quickly to the furthest extent of the load swing and stop again. This will remove the swing from the load. Make sure your crane does not collide with others operating in the area. To prevent this kind of accident: Report all crane accidents and any faults or malfunctions in machine operation to your supervisor immediately. Cranes must not be used after an accident. The supervisor, or authorised personnel, must make sure the machine is in a safe operating condition before letting the work continue. A general process to follow to move loads involves: 1. Check the area before lifting the load to make sure it is free of obstructions and the lifting area is clear of other people. 2. Using the crane controls, hoist the hook block up slowly until the slings become tight. 3. Check that all lifting gear is properly attached. 4. Raise the hook block until the load is lifted off the ground. You shouldn't raise the load more than necessary as this can cause it to be less stable. 5. Mobile the load, following the lifting plan and any directions and signals from the dogger. 6. Monitor the work area for hazards, including people going into the path of travel. 7. Position the load over the landing area. Ensure smooth movements are used to prevent load swing. 8. Lower the load and secure as required. Page 30 of 27 Operate a Gantry or Overhead Crane Dual Hoists If you are using dual hoists to lift a load you will need to engage hoist operating mode before operation: Note: You must be an Intermediate rigger to lift using dual hoists Follow Directions and Signals There are different communication methods that can be load movement. used for directing the The most common communication methods are: Hand signals. Whistle signals. Two-way radio. Verbal directions. Always follow the directions given to you by the person dogging the load. They may use hand/whistle signals or two-way radios to direct you. If at any point you are unsure of the directions being given to you, stop and confirm the instructions with the dogger/rigger. Page 31 of 27 Operate a Gantry or Overhead Crane Shown below are the hand and whistle signals commonly used in Australia: Steadying a Load During the load movement the load maybe begin to sway, swing or twist and may need to be steadied. If the load is well balanced and is lifted, moved and lowered at an appropriate speed, there should be very little twisting or swinging of the load. If associated personnel are involved in the lift, such as the dogger, they may use a tagline to steady the load during the move and when landing the load. Some loads are too heavy to control by holding with your hand and the crane operator would be safer away from the load. A tagline might also be used if there is a light wind which may act on the load causing it to swing. Only a non-conductive rope can be used as a tagline. Page 32 of 27 Operate a Gantry or Overhead Crane At some sites a purpose built tool may be used to aid in load positioning. Lower and Place the Load Once the load has reached the landing spot you will need to safely bring the load to a halt over the landing spot. You should never stop the load by 'plugging' the controls. This means continuously pushing and releasing the control button. This causes the motor to run too slowly to activate the cooling fan. This can cause the motor to burn out and the contacts to overheat. A general process to follow to lower and place loads includes: 1. Position the load - over the landing spot. 2. Slowly lower the load - until it is on the ground or landing surface (such as tray of a truck). You may need to pause during the lowering to let the dogger or other personnel correctly position any dunnage or to adjust the load so it lands in the correct spot, particularly if it has twisted during the move. 3. Continue to lower the hook block - slowly until the sling/lifting gear is slack. 4. Remove the lifting gear - from the load or hook block. 5. Raise the crane hook - to a safe height so it is not a danger to people and will not damage property or equipment. Turn off the crane or move it to the next location - this will depend on the requirements of the site and your work. Other points to remember when lowering the load are: ♦ Always lower the load into the designated area. ♦ Smoothly and slowly lower the load. Fast or jerky movements could cause the load to swing, damaging the load or equipment or injuring personnel. ♦ Place the load correctly. This could include: In a defined storage area to avoid product damage. On the appropriate dunnage. With sufficient clearance around it for easy access and removal of lifting gear. Neatly stacking and aligning the load as required. o Making sure the load has sufficient support as needed (e.g. dunnage). ♦ Detach lifting gear and raise the crane hook to a safe height so that it is not a danger to people and will not damage property or equipment. ♦ The main hook should not be left to rest on the load or the ground. Resting the crane hook will make the wire loose, which could then double up on the drum and cause the rope guide on the hoist to break. NEVER leave a load suspended. Stay with the load until the move is finished. Page 33 of 27 Operate a Gantry or Overhead Crane Remove Lifting Gear from the Load Once the load has been safely lowered and placed the lifting gear will need to be removed from the load. Depending on the type of load and where it has been placed the lifting gear will be removed in one of 2 ways: The procedure you should use could be detailed in the lifting plan or workplace procedures, or will be decided in consultation with the dogger. A general procedure for removing lifting gear from the load includes: 1. Lower the crane hook block/attachment. 2. Remove the lifting gear from a load to prevent the hooks being snagged on the load when raising the crane hook up and out of the way. 3. Move the crane and lifting gear away from the load. After unhooking the load make sure the lifting gear is clear of the load before moving the crane away. Load Destination Make sure the load destination area is safe before leaving the area: Check the landed load is secure: o There is appropriate dunnage or chocks in place to prevent it from moving. Any applicable access restrictions are put in place for items such as hazardous substances, according to workplace procedures, such as locks, gates or barriers. Inspect walkways to determine they are clear at all times. o Check that stacked loads and dunnage is clear of passageways. o Check that cages, trolleys and pallets etc. are clear of passageways. Access to fire equipment and emergency exits is maintained. Restraining Loads on Vehicles You may need to work with vehicle operators when placing loads onto vehicles to ensure the load is correctly placed for weight distribution and load restraint requirements. This should be done as part of planning the load movement. Once landed on the vehicle, loads must be appropriately restrained to prevent load movement during transport. Page 34 of 27 Operate a Gantry or Overhead Crane Restraints include: Chains Webbing straps Rope. The vehicle operator will usually restrain loads but you may need to assist. Follow the vehicle operator's instructions and any relevant workplace procedures. All relevant rules and guidelines for load restraint should be followed, including rules relating to oversize loads. Shut Down the Crane All shut down procedures should be done in accordance with manufacturer's instructions and safe operating procedures. Partial Shut Down If you leave the crane temporarily (for example to answer a phone call, have a tea break or go to the toilet) you MUST do a partial shutdown. You MUST make sure that the crane is safe whenever it is left unattended, even for short periods. If an unattended crane becomes involved in an accident, the crane driver can still be held accountable if the crane was not properly shut down. Each time you leave the crane, carry out the proper partial shutdown procedure. Full Shut Down The crane must be fully shut down: A typical shut down procedure would include the following: 1. Move crane to an appropriate and safe storage area. 2. Apply motion locks and brakes (where applicable). 3. Raise the hook block high enough so it is well above and away from machinery and pedestrian traffic. Page 35 of 27 Operate a Gantry or Overhead Crane 4. Turn off the remote control by pressing the emergency stop button. Remove the red cap key and place it and the remote control locked away in a designated area. 5. Turn the crane off at the isolation switch. 6. Secure against unauthorised operation by locking the isolation switch with padlock if it is for an extended period of time as in the end of a shift or overnight. 7. Turn the main isolator switch off. 8. Apply storm brakes and rail clamps (if applicable). 9. Secure site in accordance with workplace procedures. Always check the specific procedures for the crane you are operating as each crane can differ slightly and may have a different shut down procedure. Conduct Post Operational Checks After you have finished your work and shut down the crane it should be checked and inspected to make sure it is ready for the next operator. As part of your job as a crane operator, you need to inspect the crane to find and report any faults or damage that may have occurred during your work activities. Your inspection should include: Post-operational checks should include all of the things you look for when conducting pre-start checks. Reporting Faults Once a fault has been found, it needs to be reported and fixed. Most sites have a fault report form that will need to be filled in with the details. The form will generally need the crane details, such as the make and model, the site identification numbers, the type of fault and the person reporting the fault. You also need to make sure the crane is tagged out (isolated from use) until the repairs have been made. Some sites will have a verbal system of reporting where you speak with a supervisor who then documents the fault, while others may require the operator to organise repairs of the fault directly. Do not use the crane until it has been fixed and approved for return to service. Page 36 of 27 Operate a Gantry or Overhead Crane 9. Carry Out Routine Maintenance You may be required to carry out servicing and lubrication of the crane to ensure the crane stays at its operating capacity for as long possible. Servicing requirements will be outlined in the operator's manual as well as workplace procedures. You should only carry out servicing which you are approved to complete. When conducting maintenance activities it is important to keep people in the area safe by using barricades or fences if necessary and locking out machines. Routine maintenance tasks include: Replacement of minor parts. Running diagnostics on warning, safety and control systems. Lubrication tasks. Appropriate hazard controls should be put in place before beginning any maintenance. These could include: Move the crane to a location where it will cause the least interference to other tasks on site. There could be a designated area or it may need to be coordinated with your supervisor and other operators. Place controllers/remotes in the "off" position. Place the main switch in the "off" or "open" position, depending on the crane, and lock out the crane, except where power is necessary for the maintenance tasks to be completed. Place appropriate warning signs on the controller or control station. Make sure the area is properly lit so that others can clearly see you. Inform others of what you are doing. If any other crane uses the same runway: Use protective devices to prevent interference with the idle crane undergoing repairs. If protective devices are impracticable, place a signal person at a visual vantage point to warn operators of active cranes when they reach the safe distance limit from the idle crane. If there is anything that you are not trained to change or repair, or you are not sure how to safely maintain the crane, speak with your supervisor. Page 37 of 27 Operate a Gantry or Overhead Crane Carry Out Lubrication Tasks Some parts of the crane may need to be regularly lubricated to keep it in safe working order. Check the operator's manual for details. Common parts or items that may require lubrication tasks may relate to the: A component that will commonly require lubrication is the crane hoist rope. Without lubrication the friction on the rope will increase, causing it to wear faster. Carry Out Housekeeping Tasks Housekeeping tasks may include: Cleaning up work areas. Disposing of waste materials. Recycling materials. All housekeeping activities should follow the procedures for the worksite. Dispose of Environmentally Sensitive Fluids and Materials You may be required to dispose of environmentally sensitive fluids or materials as part of your housekeeping tasks, such as oils used in lubrication activities. The environmental management plan will detail the requirements for the disposal of environmentally sensitive fluids and materials. It is part of your role to ensure that you are familiar with these requirements. You should also consult the Safety Data Sheet (SDS) for the fluid or material that you are working with for the best methods of disposal. Your site will have specific areas or procedures for disposing of fluids and materials. The 2 most common procedures on site will include: For any requirements that you are unsure of, you should check with your supervisor or other authorised personnel. Page 38 of 27 Operate a Gantry or Overhead Crane Process Records Site record keeping procedures keep the site running smoothly. Part of your role will include completing and processing records for your crane and the tasks that you have completed. As well as the maintenance records you have filled in, some other records, reports and paperwork that may be needed include: Computer readings - from process monitoring, test results, activity reports, and materials readings. Logs- supply logs, work activity logs, training logs, stockpile logs, usage or driver logs. Shift documents- end of shift, end of process, quality information. Fault reports. Hazard reports - including Take-5 forms. Incident reports - accident forms, incident reports, environmental incident reports, WHS investigation reports, quality assurance (QA) reports. It is important that you keep detailed records of all your activities, especially any problems you had during your shift. Make sure you keep notes about what happened and what you did to fix it. This includes faulty or broken equipment, operational issues (mistakes or not following procedures correctly for some reason) and any other unusual things. As well as completing the required records you also need to make sure you process them properly, so that they get to the right person and any required actions can be taken. Some sites will require you to report verbally to your supervisor or other authorized person, while others will require you to file or hand-over written records. Always make sure you process records according to your site requirements so that issues or problems can be followed up. Page 39 of 27 Operate a Gantry or Overhead Crane Practical Assessment Instructions The practical assessment consists of 2 individual assessments, which may run in a single sequence from task to task under the guidance of the assessor. Conditions of Assessment 1. 2. 3. 4. 5. 6. 7. You are required to undertake an assessment for operating a gantry or overhead crane in the civil construction industry. The assessor will provide you with instructions about what you are required to do. If you are unclear about what you have to do, ask the assessor before you start. Each person must be observed and be assessed as being competent in each task even in situations where the work is completed by a team. You may not use any references, books or course notes during the assessment, unless these resources are common to completing the task when performed in a real work environment. All assessments must be satisfactorily demonstrated. If you do not satisfactorily complete an assessment a result of 'Not yet competent' will be recorded. You should be able to complete all assessments within 2 hours. The time stated is a guide only. If you cannot complete the assessment in the stated time then this will be considered when assessing overall competency. Personal Protective Equipment (PPE) Requirements You must wear safety clothing and equipment as required by the risk assessment of the workplace or assessment environment. This includes: Safety helmet (where required). Appropriate footwear. High-visibility vest or other similar clothing. Other protective clothing and equipment as appropriate. Your assessor will confirm the availability of required PPE when making arrangements to conduct the assessment. If you do not have the appropriate equipment the assessment cannot be undertaken. Grounds for Stopping the Assessment If at any time during the practical assessment, you act in a way that puts yourself, other students, equipment or property in any danger, the assessment will be stopped immediately. Your assessor will identify and record the dangerous act to you and re-schedule the assessment to be attempted again at a later time. You may be required to complete part or all of the practical assessment again at that time, at the discretion of your assessor. Achieving a Satisfactory Outcome In order to achieve a satisfactory outcome for the practical assessment you will need to: Complete all tasks and assessments in their entirety. Complete all tasks and assessments satisfactorily in a timely manner, representative of real world conditions, expectations and outcomes. Complete all tasks and assessments safely, using the correct techniques and methods and ensuring your own safety and the safety of others at all times. Working with others, where necessary, to safely, effectively and efficiently achieve all outcomes of the tasks and assessments. Practical Assessments The practical assessments are outlined below: Assessment 1 &2: Operate an Overhead or Gantry Crane to Complete the Following Tasks More than One Occasion Prepare for the work by locating workplace policies and instructions for crane operations and confirming: Task requirements, including your own responsibilities in line with the National Standard for High Risk Work. Site policies and procedures. Inspect and prepare the work area in coordination with other personnel, including: Identifying and reporting hazards. Applying hazard controls, including selecting and fitting PPE. Applying environmental protection measures. Page 40 of 27

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