NCCCO Overhead Crane cheat sheet

Treat every power line as energized; OSHA crane minimum approach distance is 10 ft at 50 kV or less and increases 0.4 in per kV above 50 kV.

Outdoor lifting stops when wind exceeds the manufacturer's limit or when the load cannot be controlled with tag lines; capacity charts assume still air unless stated otherwise.

Lightning response: land the load, lower the hook, and secure or move the crane per the site plan; do not resume until the storm has passed.

Verify the floor, runway, or support surface can carry the crane plus load; check for trenches, voids, soft fill, and uncompacted areas.

Adequate illumination must reach the load, rigging, hook, and signal person; if these cannot be seen clearly, the lift does not proceed.

Ice, snow, mud, and grease reduce traction and brake friction; remove accumulations from walkways, rails, and crane surfaces before operation.

Barricade the swing radius and keep pedestrians out from under or near the load; a load must not pass over personnel.

Check clearance to roof trusses, piping, doors, and other cranes through the full travel path before moving.

Before first use each shift, inspect hook, wire rope, chains, brakes, limit switches, controls, warning devices, rails, bumpers, and record defects.

Remove a hook from service if throat opening increased more than 15 percent, twist exceeds 10 degrees, cracks are present, or the latch is missing or inoperative.

Inspect wire rope for broken wires, kinks, birdcaging, corrosion, crushed areas, and diameter loss; reject rope exceeding ASME B30.2 criteria.

Test the hoist brake by lifting a load slightly, stopping, and confirming the brake holds without drift.

Test upper and lower hoist limits and bridge and trolley travel limits without a load at safe speed.

Check runway rail alignment, end stops, rail sweeps, and clearance; remove obstructions from the travel path.

Verify control function and labeling, and test the emergency stop before placing the crane into service.

Do not operate a crane with a safety defect; document the defect and keep the crane out of service until repaired.

Gross load equals the load weight plus all rigging, slings, shackles, spreader beams, and attachments; capacity ratings apply to this total.

Determine weight from shipping papers, drawings, manufacturer markings, or a scale; do not rely only on appearance or volume.

For a known material, weight equals volume multiplied by material density, with consistent units.

Position the hook over the load's center of gravity; off-center lifts require multiple pick points or a plan to prevent tilt and load shift.

For a symmetric two-leg lift, tension per leg equals load divided by two times the sine of the sling angle from horizontal: T = W/(2 sin theta).

As sling legs approach horizontal, tension increases; at 30 degrees from horizontal each leg carries the load divided by two times 0.5.

Never exceed a sling's working load limit; the WLL changes with hitch type, angle, wear, and configuration.

Attach to designated lifting points, protect slings from sharp edges, and inspect shackles and slings before use.

Hoist vertically over the load's center of gravity; side pulls, dragging, and swinging loads create forces the crane was not designed to resist.

Raise the load a few inches, stop, and check load stability, rigging security, brake holding, and crane response before continuing.

Never leave a suspended load unattended and never allow personnel under or on a load; land the load before leaving the controls.

Use smooth acceleration and deceleration; shock loading from rapid starts or stops can exceed structural and rigging limits.

Travel with the load as low as practical and controlled; use tag lines to prevent rotation and drift.

Multiple-crane lifts require a written plan and a qualified person to determine load distribution and coordinate signals.

If the load becomes uncontrollable, stop motion, lower the load if possible, and keep personnel clear.

On power failure, set brakes, keep the area clear, and lower the load using the crane's controlled lowering procedure; do not allow free fall.

Rated capacity is the maximum gross load allowed for a specific crane configuration and includes load, rigging, and attachments.

Match the load chart to the crane model, serial number, reeving, trolley position, hook height, and site-specific restrictions.

On cranes with variable ratings, capacity can change with trolley position, hoist reeving, hook height, and bridge or runway configuration.

Two-blocking occurs when the hook block contacts the hoist drum or upper block; the upper limit switch and operator control prevent rope damage.

Limit switches are safety devices; they are tested without a load and are not used as normal stopping controls.

Structural warning signs include cracks, deformation, unusual noise, vibration, and loose fasteners; stop operation and report them.

Do not use the crane as an anchor, tow point, or drag line; such forces are outside the load chart rating.

If load weight is unknown, the chart is missing or illegible, or gross load exceeds rated capacity, do not lift until verified.

The operator follows signals from one designated signal person; anyone may give an emergency stop signal, and the operator must obey it immediately.

Hoist: arm extended horizontally, forearm vertical, forefinger pointing up, move hand in a small horizontal circle.

Lower: arm extended downward, forefinger pointing down, move hand in a small horizontal circle.

Bridge travel: arm extended forward, hand open and slightly raised, push hand in the direction of travel.

Trolley travel: palm up, fingers closed, thumb pointing in the direction of travel, jerk hand horizontally.

Stop: arm extended, palm down, move arm back and forth horizontally.

Emergency stop: both arms extended, palms down, move arms back and forth horizontally.

Dog everything: clasp hands in front of the body to signal securing or locking the crane motions.

Normal shutdown: land the load, raise the hook to a safe height, set brakes, neutralize controls, turn off power, and lock out the disconnect when required.

Park the crane at the designated location so it does not block walkways, exits, or other equipment travel paths.

For outdoor cranes, set rail clamps or brakes, install storm anchors or tie-downs, and follow the manufacturer's wind-securing procedure.

Out-of-service condition: attach a lock and tag at the disconnect, remove the key, and record the defect.

A crane tagged out of service remains unavailable until a qualified person repairs it and returns it to service.

After shutdown, inspect slings and rigging, remove them from the crane, and store them in a clean, dry area.

Report all defects and abnormal conditions to supervision; do not conceal or defer safety-related damage.

Emergency shutdown: activate the emergency stop, then disconnect power and secure the crane per the site emergency plan.

Treat every power line as energized; OSHA crane minimum approach distance is 10 ft at 50 kV or less and increases 0.4 in per kV above 50 kV.

Outdoor lifting stops when wind exceeds the manufacturer's limit or when the load cannot be controlled with tag lines; capacity charts assume still air unless stated otherwise.

Lightning response: land the load, lower the hook, and secure or move the crane per the site plan; do not resume until the storm has passed.

Verify the floor, runway, or support surface can carry the crane plus load; check for trenches, voids, soft fill, and uncompacted areas.

Adequate illumination must reach the load, rigging, hook, and signal person; if these cannot be seen clearly, the lift does not proceed.

Ice, snow, mud, and grease reduce traction and brake friction; remove accumulations from walkways, rails, and crane surfaces before operation.

Barricade the swing radius and keep pedestrians out from under or near the load; a load must not pass over personnel.

Check clearance to roof trusses, piping, doors, and other cranes through the full travel path before moving.

Before first use each shift, inspect hook, wire rope, chains, brakes, limit switches, controls, warning devices, rails, bumpers, and record defects.

Remove a hook from service if throat opening increased more than 15 percent, twist exceeds 10 degrees, cracks are present, or the latch is missing or inoperative.

Inspect wire rope for broken wires, kinks, birdcaging, corrosion, crushed areas, and diameter loss; reject rope exceeding ASME B30.2 criteria.

Test the hoist brake by lifting a load slightly, stopping, and confirming the brake holds without drift.

Test upper and lower hoist limits and bridge and trolley travel limits without a load at safe speed.

Check runway rail alignment, end stops, rail sweeps, and clearance; remove obstructions from the travel path.

Verify control function and labeling, and test the emergency stop before placing the crane into service.

Do not operate a crane with a safety defect; document the defect and keep the crane out of service until repaired.

Gross load equals the load weight plus all rigging, slings, shackles, spreader beams, and attachments; capacity ratings apply to this total.

Determine weight from shipping papers, drawings, manufacturer markings, or a scale; do not rely only on appearance or volume.

For a known material, weight equals volume multiplied by material density, with consistent units.

Position the hook over the load's center of gravity; off-center lifts require multiple pick points or a plan to prevent tilt and load shift.

For a symmetric two-leg lift, tension per leg equals load divided by two times the sine of the sling angle from horizontal: T = W/(2 sin theta).

As sling legs approach horizontal, tension increases; at 30 degrees from horizontal each leg carries the load divided by two times 0.5.

Never exceed a sling's working load limit; the WLL changes with hitch type, angle, wear, and configuration.

Attach to designated lifting points, protect slings from sharp edges, and inspect shackles and slings before use.

Hoist vertically over the load's center of gravity; side pulls, dragging, and swinging loads create forces the crane was not designed to resist.

Raise the load a few inches, stop, and check load stability, rigging security, brake holding, and crane response before continuing.

Never leave a suspended load unattended and never allow personnel under or on a load; land the load before leaving the controls.

Use smooth acceleration and deceleration; shock loading from rapid starts or stops can exceed structural and rigging limits.

Travel with the load as low as practical and controlled; use tag lines to prevent rotation and drift.

Multiple-crane lifts require a written plan and a qualified person to determine load distribution and coordinate signals.

If the load becomes uncontrollable, stop motion, lower the load if possible, and keep personnel clear.

On power failure, set brakes, keep the area clear, and lower the load using the crane's controlled lowering procedure; do not allow free fall.

Rated capacity is the maximum gross load allowed for a specific crane configuration and includes load, rigging, and attachments.

Match the load chart to the crane model, serial number, reeving, trolley position, hook height, and site-specific restrictions.

On cranes with variable ratings, capacity can change with trolley position, hoist reeving, hook height, and bridge or runway configuration.

Two-blocking occurs when the hook block contacts the hoist drum or upper block; the upper limit switch and operator control prevent rope damage.

Limit switches are safety devices; they are tested without a load and are not used as normal stopping controls.

Structural warning signs include cracks, deformation, unusual noise, vibration, and loose fasteners; stop operation and report them.

Do not use the crane as an anchor, tow point, or drag line; such forces are outside the load chart rating.

If load weight is unknown, the chart is missing or illegible, or gross load exceeds rated capacity, do not lift until verified.

The operator follows signals from one designated signal person; anyone may give an emergency stop signal, and the operator must obey it immediately.

Hoist: arm extended horizontally, forearm vertical, forefinger pointing up, move hand in a small horizontal circle.

Lower: arm extended downward, forefinger pointing down, move hand in a small horizontal circle.

Bridge travel: arm extended forward, hand open and slightly raised, push hand in the direction of travel.

Trolley travel: palm up, fingers closed, thumb pointing in the direction of travel, jerk hand horizontally.

Stop: arm extended, palm down, move arm back and forth horizontally.

Emergency stop: both arms extended, palms down, move arms back and forth horizontally.

Dog everything: clasp hands in front of the body to signal securing or locking the crane motions.

Normal shutdown: land the load, raise the hook to a safe height, set brakes, neutralize controls, turn off power, and lock out the disconnect when required.

Park the crane at the designated location so it does not block walkways, exits, or other equipment travel paths.

For outdoor cranes, set rail clamps or brakes, install storm anchors or tie-downs, and follow the manufacturer's wind-securing procedure.

Out-of-service condition: attach a lock and tag at the disconnect, remove the key, and record the defect.

A crane tagged out of service remains unavailable until a qualified person repairs it and returns it to service.

After shutdown, inspect slings and rigging, remove them from the crane, and store them in a clean, dry area.

Report all defects and abnormal conditions to supervision; do not conceal or defer safety-related damage.

Emergency shutdown: activate the emergency stop, then disconnect power and secure the crane per the site emergency plan.