Unauthorized Hand Signals
You are the designated qualified signal person for a 15-ton rough-terrain crane lifting a 3,000-pound steel beam. The lift plan names you as the only signal person. You step 40 feet away to check that the permit board matches the plan. While your back is turned, a worker who has not been qualified begins giving hand signals to the operator. The operator follows a “swing” signal, and the beam moves toward a pipe rack where two fitters are working. You return, see the movement, and still have your radio. The worker says he was “just helping” because the operator could not see you. The fitters are not aware of the beam.
1. Who is authorized to give operational hand signals on this lift, and what should you do first when you see the unauthorized signal?
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Only the designated qualified signal person gives operational signals. When I see the unauthorized signal, I give the stop signal immediately and key the radio: “All stop, all stop.” The operator must stop hoisting and swinging and hold the load. The unauthorized worker may give an emergency stop, but he may not direct swings, hoists, or lowers. After the stop, lower the beam to a safe landing, dog it, and move the fitters out of the travel path. Then address the unauthorized signal at the crew level.
2. What should the operator have done, and what should be done before the lift resumes?
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The operator should have stopped when the signal source changed and should have verified that the signal came from the designated signal person. Before resuming: hold a pre-lift meeting with the operator, rigger, fitters, and the worker; restate that only the named signal person gives operational signals; confirm radio channel and hand-signal visibility; remove the worker from the signal role; and document the event. The operator should not resume until he can identify the correct signal person and the load path is clear.
3. What qualifications and documentation should the employer maintain for signal persons?
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The employer must qualify the signal person and keep a record of that qualification-training on standard hand signals, voice and radio procedures, crane and rigging awareness, and the site's stop authority. A card alone is not enough; the employer must verify the person can perform. The lift plan should name the signal person and a backup. The crew should know the backup's name and how to reach him. If no qualified backup is on site, the lift stops until one is available.