Raising The Bar Guidance - Crawler Crane Equipment Requirements

Raising The Bar Guidance - Crawler Crane Equipment Requirements

The Crawler Crane is a heavy-duty lifting machine mounted on an undercarriage with tracks, providing stability and mobility across rough terrains. It is integral to large-scale construction projects, where lifting heavy materials and equipment is required. The "Raising the Bar 1 - Plant and Equipment" guidelines from National Highways outline comprehensive safety and operational standards for Crawler Cranes to mitigate risks associated with lifting and manoeuvring in challenging environments. Below is an in-depth look at the critical requirements for Crawler Cranes used in National Highways projects.

General Minimum Requirements

The General Minimum Requirements (GMR) section applies to all types of plant and equipment, ensuring safety and operational efficiency across National Highways projects:

1. Daily Inspections: Crawler Cranes must undergo a thorough inspection before each use, including a documented pre-start checklist to confirm the crane’s operational readiness.

2. Compliance with Legislation: All cranes must comply with UK regulatory standards, including the European Commission Machinery Directive (2006/42/EC) or UKCA certification, with a declaration of conformity.

3. Visibility and Safety Markings: Safety decals should be clear and legible, and all access steps and handrails should be highlighted in high-visibility colours to facilitate safe entry and exit.

4. Seat Belts: Operators must wear functional seat belts at all times while operating the crane.

5. Public Highway Compliance: When used on public roads, Crawler Cranes must display registration plates, have fully operational lights, and use flashing amber beacons as outlined in Chapter 8 of the Traffic Signs Manual.

Equipment-Specific Safety and Compliance Standards

Crawler Cranes have unique operational and safety challenges due to their lifting capabilities and the risks associated with large loads and extended boom heights. The following standards apply:

1. Flashing Amber Beacon and Seat Belt Indicator: A flashing amber beacon must be in place for visibility, and a green light should indicate when the operator’s seat belt is engaged. The green light should be turned off on public highways where it could violate lighting regulations.

2. 360° Visibility: The crane must meet 360° visibility requirements with mirrors, cameras, or other visual aids ensuring visibility around the machine up to a height and distance of 1 meter.

3. ROPS and FOPS Requirements: A Roll Over Protective Structure (ROPS) and, if required by risk assessment, a Falling Object Protective Structure (FOPS) should be fitted to the cab to protect the operator.

4. Reversing Alarm: Crawler Cranes must have a directional, white-noise reversing alarm that is clearly audible outside the cab to alert nearby personnel.

5. Fire Extinguisher: A fire extinguisher should be located in the cab and be easily accessible to the operator in case of emergency.

6. Safety Handrails and Fall Protection: The crane must have handrails on the running boards and upper structure, as well as fall protection on walkways and areas where operator access is required for maintenance.

Lifting Operations Standards

Lifting operations are a critical function of the Crawler Crane, requiring strict adherence to Lifting Operations and Lifting Equipment Regulations (LOLER) standards to ensure safe operation.

1. LOLER Certification: All cranes must have a current 12-month LOLER thorough examination certificate, and all lifting tackle must have a six-month LOLER inspection certificate.

2. Four-Year Overload Test: Crawler Cranes must undergo a four-year overload test or follow a defined examination scheme with a declaration of compliance, as per mobile crane maintenance guidelines.

3. Load Indicators and Warnings: Crawler Cranes should be equipped with overload indicators and alarms to alert the operator if the lifting load exceeds safe limits. Hydraulic lock-out and warning lights should activate to prevent lifting beyond rated capacity.

4. Certified Lifting Points and SWL: All lifting points must be certified, with the Safe Working Load (SWL) clearly marked to prevent overloading. Additionally, the boom and hoist system should have a cut-out facility to prevent dangerous extensions.

5. Slew, Height, and Radius Restrictors: These restrictors are necessary when working near hazards, such as power lines, railways, or adjacent traffic, to prevent the crane from slewing or extending into hazardous areas.

6. Lift Plan and Risk Assessment: Each lifting task must be accompanied by a lift plan, a risk assessment, and a machine-specific duty sheet. This ensures that all lifting parameters and safety protocols are met.

7. Hoist Rope and Safety Catches: Carrier hoisting ropes must have a minimum diameter of 8 millimetres. All hooks should have a safety catch to prevent load detachment.

Operator Competency and Requirements

Operator competency is essential for the safe operation of a Crawler Crane. The following standards apply:

1. Licensing and Medical Certification: Operators must hold the necessary driving and operating licenses, and a valid medical certificate to ensure they are physically capable of managing crane operations.

2. Familiarization Training: Operators must complete familiarization training for the specific type of Crawler Crane they will be operating, including understanding all lift plans and emergency procedures.

3. Seat Belt Use: Operators must wear seat belts at all times during operation, in compliance with safety protocols.

4. Emergency Stop and Rescue Procedures: Specific emergency stop procedures must be tested before starting operations. Emergency recovery procedures should be communicated to all relevant personnel.

Desirable Features

To further improve the safety and efficiency of Crawler Crane operations, certain additional features are recommended:

1. 360º Camera System: A 360º camera system with interlinked views around the crane enhances operator awareness and reduces risks of collision with personnel or other machinery.

2. Pedestrian Detection System: Some systems can detect pedestrians within a 5-meter proximity, providing audio-visual alerts to operators and ensuring the safe exclusion of pedestrians around the crane.

3. Jib Head Tracker: In sites with blind spots, a jib head tracker improves operator awareness of the boom’s position and helps prevent potential clashes.

4. Engine Emission Compliance: Stage V engine compliance is recommended for Crawler Cranes to reduce environmental impact, particularly on projects where emission standards are prioritized.

5. Wind Speed Monitor: An anemometer or other device to monitor wind speeds helps operators make informed decisions, particularly during lifts in exposed or high-wind areas.

Hazard Identification and Mitigation

Operating a Crawler Crane involves significant risk factors, which must be managed through safety protocols and hazard mitigation:

• Overturning Risk: Crawler Cranes are at risk of overturning if the ground is unstable or lifting duties are exceeded. Operators should always assess ground conditions and ensure the crane remains within lifting limits.

• Dropped Loads: The risk of dropped loads is high, especially in high-wind conditions. All load-bearing hydraulic cylinders should be fitted with check valves, and load-path safety protocols should be followed.

• Ground Stability: Operators should ensure ground conditions are stable enough to support the crane’s track loadings, and any underground services must be checked to avoid structural damage.

• Height and Slew Restrictions: Operators must be cautious when slewing or raising the boom near power lines or high structures, and height and slew restrictors should be used to prevent unintended contact.

• Fall from Height Risks: Fall protection is essential on walkways and platforms, and operators must use handrails and fall restraints where available.

• Noise and Visibility Hazards: Crawler Cranes can produce significant noise, creating additional hazards on-site. Operators should use hearing protection where necessary and rely on visibility aids to mitigate blind spots.

Summary

Crawler Cranes play a pivotal role in heavy-duty lifting tasks on construction and highway projects. However, their powerful lifting capabilities also come with heightened safety risks, making strict compliance with "Raising the Bar 1" guidelines essential. By adhering to the requirements for LOLER certification, load indicators, and slew restrictors, operators and site managers can ensure safe and effective crane operation. Additional recommended features such as 360° cameras, pedestrian detection, and Stage V emission compliance further enhance safety and environmental responsibility on-site.

This article provides an extensive overview of the standards and protocols essential for operating Crawler Cranes on National Highways projects, ensuring that both safety and efficiency are prioritized in every lift.