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AFOSHSTD91-46, Materials Handling and Storage Equipment

1. 7 2 5 2 1 3 If electrically powered the main or emergency switch will be locked in an open off position except for tests 7 2 5 2 1 4 Do Not Start tag will be placed on the main switch AFOSHSTD91 46 1 FEBRUARY 1997 87 7 2 5 2 1 5 Where other moving units are in operation on the same runways or monorail track rail stops or other suitable means will be provided to prevent interference with the idle equipment 7 2 5 2 1 6 Where temporary protective rail stops are not possible or practical a signal person will be placed at a visual vantage point to observe the approach of an active unit and to warn the operator when the limit of safe distance from the idle unit has been reached 7 2 5 2 2 Equipment that cannot be readily moved from its operating location can be inspected and maintained at the site providing precautions are taken to ensure the safety of the inspection and maintenance personnel 7 2 5 2 3 After adjustments and repairs have been made the equipment will not be operated until all guards have been reinstalled safety devices are reactivated and tools and mainte nance equipment are removed Do Not Start tags and locks will be removed by the supervi sor or the person who attached them 7 2 5 3 Adjustments and Repairs 7 2 5 3 The using agency will ensure that any unsafe conditions disclosed by inspection are corrected before operation of the crane or monorail system is resumed Adjustments and repairs
2. device installed on booms which alerts or warns the operator when the boom is in proximity to energized electric power lines Pulpit Operated 4A crane or unit operated from a fixed operator station not attached to the unit Push button Station An electrical control device consisting of push button operated contacts in an enclosure used by the operator for control of the powered motions of the crane hoist and other auxiliary equipment Qualified Engineer A person who by possession of a recognized degree certificate or professional standing or who by extensive knowledge training and experience has successfully demonstrated ability to solve problems relating to the subject matter and work Rail e One of the longitudinal members in a conveyor frame The supporting surface under the wheels or rollers of a chain conveyor or The supporting track for equipment mounted on wheels such as belt tripper weigh larry etc Rail Clamp An attachment or device for clamping movable equipment to the rail to hold it in a fixed location Rail Stop A stop mounted at the ends of conveyor rails to limit the travel of traversing machinery Ratchet A toothed member for engagement of the pawl Rated Load Capacity The maximum load designated by the manufacturer or qualified engineer for which the equipment or system is designed and built Rated Load Test A 100 percent minimum load test of the maximum load as designated by th
3. 008 p ooe c 0021 soyout 79 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 22 Synthetic Web Slings 1 600 Pounds Per Inch of Width Single Ply 00L L 001 006 009 00 yeg 006 01 0 0 6 007 L 005 0 81 19458 o0 et 0 0 11 008 8 052 9 005 Ostet yyseg o0r sT 0081 00701 008 002s 009 194589 0079 0 1 oorr 0 1 001 0507 940029 uorejodsoyut Aq oq umoys 0 soniede c Wo UMOYS 8 T SILON 0024 oor st 00812 00L 97 0080 00r e1 009 6 009 l 009 91 00261 0021 0096 9 00p 9 0081 001 1 00002 00952 00201 008 CI 0008 0081 000 91 000 9 0008 oors 00Z OT 00441 00 0 0058 00101 00t 9 0006 OOT TT O08 CI 008 00r9 t 006 O0L L 00601 00 1 005 9 0014 008 008 9 00 8 009 6 009 008 009 001 0024 0088 00201 001 oor e 0055 00 009 00t 9 005 c 0 0 1 0055 0021 0091 I WA yyseg joxseg BII 90 WA 5815 1 ao pue o 80115 pu odo pue M J odAy 58 o dueuT Apog oj8ueu 1 244 580115 IJOY ABUL spunod yroede poyes 80 AFOSHSTD91 46 1 FEBRUARY 1997 Chapter 7 OVERHEAD GANTRY UNDERHUNG CRANES AND MONORAIL SYSTEMS 7 1 Haza
4. 7 2 4 5 4 3 Equipment is not used for side pulls except when specifically authorized by a designated person who has determined the suitability of the equipment is not thereby endangered and that various parts of the equipment will not be overstressed 7 2 4 5 4 4 The operator does not hoist lower or travel while anyone is on the load or hook unless specifically recommended for such use by the manufacturer approved by MAJCOM DRU or FOA and so indicated on a permanent name plate attached to the hoist See paragraph 9 6 and 29 CFR 1926 550 Cranes and Derricks 7 2 4 5 4 5 The operator does not carry loads over personnel 7 2 4 5 4 6 The operator tests the brakes each time a load is handled by raising the load 2 inches above floor or ground level and applying the brakes 7 2 4 5 4 7 The load is not lowered below the point where less than two full wraps of rope remain on the hoisting drum EXCEPTION One wrap may remain on the drum if a lower limit device is provided See ANSI ASME Standard B30 2 7 2 4 5 4 8 When two or more pieces of equipment are used to lift a load one qualified responsible person is in charge of the operation The person in charge analyzes the opera tion and instructs all personnel involved in the proper positioning rigging of the load and the movements to be made 7 2 4 5 4 9 The operator does not leave his or her position at the controls while the load is suspended 7 2 4 5 4 10 When starting the
5. device to limit travel of a trolley or crane bridge This device normally is attached to a fixed structure and does not have energy absorbing ability Stop Switch Emergency A manually or automatically operated electric switch to cut off electric power independently of the regular operating controls Straddle Lift Truck A general class of lift truck designed for picking up and hauling loads between its outrigger arms Strand Laid Endless Sling Mechanical Joint A wire rope sling made endless from one length of rope with the ends jointed by one or more metallic fittings Strand Laid Grommet Hand Tucked An endless wire rope sling made from one length of strand wrapped six times around a core formed by hand tucking the ends of the strand inside the six wraps Strand Laid Rope A wire rope made with strands usually six or eight wrapped around a fiber core wire strand core or independent wire rope core IWRC Stripper A device that aids the load chain in leaving the load sprocket Superstructure The rotating upper frame structure of the machine and the operating machinery mounted thereon Swing Rotation of the superstructure for movement of loads in a horizontal direction about the axis of rotation Switch e A control device for making breaking or changing connections in an electric circuit Any device for connecting two or more continuous package conveyor lines mechanism which transfers a trol
6. these breaks are caused by strand nicking resulting from the heavy loads A close up of a rope subjected to drum crushing Note the distortion of the individual wires and displacement from their normal position This is usually caused by the rope scrubbing on itself AFOSHSTD91 46 1 FEBRUARY 1997 A wire rope which has jumped a sheave The rope is deformed into a curl as if bent around a round shaft Close examination of the wires show two types of breaks normal tensile cup and cone breaks and shear breaks which give the appearance of having been cut on an angle with a cold chisel A wire rope which has been kinked A kink is caused by pulling down a loop in a slack line during improper handling installation or operation Note the distortion of the strands and individual wires Early rope failure will undoubtedly occur at An example of a wire rope that has provided maximum service and is ready for replacement A fatigue break in a cable tool drill line caused by a tight kink developed in the rope during operation AFOSHSTD91 46 1 FEBRUARY 1997 117 Figure 9 7 Hook Inspection Areas Check for wear Check for cracks and deformation and twisting Check for signs of opening up 4 Check for wear and cracks Figure 9 8 Hook Showing Block Interface Shank 118 AFOSHSTD91 46 1 FEBRUARY 1997 Table 9 1 Number of Spacing of Clips for Ropes of Various Sizes Diameter of Ro
7. 4 2 4 3 Clearing jams 4 2 4 4 Making adjustments and 4 2 4 5 Lockout and or tagout see AFOSH Standard 127 45 Hazardous Energy Control and Mishap Prevention Signs and Tags 4 2 5 Safe Operations 4 2 5 1 Personnel will not ride on a conveyor or step on or cross over conveyors except at desig nated locations 4 2 5 2 Personnel will not operate conveyors unless all guards are in place 4 2 5 3 Operators will check the entire conveyor before starting the system to ensure it is clear of personnel 4 2 5 4 Workers will place small objects in tote boxes on conveyors 4 2 5 5 Personnel will not place hands or fingers between moving objects fixed parts of the con veyor rollers or on the rollers 40 AFOSHSTD91 46 1 FEBRUARY 1997 4 2 5 6 Personnel will not take off guards at the end of the conveyor and rollers or from belts feeding the conveyor 4 2 5 7 Workers will use caution in resolving jam up of boxes or other objects on the conveyor to prevent hand or finger injuries 4 2 5 8 To prevent being struck by falling objects workers will remain outside of the path of overhead conveyors 4 2 5 9 Operators will report defective or worn shafts rollers or bearings that may break and per mit rollers to fall from the frame 4 2 5 10 Workers will not wear loose clothing loose sleeves or jewelry that may catch in the conveyor 4 2 5 11 Workers will keep the area around them free of obstructions to permit a
8. tele 11 Chapter 3 POWERED INDUSTRIAL TRUCKS 13 3 1 Hazards and or Human Factors nennen eene eene 13 34 General Requirements taedio je Ado iu obtuli euis fae teens 13 3 Special Regurements pend tapas eis Cau ER EE 20 Fig te 3 1 Approved Safety Pallet iunc ates tu uote ut ues 22 Figure 3 2 Extension Forks Used With the Safety Pallet 23 Ligure 2 Higsb Lift Leo acis ant incid tous 24 Figure 3 4 highs Litt s e E RR Eu es 23 Figures sc too inte E seit etat pet 26 Figure 3 6 Motorized Hand Truck Also known as Pallet Truck eee 27 Figure 5 7 Industrial Tractor uir 28 Figure 3 8 Motorized Hand and or Rider Truck eee 29 Figure 3 9 Reach Truck Ea den die ee 30 Figure 3 16 SidesDEoader Track ierat E 31 Figure 3 11 Order Picken Truck S gta 32 AFOSHSTD91 46 1 FEBRUARY 1997 3 Figure 3 12 Narrow Aisle Truck Also Known as Straddle Truck esee 39 2 E Truck Straddie Cary uiae 34 Figure 3 14 Truck Warehouse Double Handle Type 2 Wheel Solid Rubber Tires 35 Figure 3 15 Truck Hand Platform 4 W heel 36 Figure 3 16 Crane Truck Warehouse Electric eee eene
9. 11 200 44 6001 38 700 31 600 22 300 2 1 2 149 0 13 900 6 950 27 800 24100 19 700 13 900 23 000 12 500 50 000 43 300 35 400 25 000 2 5 8 168 0 116 000 8 000 32 000 27 700 122 600 116 000 28 800 14 400 157 600 49 900 40 700 28 800 rN _ See Figures 6 1 and 6 2 for sling configuration descriptions AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 18 Polyester Rope Slings Rope Nominal dia wt per erti 1 2 9 16 5 8 3 4 13 16 7 8 1 1 1 16 1 18 1 1 4 1 5 16 1 1 2 1 5 8 1 3 4 2 2 1 8 2 1 4 2 1 2 2 5 8 Angle of rope to vertical shown in parentheses 90 0 1 270 1 580 1 980 2 480 3 080 3 560 4 360 5 060 5 840 6 580 7 420 9 260 11 300 13 400 15 800 18 200 21 200 24 200 27 200 Basket hitch Angle of rope to horizontal 60 45 30 45 900 1 100 1 370 1 710 2 150 2 670 3 080 3 780 4 380 5 060 5 700 6 430 8 020 9 770 11 600 13 700 15 800 18 400 21 000 23 600 1 120 1 400 1 750 2 180 2 520 3 080 3 580 4 130 4 650 5 250 6 550 7 980 9 490 11 200 12 900 15 000 17 100 19 200 See Figures 6 1 and 6 2 for sling configuration descriptions 30 60 635 790 990 1 240 1 540 1 780 2 180 2 530 2 920 3 290 3 710 4 630 5 640 6 710 7 920 9 110 10 600 12 100 13 600 Verti cal hitch 1 140 1 420 1 780 2 230 2 770 3 200 3 920 4 550 5 260 5 920 6 680 8 330 10 200 12 100 14 300 1
10. 6 3 5 1 In addition to the general identification requirements each sling will be marked to show the type of synthetic web material AFOSHSTD91 46 1 FEBRUARY 1997 55 6 3 5 2 Synthetic webbing will be of uniform thickness and width and selvage edges will not be split from the webbing s width 6 3 5 3 Fittings will be 6 3 5 3 1 Of a minimum breaking strength equal to that of the sling and 6 3 5 3 2 Free of all sharp edges that could damage the webbing 6 3 5 4 Stitching will be the only method used to attach end fittings to webbing and to form eyes The thread will have an even pattern and contain a sufficient number of stitches to develop the full breaking strength of the sling 6 3 5 5 Synthetic web slings illustrated in Figure 6 3 will not be used with loads in excess of the rated capacities specified in Table 6 20 through Table 6 22 Slings not included in these tables will be used only according to the manufacturer s recommendations 6 3 5 6 When synthetic web slings are used the following precautions will be taken 6 3 5 6 1 Nylon web slings will not be used where acid or phenolic fumes vapors sprays mists or liquids are present 6 3 5 6 2 Polyester and polypropylene web slings will not be used where caustic fumes vapors sprays mists or liquids of acids are present 6 3 5 6 3 Web slings with aluminum fittings will not be used where caustic fumes vapors sprays mists or liquids are present 6 3 5 7 Synthe
11. A3 27 Are records of all load tests available Reference paragraph 8 2 3 1 5 A3 28 Are energy control lockout tagout procedures developed and used during maintenance activi ties Reference paragraphs 8 2 3 2 and AFOSH Standard 127 45 A3 29 Is there a procedure developed to provide safe operations in the vicinity of electrical power lines Reference paragraph 8 2 6 39 A3 30 If an approved crane is used to lift personnel is the platform used to suspend personnel designed correctly Reference paragraphs 8 2 6 50 and 9 6 and 29 CFR 1926 550 A3 31 Are wire rope inspections conducted at least monthly and records maintained on file by the user and the agency responsible for hoist maintenance and inspections Reference paragraphs 9 1 3 1 and 5 2 4 1 A3 32 Are chains inspected before each use and monthly and are these inspections documented Refer ence paragraph9 2 1 4 A3 33 Is a preventive maintenance program established for derricks and are these maintenance activities documented Reference paragraph 10 4 A3 34 Are energy control lockout tagout procedures established and followed during maintenance tasks Reference paragraph 10 4 2 1 4
12. Proof Testing 6 2 3 1 Proof testing to identify sling rated capacity will be performed with only approved and calibrated weight testing equipment A record of the most recent proof test will be retained on file 6 2 3 2 Slings will be initially proof tested at 200 percent of rated capacity Synthetic and natural fiber rope slings will be proof tested at two times their assigned rated loads before being put into service Note Wire rope slings of the hand tucked type and certain special spreader bars and lifting beams are limited to test loads of 125 percent 6 2 3 3 Proof load for single leg and endless slings shall be two times the vertical rated capacity 6 2 3 4 Proof load for multileg bridle slings shall be applied to the individual legs and shall be two times the vertical rated capacity of a single leg sling of the same size grade and construction of rope 6 2 3 5 Proof testing at 200 percent of rated capacity of slings spreader bars lifting beams and other specialized lifting attachments used to lift critical loads shall be performed annually See Attachment 1 for critical load definition Also see NOTE in paragraph 6 2 3 2 AFOSHSTD91 46 1 FEBRUARY 1997 51 6 3 Specific Requirements 6 3 1 Alloy Steel Chain Slings 6 3 1 1 Hooks rings oblong or pear shaped links welded or mechanical coupling links or other attachments will have a rated capacity at least equal to that of the alloy steel chain with which they ar
13. manlifts moving walks moving stairways highway or rail vehicles cableways tramways pneumatic conveyors or integral machine transfer devices Conveyor Belt belt used to carry materials and transmit the power required to move the load being conveyed Countertorque A method of control by which the power to the motor is reversed to develop torque in the opposite direction Also used to slow or stop motion Counterweight A weight used to balance or counter a load Examples are e Additional weight usually attached to the rear of the forklift to provide better weight distribution e Weight used to supplement the weight of the crane in providing stability for lifting working loads Control The system governing the starting stopping direction of motion acceleration speed retardation and function of the moving member in a predetermined manner Control Braking method of controlling motor speed when in an overhauling condition i e as ina crane motor Control Voltage The voltage passing through the operator s push button station or the controller and the control circuits Controller An electro mechanical device or assembly of devices for starting stopping accelerating or decelerating a system or which serves to govern in some predetermined manner the electric power delivered to the system Controller Electric An electric controller is a device or group of devices which serves to govern in some predeter
14. may be sufficient cause for dis qualification In such cases specialized clinical or medical judgments and tests may be required Note A history of epilepsy or a disabling heart condition may be sufficient reason for disqualification be examined annually according to paragraphs 5 2 3 1 2 1 through 5 2 3 1 2 3 Requirements 5 2 3 1 3 Operators of cab operated overhead portal tower pedestal and gantry cranes will in paragraphs 5 2 3 1 2 4 and 5 2 3 1 2 5 are used for initial screening only 5 2 3 1 4 Potential operator trainees will have good depth perception field of vision reaction time manual dexterity or coordination and no tendencies to dizziness or similar undesirable characteristics Physical defects such as loss of arm hand leg foot or gross loss of function thereof may be considered as cause for denial of acceptance into an entry level training pro gram for operators 5 2 3 1 5 Initial and if required recurring physicals may be documented in item 7 of the AF Form 55 5 2 3 2 Operating Practices 5 2 3 2 1 If an operator must divert their attention while operating a hoist he or she will stop the hoist 5 2 3 2 2 When an AF Form 979 Danger AF Form 981 Out of Order or AF Form 982 Do Not Start tag is attached to the starting controls the hoist operator will not apply power to the unit or start operations until the condition has been corrected and the tag removed Also see paragraph 5 2 4 3 3 44
15. 1 5 Reductions from nominal diameter of more than 9 1 4 1 5 1 One sixty fourth of an inch for diameters up to and including five sixteenths inch 9 1 4 1 5 2 One thirty second of an inch for diameters three eighths inch to and including one half inch 9 1 4 1 5 3 Three sixty fourths of an inch for diameters nine sixteenths inch to and including three fourths inch 9 1 4 1 5 4 One sixteenth of an inch for diameters seven eighths inch to and including one and one eighth inch 9 1 4 1 5 5 Three thirty seconds of an inch for diameters one and one quarter inch to and including one and one half inch 9 1 4 1 6 In standing ropes more than two broken wires in one lay in sections beyond end connections or more than one broken wire at an end connection 9 1 4 2 Special attention will be given to the end fastenings Ropes will be examined at socketed fittings and when two broken wires are found next to this point the rope will be resocketed Those portions of the rope subjected to reverse bends and operation over small diameter sheaves or drums will be given close attention 9 1 4 3 A rope which has been in service but idle for a period of 1 month or more will be thor oughly examined before it is put back into service This examination will be for all types of dete rioration particularly corrosion This inspection will be performed by a designated person whose approval will be required for further use of the rope A written and date
16. 1997 78 Table 6 21 Synthetic Web Slings 1 200 Pounds Per Inch of Width Single Ply 008 052 008 058 00641 056 124588 909 007 8 0sL 9 00 s 050 000 ose Toxseg St 000 01 0528 009 9 056 0058 0591 81 OE 00911 0056 009 L 004 008 0061 12158 WA 009 0sL 000 OSTZ 00 l 052 22404 sdut s 008 050 008 0582 0067 056 6091 009 6 00L L 008 008 0061 Joyseg o09 005 91 009 1 006 01 0078 0075 002 00661 009 91 00 T 000 01 009 9 00 joxseg 90 A 5811 000 002 61 00t e1 009 11 009 L 008 197589 UPA worejoduequr Aq peurniqo sq JOU SPM arerpeunoqut Joj 4 Z uonaA woy ore UMOYS sofSuv 1 SALON 006 00 0029 009 000 00 1 spunod pores 00811 009 6 00L L 008 008 0061 005 000 9 008 009 0075 0041 09 11 1 2443 8 124045 00501 005 8 008 9 001 00v 00L l wyseg oS 00 71 00 01 005 8 0059 002 oor yoyseg 0 oorti 000 71 009 6 008 005 00 00 t 009 000 008 1 006 154584 293049 WA AI 244 saut s poisua p pue JJ 2 3 s8ut s qii pue 24 58 1 o gueu 0022 9 0009
17. 2 2 3 2 Date of proof test 2 2 2 3 3 Capacity of hoist and 2 2 2 3 4 Identification number of hoist 2 2 3 Maintenance and Testing 2 2 3 1 hoists which have had load sustaining parts altered replaced or repaired will be proof load tested before use by the owning activity All new hoists will have the manufacturer s 12 AFOSHSTD91 46 1 FEBRUARY 1997 certification that all proof load testing has been accomplished These tests will be 125 percent of the rated capacity A record of all tests will be maintained by the user 2 2 3 2 Maintenance will be performed according to the manufacturer s instruction or applicable TO 2 2 4 Safe Operations 2 2 4 1 Lever operated hoists shall only be used in a direct pull Where indirect pulls are permit ted by design of the hoist a sheave or pulley of adequate size shall be used 2 2 4 2 Hoist cables ropes and chain shall not be wrapped around the load Use only slings or other approved lifting fixtures For example cargo straps shall not be used for lifting unless stated in approved Air Force technical data or TOs Refer to Chapter 6 for information on slings 2 2 4 3 Positive action safety latches shall be installed on all hooks 2 2 4 4 Hooks shall not be point loaded unless designed for this purpose AII loads shall be seated in the saddle of the hook 2 2 4 5 Extensions to levers cheater bars or pipes shall not be used to increase leverage Extend ible levers
18. 2 6 35 3 If the load hoist mechanism is not equipped with a means to hold the drum from rotating in the lowering direction without further action by the operator loads should not remain suspended for a considerable length of time 8 2 6 36 Standard hand signals to the operator will be according to those depicted in Figure 7 1 unless voice communication equipment is used The operator will not respond to any signal unless he or she clearly understands it 8 2 6 37 If itis necessary to give instructions to the operator other than those provided herein the crane motions will be stopped 8 2 6 38 All crane controls will be placed in the OFF position and the main switch opened when equipment is not being used 8 2 6 39 When operating near electric power lines 29 CFR 1926 550 8 2 6 39 1 Overhead power lines will be considered to be energized unless it is definitely known by the operator supervisor that the lines are not energized 8 2 6 39 2 No part of a crane or its load will be permitted to come within 10 feet of any ener gized electrical power line When this is impractical the electrical power line will be de ener gized and visibly grounded or a different route of travel will be used 8 2 6 39 3 For lines rated over 50 kilovolts KV minimum clearance will be 10 feet plus 0 4 inch for each kV over 50 or twice the length of the line insulator but never less than 10 feet 8 2 6 39 4 A permanent sign will be p
19. 3 2 Suspend the chain vertically under tension and using a caliper type gauge measure the outside length of any convenient number of links approximately 12 to 14 inches overall 9 2 1 3 3 Measure the same number of links in the used sections and calculate the percentage increase in length If the used chain exceeds the hoist manufacturer s recommended length or in the absence of such a recommendation if the chain is 1 5 percent longer than unused chain replace the chain Do not repair load chain by welding or any other means this repair is only accomplished by the chain manufacturer 9 2 1 3 4 Install load chain links which pass over the hoist load sprocket on edge alternate to those which lie flat in the pockets with the welds away from the center of the sprocket 9 2 1 4 Inspect hoist chains including end connections for excessive wear twist and distorted links interfering with proper function or stretched beyond manufacturer s recommendations Con duct visual inspection on the day of use conduct monthly inspection and maintain a record which includes the date of inspection the signature of the inspector and an identifier of the inspected chain 9 2 1 5 When chain is replaced the mating parts chain sprockets guides stripper will be disas sembled and inspected for wear and replaced if necessary 9 2 1 6 For non load bearing drive slack chains inspect for cracks weld splatter burrs or other damage Repair or replac
20. 30 000 26 000 21 200 15 000 Light Duty 14 Ga 59 Spirals Ft of sling width 2 900 1 800 1 600 1 300 900 3 1 400 2 800 2 400 2 000 1 400 4 2 000 4 000 3 500 2 800 2 000 6 3 000 6 000 5 200 4 200 3 000 8 4 000 8 000 6 900 5 700 4 000 10 5 000 10 000 8 600 7 100 5 000 12 6 000 12 000 10 400 8 500 6 000 14 7 000 14 000 12 100 9 900 7 000 16 8 000 16 000 13 900 11 300 8 000 18 9 000 18 000 15 600 12 700 9 000 20 10 000 20 000 17 300 14 100 10 000 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 16 Manilla Rope Slings Angle of rope to vertical shown in parentheses Eye and eye sling Endless sling Rope Nominal Basket hitch Angle of rope to Basket hitch Angle of rope to dia wt per Verti horizontal Verti horizontal nominal 100 Rin cal cal in pounds hitch 90 60 45 30 hitch 90 60 45 30 12 7 5 480 240 960 830 680 480 865 430 1730 865 916 104 620 310 1240 1070 875 620 1120 560 2 230 1 120 5 8 13 3 790 395 1 580 1 370 1 120 790 1420 710 2 840 1 420 3 4 16 7 970 485 1940 1 680 1 370 970 1750 875 3 490 1 750 1316 195 11 170 585 2 340 2 030 1 650 1170 2 110 1 050 4 210 2 110 7 225 1390 695 2 780 2 410 1970 1 390 2 500 1250 5 000 2 500 1 270 1620 810 3 240 2 810 2290 1 620 2 920 1 460 5 830 2 920 1 116 313 1 890 945 3780 3270 2670 1 890 3 400 1 700 6 800 3 400 1 18 360 2 160 1080 4320 3740 3 050 2 160 3 890 1
21. 5 2 2 2 Signals Standard operating signals understood by operators and signalmen will be used in hoist operations See Figure 7 1 for examples of approved signals 5 2 2 3 Engines and Motors Hoist engines and motors will be guarded to protect personnel 5 2 2 4 Brakes Self locking brakes capable of holding at least 125 percent of the rated load will be installed on all hoists A locking device as applicable will be provided to hold suspended loads 5 2 2 5 Electric Hoists The conductors and switches of electric hoists will be guarded against accidental contact 5 2 2 6 Loads loads will be balanced on hoist carriages and secured to prevent slipping or shifting 5 2 2 7 Monorail Hoists This type of hoist will not be used to move an object by pulling side ways unless properly designed for that purpose Monorail hoists operated on swivels will be equipped with one or more safety catches that will support the load if a suspension pin fails Each trolley frame will be safeguarded against spreading The track supports and track of all monorails will be installed according to good engineering practices They will be capable of safely carrying the loads for which they are intended Rail stops will be provided at the ends of the monorail track Such rail stops will extend at least as high as the radius of the wheels At switches turntables and transfer tables automatic bumpers shall drop onto position to prevent the trolley fro
22. Interlocking A crane with an interlock mechanism on one or both ends enabling it to be mechan ically locked to another crane or spur track for the purpose of transferring a carrier from one to the other Jib A fixed crane consisting of a vertical member pivoting on fixed supports at its top and bottom ends and a horizontal arm fit with a trolley Single Leg Gantry crane whose bridge is supported on one end by a vertical leg rolling on a fixed runway and on the other end by trucks running on elevated runways Wheel Mounted crane consisting of a rotating superstructure with power plant operating machinery and boom mounted on a base or platform equipped with axles and rubber tired wheels for travel The base is usually propelled by the engine in the superstructure but it may be equipped with a separate engine controlled from the superstructure Deflector A device across the path of a conveyor placed at the correct angle to deflect objects 142 AFOSHSTD91 46 1 FEBRUARY 1997 e plate inserted in the necessary structural mechanical and electrical parts which provides the motive power for a conveyor monorail crane etc Derrick A Frame Derrick A derrick whose boom is hinged from a cross member or pedestal between the base of an upright A frame The point of the A frame 1 braced or guyed to the top of the boom which serves as the lift point Basket Derrick boomless derrick whose lift mast is held within a support
23. Lifting people or loads over people 5 2 2 11 7 Removing or obscuring the warning label 5 2 2 12 Pendants The pendant station will be supported by a cable chain or rope that will pro tect the electrical conductors against strain Metallic pendant stations will be grounded to the hoist Pendant control stations shall be kept clean and function labels kept legible 5 2 2 13 Support The supporting structure of the hoist including trolleys monorail crane or beam will have a load rating at least equal to that of the hoist 5 2 2 14 Location The hoist will be installed to give the operator room to stay free of the load at all times 5 2 2 15 Hoist Controls Hoist controls for trolley and bridge movement shall use compass points north south east and west as the preferred identification whenever possible 5 2 2 16 Synchronous Controls Hoists utilizing synchronous controls for multiple lifting move ments shall be of fail safe design to preclude inadvertent operation caused by malfunction of selector switches power failure or improper sequencing of controls 5 2 2 17 Remote Operated Hoists Remote operated hoists shall function so that if the central sig nal for any hoist motion becomes ineffective hoist motion shall stop 5 2 2 18 Tag Lines Tag lines will be used on free swinging loads to help guide and prevent strik ing nearby objects 5 2 2 19 Upper Limit Switches Upper limit switches shall be installed and operab
24. Motivation emotional status job satisfaction and attitude toward work 1 1 1 3 Pre existing Injury 1 1 2 Task Variables 1 1 2 1 Load Handled Weight size shape distribution of the load ease or difficulty of coupling degree of shift of the load in the container and the location of the center of gravity CG 1 1 2 2 Workplace Layout Degree of movement required obstacles distances moved and direc tion of movement 1 1 2 3 Level of Demand Frequency of lift duration of lifting tasks accelerations and velocities of lift shift duration degree of precision and relative proportion of muscles involved in the lift ing 1 1 3 Environmental Variable Heat and cold stress noise and vibration lighting toxic agents trac tion stability of the work platform and atmospheric contaminants 1 2 Requirements No single technique for preventing injury during lifting and material handling has been discovered despite numerous research efforts The best prevention strategy is to ensure workstations are properly designed loads are manageable in both size and weight distribution the frequency and dura tion of lifting are not excessively stressful and workers can demonstrate a knowledge of proper tech niques for material handling 1 2 1 Training The training program should be developed and presented by the supervisor and be designed to provide the worker a general awareness of ergonomic principles including e procedures for pe
25. actuated unit which receives only inanimate objects on a track roller conveyor or power conveyor forming the bed of the carrier and transmits these inanimate objects vertically from one elevation to another Warehouse Tractor or Tug An industrial vehicle designed to draw one or more nonpowered trailers AFOSHSTD91 46 1 FEBRUARY 1997 139 Attachment 2 SIGNIFICANT REFERENCES GLOSSARY OF COMMON USAGE TERMS NOT USED IN THIS STANDARD Antirunway A safety device to stop a declining conveyor in the event of a mechanical or electrical fail ure Apron Pan One of a series of overlapping or interlocking plates or shapes which together with others forms the conveyor bed Automatic Crane A crane which when activated operates through a preset cycle or cycles Axis of Rotation The vehicle axis around which the crane superstructure rotates Backstop A mechanical device to prevent reversal of a loaded conveyor under action of gravity when forward travel is interrupted Base Mounted Hoist A power driven drum or drums capable of lifting and lowering loads Battery Electric Truck A truck powered with a storage battery or batteries Bed e The part of a conveyor upon which the load or carrying medium rests or slides while being con veyed n bulk material conveyors the mass of material being conveyed Belt Tripper A device incorporating a system of pulleys which causes the conveyor belt to discharge material at one or more points
26. are started on a hoist the fol lowing precautions will be taken 5 2 4 3 1 If electrically powered the main switch on the line feeding the hoist will be locked in the open off position 5 2 4 3 2 If air powered the valve in the air line feeding the hoist will be closed with appro priate warning sign and or tag attached to the closed valve 5 2 4 3 3 An AF Form 979 981 or 982 tag will be placed on the hoist and the energy control locked out when adjustments modifications or repairs are scheduled The hoist operator will not apply power to the equipment or start operations until the conditions have been corrected and the tag removed Refer to AFOSH Standard 127 45 5 2 4 3 4 Drum pawls will be engaged or other means provided to prevent load ropes from inadvertently rotating the mechanism 5 2 4 4 Adjustments and Repairs Repair replacements or adjustments will be made to ensure correct performance of all hoist components The following are examples 5 2 4 4 1 Replace all worn braking components such as friction discs ratchets pawls and pawl springs 5 2 4 4 2 Replace worn corroded or otherwise damaged load chain and rope 5 2 4 4 3 Replace hooks showing defects Repair or replace damaged hook safety latches 5 2 4 4 4 Replace all other load supporting components which are cracked bent or exces sively worn 5 2 4 4 5 Replace missing or illegible warning labels 5 2 4 4 6 Replace pitted or burned electr
27. clear view of the conveyor and ready access to the devices AFOSHSTD91 46 1 FEBRUARY 1997 41 Chapter 5 HOISTS 5 1 Hazards and or Human Factors The most common hazards associated with hoists are overload ing dropping or slipping of the load caused by improper hitching or slinging obstruction to the free pas sage of the load failure to stabilize the load during the movement failure to detect or correct equipment deficiencies or malfunctions ignoring inspection or maintenance requirements unfamiliarity with con trols and misuse of the equipment Human factors such as inattention and failure to keep the load clear of people and objects are also factors which result in mishaps 5 2 Requirements 5 2 1 Acquisition Overhead hoists will meet the design specifications characteristics and rules of ANSI and or American Society of Mechanical Engineers ASME Standards B30 7 Base Mounted Drum Hoists B30 10 Hooks and B30 16 Overhead Hoists Underhung When applicable a sys tem safety program will be established The guidelines of Crane Manufacturer s Association of Amer ica Inc CMAA Specification Numbers 61 and 74 will be followed Nuclear certified hoists must meet requirements in 91 118 Safety Design and Evaluation Criteria for Nuclear Weapon Systems 5 2 2 General 5 2 2 1 Platforms Hoist platforms will be made with suitable side and overhead protection to prevent operator injury from a falling load
28. crane before their feet touch the ground 8 2 6 40 Except as otherwise stated herein operators of mobile cranes will maintain at least 2 feet of clearance from all walls overhead trestles columns and other structures In operations where motorized and or pedestrian traffic is anticipated or encountered the working area will be blocked off or controlled to keep people and vehicles away 8 2 6 41 Appropriate head protection will be worn by crane crew personnel when such protection is needed to protect workers from falling objects or impact type hazards Safety toe shoes will be worn by all materials handling and construction personnel involved in crane operations 8 2 6 42 Rail clamps will not be used as means of restraining tipping of a locomotive crane The weight of loads will be kept within the limitations of the cranes without using these clamps 8 2 6 43 Cranes will not be operated without the full amount of ballast or counterweight in place unless specifically authorized by the manufacturer s instructions 8 2 6 44 Clothing and personal belongings will be kept away from operator controls Tools oil cans waste extra fuses and other necessary articles will be stored in the tool box and will not be permitted to lie loose in or about the cab 8 2 6 45 Firm level within 1 percent footing under the crane is essential to prevent it from tip ping or sinking as loads are lifted and swung Where necessary this footing will be prov
29. device extending vertically from the fork carriage to keep cargo from falling rearward Bars The load carrying member mounted between two trolleys or two trolley yokes Belt Conveyor An endless fabric rubber plastic leather or metal belt operating over suitable drive 128 AFOSHSTD91 46 1 FEBRUARY 1997 tail end and bend terminals and over belt idlers or slider bed for handling bulk materials packages or objects placed directly upon the belt Belt Idler A roller or series of rollers which support the belt of a belt conveyor A cantilevered member or structure which may be hinged fixed or pivoted Boom Angle The angle between the longitudinal centerline of the boom and the horizontal The boom longitudinal centerline is a straight line between the boom foot pin heel pin centerline and the boom point sheave pin centerline Boom Crane A member fixed or telescoping hinged to the rotating superstructure and used to support the hoisting tackle Boom Hoist A hydraulic or mechanical hoist drum and rope reeving system used to raise and lower the boom The rope system may be all live reeving or a combination of live reeving and pendants Boom Stop A device used to limit the angle of the boom at the highest position Braided Wire Rope wire rope formed by plaiting braiding component wire strands Brake A friction device for slowing down a conveyor component bringing conveyor equipment to a contr
30. ends near the edges of the platform of the car or truck to prevent it from sliding 3 2 6 5 13 2 Dockboards and or bridgeplates are strong enough to carry the load 3 2 6 5 13 3 Dockboards and or bridgeplates have handholds or other effective means to permit safe handling 3 2 6 5 13 4 Dockboards and or bridgeplates are of proper width and or length and contain a nonskid surface 3 2 6 5 14 Operators will approach elevators slowly and enter squarely after the elevator car is properly level Once on the elevator the operator will neutralize the controls shut off the power and set the brakes AFOSHSTD91 46 1 FEBRUARY 1997 3 2 6 5 15 Motorized hand trucks will enter elevators or other confined areas with the load end first 3 2 6 6 When loading 3 2 6 6 1 The operator will ensure that only stable or safely arranged loads are transported 3 2 6 6 2 The operator will not exceed the rated capacity of the lift 3 2 6 6 3 When attachments are used the operator will take extra care in securing manipulat ing positioning and transporting the load 3 2 6 6 4 The operator will use extreme care when tilting loads forward or backward partic ularly when high tiering The operator will not tilt equipment forward with a fork s engaging means elevated except to pick up a load An elevated load will not be tilted forward except when the load is in a deposit position over a rack or stack When stacking or tiering operators wil
31. foot section 108 AFOSHSTD91 46 1 FEBRUARY 1997 9 2 2 4 Inspect the chain more thoroughly by removing chain from the hoist and cleaning it thor oughly in an acid free solvent Then check for any of the following deficiencies 9 2 2 4 Pins turned from their original position 9 2 2 4 2 Rollers that do not turn freely with light finger pressure 9 2 2 4 3 Joints that cannot be flexed by easy hand pressure 9 2 2 4 4 Link plates that are spread open A visual check of the pin extension at the free end of the chain can determine the amount of spread and the condition of the chain 9 2 2 4 5 Corrosion pitting or discoloration of chain which is generally indicative of serious impairment 9 2 2 4 6 Gouges nicks or weld spatter 9 2 3 Maintenance All chain should be kept clean and free from rust or any coating deposit that will build up and change its dimensions or reduce flexibility Excessively dirty chain should be soaked in a clean acid free solvent and agitated to ensure all joints are free from grit and foreign matter Hand chain normally needs no lubricant Roller and load chain should be lubricated according to the hoist manufacturer s recommendations In absence of recommendations the chain may be lubricated with a good grade of automotive motor oil SAE grade 20 30 Grease will never be applied to a chain 9 3 Sheaves and Equalizers 9 3 1 Sheaves 9 3 1 1 Sheave grooves will be smooth and free from surface defects
32. for load testing shall be tagged or adequately marked indicat ing total weight in pounds and owner and or agency identification number Rebar steel shall not be used for test weight lift points 8 2 3 2 Maintenance Procedure preventive maintenance program based on this standard and crane manufacturers recommendations will be established by the Vehicle Maintenance Officer Records of maintenance on the crane will be maintained according to AFI 24 302 or other appro priate directives 8 2 3 2 1 Before adjustments and repairs are started a crane the following precautions will be taken as applicable 8 2 3 2 1 1 Locate the crane where it will cause the least interference with other equip ment or operations 8 2 3 2 1 2 Place warning Do Not Start tag on the crane energy control 8 2 3 2 1 3 Lower the boom to the ground if possible or secure it against dropping 8 2 3 2 1 4 Lower the lower load block to ground or secure it against dropping 8 2 3 2 1 5 Stop the power plant 8 2 3 2 1 6 Disengage and lockout all starting controls 8 2 3 2 1 7 Turn off all controls and engage the pawls 8 2 3 2 1 8 Relieve hydraulic oil pressure from all hydraulic systems before loosening or removing hydraulic components 8 2 3 2 1 9 Retract all hydraulic cylinders used for boom hoisting and boom telescoping 8 2 3 2 2 After adjustments and repairs have been made the crane will not be operated until all guards have been reinstalled
33. formerly designated AFR 127 2 The US Air Force Mishap Prevention Program and will monitor the explosives phase of the training through spot checks 3 2 4 6 Materials handling and lifting equipment training will include 3 2 4 6 1 Equipment design to include restrictions limitations and hazards relative to the environment where used 3 2 4 6 2 Operating and maintenance instructions including those contained in this standard 3 2 4 6 3 Safe loading and or unloading requirements AFOSHSTD91 46 1 FEBRUARY 1997 15 3 2 4 6 4 Operating techniques inside and outside of warehouses 3 2 4 6 5 Flight line rules and or regulations when applicable 3 2 4 6 6 Fire extinguisher training which will be accomplished annually after initial instruc tions 3 2 4 6 7 Use of attachments such as extended forks or tines or personnel lift pallets 3 2 4 6 8 Clearances heights and limitations 3 2 4 6 9 Safety clothing and equipment 3 2 4 6 10 Fire protection fuel spills maintenance of equipment smoking etc 3 2 4 6 11 Operating restrictions in relation to potentially hazardous storage areas flamma ble toxic lumber coal etc 3 2 4 6 12 Computing inch pound rating of loads and equipment 3 2 4 6 13 Damage that may be caused by acid or caustic material 3 2 4 6 14 Workplace related topics such as surface conditions local policies on stacking unstacking and load manipulation 3 2 4 6 15 Applicable informatio
34. frame by a series of guys running from its base to high points on the support structure A second series of multiple guys are reeved from the top of the lift mast to the support frame for use in varying the position of the lift point at the mast top both longitudinally and in elevation Breast Derrick boomless derrick whose lift mast has the form of a truncated A frame with a tackle block reeved at its top end The inclination of the lift frame can be varied by reeved guy ropes Chicago Boom Derrick boom attached externally to a hoist structure The boom is hinged at its attached point and carries its own boom fall and load fall Ginpole Derrick A boomless derrick whose lift mast is guyed at its top by a fall line by which the load boom may be moved in one or more directions Guy Derrick A fixed pivot derrick consisting of a mast guyed at its top and capable of non con tinuous rotation through 360 degrees Its boom is hinged to the mast and provided with boom and lift falls Shear Leg Derrick A boomless derrick similar to a breast derrick The mast wide at the bottom and narrow at the top is hinged at its bottom and uses a multiple reeved toppings fall for changing the load lift radius The load tackle is secured to the mast top Stiff Leg Derrick A derrick similar to a guy derrick except that the mast is held in place by two or more stiff members stiff legs set to resist both tensile and compressive forces Sills are genera
35. its rated load capacity except for test purposes as provided in paragraph 7 2 5 6 7 2 4 5 2 When attaching the load ensure 7 2 4 5 2 1 The hoist chain or hoist rope is free from kinks twists and is not wrapped around the load 7 2 4 5 2 2 The load is attached to the load hook by means of slings or other approved devices 7 2 4 5 2 3 Care is taken to ensure the sling clears all obstacles 7 2 4 5 2 4 The slings or other approved devices are seated properly in the saddle of the hook before operation 7 2 4 5 3 When moving the load 7 2 4 5 3 1 The appointed person directing the lift will ensure the load is well secured and properly balanced in the sling or lifting device before it is lifted more than a few inches 7 2 4 5 3 2 Before starting to hoist the following conditions will be noted 7 2 4 5 3 2 1 Hoist rope or chain is not kinked or twisted 7 2 4 5 3 2 2 Multiple part lines are not twisted around each other AFOSHSTD91 46 1 FEBRUARY 1997 85 7 2 4 5 3 2 3 The hook is brought over the load in a way that prevents swinging 7 2 4 5 3 2 4 If there is a slack rope condition the rope is properly seated on the drum and in the sheaves before continuing the lift 7 2 4 5 3 3 Tag lines will be used for all free swinging loads 7 2 4 5 4 During hoisting care will be taken that 7 2 4 5 4 1 There is no sudden acceleration or deceleration of the moving load 7 2 4 5 4 2 Load does not contact any obstructions
36. maintenance of lubricant levels and types of lubri cant to be used 8 2 3 4 2 Unless the crane is equipped for automatic or remote lubrication it will be station ary while being lubricated and all controls will be at the OFF position the main power con trol switch if equipped locked out or off and pawls applied 8 2 4 Qualification of Operators 8 2 4 1 Crawler Locomotive Truck and Mobile Hydraulic Cranes 8 2 4 1 1 The examinee for an AF Form 483 Certificate of Competency will pass a written examination containing the safety requirements of this chapter and TO 36C 1 5 60 Rules on Safety The examinee will also be given a practical operating examination which will be developed by the using activity to demonstrate task qualification to operate the crane safely 8 2 4 1 2 Operators shall meet the following minimum physical qualifications 8 2 4 1 2 1 Have vision of at least 20 30 Snellen in one eye and 20 50 in the other with or without glasses 8 2 4 1 2 2 Be able to distinguish red green and yellow regardless of position of colors 8 2 4 1 2 3 Test for ordinary conversation in one ear with or without a hearing aid to ensure there is adequate hearing for a specific operation 8 2 4 1 2 4 Have sufficient strength endurance agility coordination and speed of reac tion to meet the demands of equipment operation 8 2 4 1 2 5 Evidence of physical defect or emotional instability which could render the
37. manually telescoped should be carefully repositioned prior to pinning to prevent injury to personnel 8 2 6 14 No crane will be loaded beyond its rated load except for test purposes as provided in paragraph 8 1 3 The weight of all loads will be determined before lifting 8 2 6 15 When attaching the load the hoist rope will not be wrapped around the load The load will be attached to the hook by means of slings or other approved devices of proper capacity 8 2 6 16 When moving the load the supervisor directing the lift will ensure 8 2 6 16 1 The crane is level and where necessary blocked properly Outriggers will be used See paragraph 8 2 6 24 8 2 6 16 2 The load is well secured and properly balanced in the sling or lifting device before it is hoisted more than a few inches 8 2 6 17 Before starting to hoist the operator will ensure that 8 2 6 17 1 The hoist rope is not kinked 8 2 6 17 2 Multiple part lines are not twisted around each other 8 2 6 17 3 The hook is brought over the load in a manner to prevent swinging and 8 2 6 17 4 If there is a slack rope condition the rope is properly seated on the drum and in the sheaves as the load is applied 8 2 6 18 During hoisting the operator will ensure that 8 2 6 18 1 There is no sudden acceleration or deceleration of the moving load and 8 2 6 18 2 Load and boom do not contact any obstructions 8 2 6 19 Side loading of booms will be limited to freely suspended lo
38. of Link Minimum Chain Allowable Size Chain Size Inches Inches 1 4 13 64 3 8 19 64 1 2 25 64 5 8 31 64 3 4 19 32 7 8 45 64 13 16 1 1 8 29 32 1 1 4 1 1 3 8 1 3 32 1 1 2 1 3 16 1 3 4 1 13 32 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 3 Rated Capacities for Single Leg Slings 6x19 and 6x37 Classification Improved Plow Steel Grade Rope With Fiber Core FC Dia Inches 1 4 5 16 3 8 7 16 1 2 9 16 5 8 3 4 7 8 Hand Tucked Splice and Hidden Tuck Splice Constr 6x19 6x19 6x19 6x19 6x19 6x19 6x19 6x19 6 x 19 6x19 6x19 6x37 6x37 6x37 6x37 6x37 6x37 HT 0 49 0 76 1 1 1 4 1 8 2 3 2 8 3 9 5 1 6 7 8 4 9 8 12 0 14 0 16 0 19 0 25 0 Vertical MS 0 51 0 79 11 1 5 2 0 2 5 3 1 4 4 5 9 77 9 5 11 0 13 0 16 0 18 0 21 0 28 0 S 0 55 0 85 12 1 6 2 1 2 7 3 3 4 8 6 4 8 4 10 0 12 0 15 0 15 0 21 0 24 0 31 0 HT 0 37 0 57 0 80 11 14 1 2 1 2 9 3 9 5 0 6 3 7 4 8 9 10 0 12 0 14 0 18 0 on 000 Choker MS 0 38 0 59 0 85 11 1 5 1 9 2 3 3 3 4 5 5 8 7 1 8 3 10 0 12 0 14 0 16 0 21 0 For hidden tuck splice IWRC use values in HT column MS Mechanical Splice S Swaged or Zinc Poured Socket These values only apply when the D d ratio for HT slings is 10 or greater and for MS and Slings is 20 or greater where D Diameter of curvat
39. on wire rope inspection replacement and maintenance 104 AFOSHSTD91 46 1 FEBRUARY 1997 Chapter 9 RELATED HOISTING EQUIPMENT 9 1 Wire Ropes 9 1 1 Use and Attachment Considerations 9 1 1 1 The crane manufacturer s recommendation will be followed when hoisting ropes are used 9 1 1 2 Socketing will be done in the manner specified by the manufacturer of the assembly 9 1 1 3 Swaged or compressed fittings will be applied as recommended by the rope or crane manufacturer 9 1 1 4 Rope will be secured to the drum as follows 9 1 4 1 No less than two wraps of rope will remain on the drum when the hook is in its extreme lowest position 9 1 1 4 2 The rope end will be anchored by a clamp securely attached to the drum or by a socket arrangement approved by the crane or rope manufacturer 9 1 1 4 3 If the crane is dual reeved with the rope terminated at the equalizer the termination fitting shall be rated as developing 100 percent of the rope strength 9 1 1 5 Rope clips attached with U bolts will have the U bolts on the dead or short end of the rope Spacing and number of all types of clips shall be according to the clip manufacturer s recom mendation or Figure 9 1 Clips shall be drop forged steel in all sizes manufactured commercially When a newly installed rope has been in operation for an hour all nuts on the clip bolts shall be retightened Refer to Figure 9 1 through Figure 9 4 and Table 9 1 9 1 2 Mainten
40. outside wires and the degree of distribution or connection of such broken wires 9 1 3 1 3 Worn outside wires 9 1 3 1 4 Sections of rope which are normally hidden or difficult to see during inspection or maintenance procedures such as parts passing over equalizer sheaves They will be given close inspection as these are points most likely to fail 9 1 3 1 5 Corroded or broken wires at end connections 9 1 3 1 6 Corroded cracked bent worn or improperly applied end connections 9 1 3 1 7 Severe kinking crushing cutting or unstranding of a hoist on which it is installed will be given a thorough inspection before it is placed in service 9 1 3 2 All rope which has been idle for a period of a month or more due to shutdown or storage Also see paragraph 9 1 4 3 9 1 4 Replacement 9 1 4 1 Precise rules to govern replacement of the ropes on lifting devices is impractical The fol lowing conditions will be sufficient reason for questioning rope safety and for possible replace ment 9 1 4 1 1 In running ropes six randomly distributed broken wires in one rope lay or three broken wires in one strand in one rope lay 9 1 4 1 2 Wear of one third the original diameter of outside individual wires 106 AFOSHSTD91 46 1 FEBRUARY 1997 9 4 1 3 Kinking crushing bird caging or any other damage resulting in distortion of the rope structure See Figure 9 6 9 1 4 1 4 Evidence of any heat damage from any cause 9 1 4
41. semiannually according to the requirements of paragraph 5 2 5 2 Those exposed to adverse environment shall be inspected more frequently 10 3 Testing 10 3 1 new derricks will have the manufacturer s certification that all proof load testing has been accomplished Prior to initial use all modified and altered derricks shall be proof load tested to ensure compliance with this standard including the following functions 10 3 1 1 Load hoisting and lowering 10 3 1 2 Boom up and down 10 3 1 3 Swing 10 3 1 4 Operation of clutches and brakes of hoist 10 3 2 anchorage shall be approved by the appointed personnel Rock and hairpin anchorages may require special testing 10 4 Maintenance 10 4 1 Preventive Maintenance 10 4 1 1 A preventive maintenance program based on the derrick manufacturer s recommenda tions shall be established Dated and detailed records should be readily available 10 4 1 2 Replacement parts should be obtained from the original equipment manufacturer 10 4 2 Maintenance Procedure 122 AFOSHSTD91 46 1 FEBRUARY 1997 10 4 2 1 Before adjustments and repairs are started on a derrick the following precautions shall be taken 10 4 2 1 1 The derrick to be repaired shall be arranged so it will cause the least interference with other equipment and operations in the area 10 4 2 1 2 hoist drum dogs shall be engaged 10 4 2 1 3 The main or emergency switch shall be locked in the open positi
42. shall meet the following minimum physical qualifications 7 2 3 1 2 1 Have vision of at least 20 30 Snellen in one eye and 20 50 in the other with or without glasses 7 2 3 1 2 2 Be able to distinguish red green and yellow regardless of position of colors 7 2 3 1 2 3 Test for ordinary conversation in one ear with or without a hearing aid to ensure there is adequate hearing for a specific operation 7 2 3 1 2 4 Evidence of physical defect or emotional instability which could render the operator a hazard to himself or others or which in the opinion of the examiner or supervi sor could interfere with the operator s safe performance may be sufficient cause for dis qualification In such cases specialized clinical or medical judgments and tests may be required Note A history of epilepsy or a disabling heart condition may be sufficient reason for disqualification 7 2 3 1 3 Potential operator trainees will have good depth perception field of vision reaction time manual dexterity or coordination and no tendencies to dizziness or similar undesirable characteristics Physical defects such as loss of arm hand leg foot or gross loss of function thereof will be considered as cause for denial of acceptance into an entry level training pro gram for operators 7 2 3 2 Floor Operated Equipment 7 2 3 2 Supervision will require personnel pass a practical operating examination adminis tered by a qualified operator and or inst
43. should be taken to repair leaking equipment 3 3 1 4 The warehouse supervisor shall conduct inspections daily to ensure that powered materi als handling equipment is parked in designated locations equipment does not contain excessive grease and lint and gasoline lines tanks oil seals and so forth are not leaking 3 3 1 5 A minimum of 10 foot clearance shall be maintained between parked equipment and combustible materials 3 3 1 6 Gasoline or diesel powered equipment used in multistory buildings shall be parked on the ground floor when not in use Also see paragraph 3 2 6 2 3 3 2 Battery Charging Operations See NFPA 505 Section 5 3 for information on charging installation design requirements 3 3 2 1 Battery charging operations shall be conducted in adequately ventilated areas that are designated for that purpose 3 3 2 2 If batteries must be removed from equipment for charging or servicing a way to flush and neutralize spilled electrolyte and facilities for quick drenching of eyes will be provided Only trained qualified equipment operators shall change or charge batteries If performing service other than removal and replacement of batteries operators will wear appropriate protective equipment 1 rubber apron face shield and gloves Rings watches and similar jewelry will not be worn 3 3 2 3 No Smoking signs will be posted in plain view of incoming personnel to prohibit smoking in the charging area 3 3
44. slings and ropes Locomotive Crane crane consisting of a rotating superstructure with power plant operating machinery and boom mounted on a base or car equipped for travel on railroad track It may be self propelled or propelled by an outside source Low Lift Truck A truck designed to raise a load sufficiently to permit horizontal movement Examples are the low lift platform truck and the pallet truck Magnet An electromagnetic device carried on a hoist hook used to pick up and carry loads magnetically 134 AFOSHSTD91 46 1 FEBRUARY 1997 Man Rated A crane specifically configured or designed and built for raising and lowering personnel in work cages or baskets having a positive controlled powered lowering system upper limit switch and dead man controls Mast A vertical support guide on a forklift truck which permits vertical movement of the forks Mechanical A method of control by friction Monorail An overhead track upon which carriers travel to transport loads Motorized Hand Truck A truck designed to be controlled by a walking operator Nuclear Certified Equipment Equipment that is nuclear certified and listed in TO 00 11ON 16 The single point of contact for Air Force to certify equipment for use with nuclear weapons is HQ AFSC SEWA This office in coordination with the Director of Nuclear Weapons Directorate SA ALC NWTD Kelly AFB TX establishes the equipment as certified and ensures the equ
45. which bulk materials or objects are directed and lowered by gravity The trough may be open or enclosed straight or curved Collector Wheel That part of a current collector that makes contact by rolling on the conductor bar or wire Conveying Medium That portion of a conveyor which moves or carries materials packages or objects Conveyor e Apron Conveyor A conveyor in which an apron forms the moving bed e Declining Conveyor A conveyor transporting down a slope En Masse Conveyor A conveyor comprised of a series of skeleton or solid flights on an endless chain or other linkage which operates in horizontal inclined or vertical paths within a closely fit ted casing for the carrying run Bulk material is conveyed and elevated in a substantially continu ous stream with a full cross section of the casing e Extendible Conveyor A conveyor which may be lengthened or shortened while in operation to suit operating needs e Flight Conveyor A type of conveyor comprised of one or more endless propelling media such as chain to which flight are attached and a trough through which material is pushed by the flights e Mobile Conveyor Conveyors supported on structures which are movable under their own power and include but are not limited to radial sand winged stackers reclaiming conveyors and ship loaders These conveyors normally handle bulk material e Oscillating Conveyor A type of vibrating conveyor having a relatively low freque
46. 0 13 800 16 900 27 600 23 900 1 19 6001 13 800 1 24 800 12 400 149 7001 43 000 35 100 24 800 Figures 6 1 and 6 2 for sling configuration descriptions 77 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 20 Synthetic Web Slings 1 000 Pounds Per Inch of Width Single Ply o09 009 000 002 E 00 0091 008 9 059 005 007 0055 011 St 00 8 006 9 005 051 008 001 0 294 s2ut s umo 0096 000 8 0079 008 0056 0091 WA 008 OSTE 009 061 00t t 059 008 000 002 00 0091 008 009 1 00 11 000 6 008 9 005 0055 00991 00261 0061 00091 0081 008 009 6 00 0079 008 005 Aq pourengo oq umoys jou supra orerpottuoqut Joy 2 Teorya so Sue IV 1 SALON 00 00v 9 oor s 008 0092 0071 A ody 59015 ssoppug spunod ur 009 6 0008 oor 008 005 009 1 000 9 000 000 000 000 000 0058 0014 004 002 008 00b 0t 0088 0069 005 00 00 71 00021 000 01 0008 000 9 000 000 3 pasm WIM 249 ody pue AJ I od sBurgs o Sueu 1 oj8uenr od 5801 24049 oost 00L 000 0022 0057 OSL 581 000 9 000 000 000 m cto D AFOSHSTD91 46 1 FEBRUARY
47. 1 7 7 19 1 1 8 7 7 19 1 1 4 7 7 19 3 4 7x6x19 IWRC 7 8 7x6x19 IWRC 1 7x6x19 IWRC 1 1 8 7x6x19 IWRC 1 1 4 7x6x19 IWRC 1 3 8 7x6x19 IWRC 1 1 2 7x6x19 IWRC These values only apply when the D d value is 5 or greater where D Diameter of curvature around which cable body is bent d Diameter of cable body 72 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 15 Rated Capacities Carbon Steel and Stainless Steel Metal Mesh Slings Horizontal angles snown in parentneses Effect of angle on rated capacities in basket hitch Sling width Vertical in or 60 inches choker 30 Heavy Duty 10 Ga 35 Spirals Ft of sling width 2 1 500 3 000 2 600 2 100 1 500 3 2 700 5 400 4 700 3 800 2 700 4 4 000 8 000 6 900 5 600 4 000 6 6 000 12 000 10 400 8 400 6 000 8 8 000 16 000 13 800 11 300 8 000 10 10 000 20 000 17 000 14 100 10 000 12 12 000 24 000 20 700 16 900 12 000 14 14 000 28 000 24 200 19 700 14 000 16 16 000 32 000 27 700 22 600 16 000 18 18 000 36 000 31 100 25 400 18 000 20 20 000 40 000 34 600 28 200 20 000 Medium Duty 12 Ga 43 Spirals Ft of sling width 2 1 350 2 700 2 300 1 900 1 400 3 2 000 4 000 3 500 2 800 2 000 4 2 700 5 400 4 700 3 800 2 700 6 4 500 9 000 7 800 6 400 4 500 8 6 000 12 000 10 400 8 500 6 000 10 7 500 15 000 13 000 10 600 7 500 12 9 000 18 000 15 600 12 700 9 000 14 10 500 21 000 18 200 14 800 10 500 16 12 000 24 000 20 800 17 000 12 000 18 13 500 27 000 23 400 19 100 13 500 20 15 000
48. 2 These values only apply when the D d ratio is 10 or greater where 7x7x7 7x7x7 7 7 7 7 7 7 7 7 7 7 7 19 7 7 19 7x7x19 7x7x19 7x7x19 7x7x19 7x6x19 IWRC 7 19 IWRC 7 19 7 19 7 19 IWRC 7 19 7 19 7 19 7 7 9 2 10 0 11 0 13 0 we 0 38 0 81 1 4 2 1 2 9 2 2 3 0 4 0 5 1 6 2 7 4 2 8 3 8 4 8 D Diameter of curvature around which the body of the sling is bent d Diameter of rope DOO 1 0 2 0 3 7 5 5 7 6 5 8 8 1 11 0 14 0 16 0 20 0 7 6 10 0 13 0 15 0 18 0 20 0 22 0 26 0 64 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 6 Rated Capacities for Single Leg Slings Part and 6 Part Braided Rope 6x7 and 6x19 Construction Improved Plow Steel Grade Rope 7x7 Construction Galvanized Aircraft Grade Rope Diameter Vertical Choker Basket Vertical to 30 degrees Inches Constr 8 Part 6 Part 8 Part 6 Part 8 Part 6 Part 3 32 6x7 0 42 0 32 0 32 0 24 0 74 0 55 1 8 6x7 0 75 0 57 0 57 0 42 1 3 0 98 3 16 6 7 1 7 1 3 1 3 0 94 2 9 2 2 3 32 7 7 0 51 0 39 0 38 0 29 0 89 0 67 1 8 7 7 0 95 0 7 0 71 0 53 1 6 1 2 3 16 7 7 2 1 1 5 1 5 1 2 3 6 27 3 16 6 19 1 7 1 3 1 3 0 98 3 0 2 2 1 4 6x19 3 1 2 3 2 3 1 7 5 3 40 5 16 6 19 4 8 3 6 3 6 2 7 8 3 6 2 3 8 6 19 6 8 5 1 5 1 3 8 12 0 8 9 7 16 19 9 3 6 9 6 9 5 2 16 0 12 0 1 2 19 12 0 9 0 9 0 6 7 21 0 15 0 9 16 19 15 0 11 0 11 0 8
49. 2 The operator will respond to signals only from the designated signal person but will obey an emergency stop signal at any time no matter who gives it 8 2 6 3 The operator will be responsible for those operations under their direct control Whenever there is any doubt as to safety the operator will have the authority to stop and refuse to handle loads until safety has been ensured 8 2 6 4 The operator will sound or give an audible warning signal each time before traveling backing and when approaching workmen or other congested areas The signal may be mechan ical automatic or oral 8 2 6 5 Before leaving their crane unattended the operator will 8 2 6 5 1 Lower to the ground any suspended load bucket lifting magnet or other device 8 2 6 5 2 Disengage clutch 8 2 6 5 3 Set travel swing boom brakes and other locking devices 8 2 6 5 4 Put controls in the OFF or neutral position 8 2 6 5 5 Stop the engine 8 2 6 5 6 Secure crane i e chocks brakes etc against accidental travel 8 2 6 6 During periods of non use high winds or weather alerts the operator will lower the boom to ground level or to a resting platform or otherwise ensure the boom is secure against dis placement from wind loads or other outside forces 8 2 6 7 If there is a warning tag or lock on the switch or engine starting controls the operator will not close the switch or start the engine until the warning tag or lock has been removed by the
50. 2 2 2 3 3 Leaks at spools or joints 8 2 2 2 3 4 Sticking spools 94 AFOSHSTD91 46 1 FEBRUARY 1997 8 2 2 2 3 5 Failure of relief valves to attain correct pressure setting as specified by the manufacturer 8 2 2 2 4 Cylinders The following may be reasons for replacement or repair 8 2 2 2 4 1 Drifting caused by oil leaking across piston 8 2 2 2 4 2 Rod seals leaking 8 2 2 2 4 3 Leaks at welded joints 8 2 2 2 4 4 Scored nicked or dented cylinder rods 8 2 2 2 4 5 Dented case barrel 8 2 2 2 4 6 Loose or deformed rod eyes or connecting joints 8 2 2 2 5 Filters Evidence of rubber particles on the filter element may indicate hose O ring or other rubber component deterioration Metal chips or pieces on the filter may denote failure in pumps motors or cylinders Further checking will be necessary to determine origin of the problem before corrective action can be taken 8 2 2 2 6 Control Mechanisms These mechanisms will be checked for maladjustment 8 2 2 3 Monthly Inspections The following items will be inspected by the operator or designated person for defects at intervals at least monthly specified by the Vehicle Maintenance Officer The inspection will include observation during the crane s operation 8 2 2 3 1 Vehicle control mechanisms for excessive wear of components and contamination by lubricants or other foreign matter 8 2 2 3 2 Installed safety devices for proper operation 8 2 2 3 3 Crane hoo
51. 2 4 Tools and other metallic objects will be kept away from the top of uncovered batteries 3 3 2 5 When charging batteries the vent caps will be kept in place to avoid electrolyte spray AFOSHSTD91 46 1 FEBRUARY 1997 21 3 3 2 6 The battery compartment or covers will be open to dissipate heat Also see paragraph 3 2 6 1 3 3 3 Liquid Petroleum LP Gas Powered Materials Handling and Lifting Equipment 3 3 3 1 Operators of LP gas industrial and lift trucks will not park trucks near sources of heat open flames or similar sources of ignition or near inadequately ventilated pits 3 3 3 2 Trucks equipped with a permanently mounted container will be refueled outdoors 3 3 3 3 Exchange of removable fuel containers should be done outdoors The exchange may be done indoors providing the exchange is made in a well ventilated area away from ignition sources and one of the following methods is used to minimize the release of fuel from the fuel lines 3 3 3 3 1 Use an approved quick closing coupling a type closing in both directions when uncoupled in the fuel line or 3 3 3 3 2 Close the shutoff valve at the fuel container and allow the engine to run until the fuel in the line is exhausted Note Ensure all indoor container change out operations are approved by local fire protection officials 3 3 3 4 Containers will be kept secured at all times Also see paragraph 3 2 6 3 3 3 4 Petroleum Equipment Servicing 3 3 4 1 Units with
52. 2 4 4 While actually engaged in operating the equipment the operator will not divert their attention 7 2 4 4 2 An operator will not engage in the operation of equipment when he or she is physi cally or mentally unfit 7 2 4 4 3 The operator will respond to signals only from the person who is directing the lift or a designated signal person but will obey a stop signal at all times 7 2 4 4 4 Each operator will be held directly responsible for the safe operation of the equip ment Whenever there is any doubt as to safety the operator will have the authority to stop and refuse to handle loads until safety has been ensured 7 2 4 4 5 A warning signal if required will be sounded each time before traveling and inter mittently during travel particularly when approaching personnel 7 2 4 4 6 Before leaving the equipment unattended the operator will lower the load to the ground place controls in the off position and open the main line switch of the specific equipment if either cab or pulpit operated 7 2 4 4 7 If the operator finds the main or emergency switch open off when starting on duty he or she will not close it turn it on until making certain no one is on or about the equipment If there is a warning tag on the main switch or the switch is locked out only the supervisor or person placing the tag or lock will remove it See AFOSH Standard 127 45 84 AFOSHSTD91 46 1 FEBRUARY 1997 7 2 4 4 8 Before closing the
53. 5 26 0 20 0 5 6 19 19 0 14 0 14 0 10 0 32 0 24 0 3 4 19 27 0 20 0 20 0 15 0 46 0 35 0 7 8 19 36 0 27 0 27 0 20 0 62 0 47 0 1 19 47 0 35 0 35 0 26 0 81 0 61 0 These values only apply when the D d rate is 20 or greater where D Diameter of curvature around which the body of the sling is bent d Diameter of component rope AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 7 Rated Capacities for 2 Leg and 3 Leg Bridle Slings 6x19 and 6x37 Classification Improved Plow Steel Grade Rope With Fiber Core FC Horizontal angies Snown 1n Rated Capacities Tons 2 000 Lb 2 Leg BridleSlings Bridle 2 Leg BridleSlings 3 Leg Bridle Slings Constr A P 60 30 30 60 pod ken m MM Hand Tucked Splice Mechanical Splice 65 66 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 8 Rated Capacities for 2 Leg and 3 Leg Bridle Slings 6x19 and 6x37 Classification Improved Plow Steel Grade Rope With Independent Wire Rope Core IWRC Horizontal angles shown in parentheses ed D DOO Lh 2 LegBridleSlings 3 Leg Bridle Slings 45 45 Angle 60 309 30 60 Angle HT Hand Tucked Splice MS Mechanical Splice AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 9 Rated Capacities for 2 Leg and 3 Leg Bridle Slings Cable Laid Rope Mechanical Splice Only 7x7x7 and 7x7x19 Constructions Galvanized Aircraft Grade Rope 7x6x19 IWRC Construction Improved
54. 515 2 060 1 780 1 460 1 030 1 850 925 3 710 3 210 2 620 1 850 3 4 14 5 1 410 705 2 820 2 440 1 990 1 410 2 540 1 270 5 080 4 400 3 590 2 540 13 16 17 0 1 680 840 3 360 2 910 2 380 1 680 3 020 1 10 6 050 5 240 4280 3 020 7 8 20 0 1 980 990 3 960 3 30 2 800 1 980 3 560 1 780 7130 6 170 5 040 3 560 1 26 0 2 480 1240 4960 4300 3 510 2480 4 460 2 230 8 930 7 730 6 310 4 460 1 1 16 29 0 2 850 1 430 5 700 4940 4 030 2 850 5 130 2 570 10 00 8890 7260 5 130 1 1 8 34 0 3 270 1 640 6 540 5 660 4 620 3 270 5 890 2 940 11 800 10 200 8 330 5 890 1 1 4 40 0 3 710 1 860 7 420 6 430 5 250 3 710 6 680 3 340 13 400 11 600 9 450 6 680 1 5 16 45 0 4 260 2 130 8 520 7 380 6 020 4 260 7 670 3 830 15 300 13 300 10 800 7 670 1 1 2 55 0 5 250 2 630 10 500 9 090 7 420 5 250 9 450 4 730 118 900 16 400 13 400 9 450 1 5 8 68 0 6 40 3 220 12 900 11 200 9 110 6 440 11 600 5 800 23 200 20 100 16 400 11 600 1 3 4 83 0 7 720 3 860 15 400 13 400 10 900 7 720 13 900 6 950 27 800 24 100 19 700 13 900 2 95 0 9110 4 560 18 200 15 800 12 900 9 110 16 400 8 200 32 800 28 400 23 200 16 400 2 1 8 109 0 10 500 5 250 21 000 18 200 14 800 10 500 18 900 9 450 37 800 32 700 26 700 18 900 2 1 4 129 0 12 400 6 200 24 800 21 500 17 500 112 400 22 300
55. 6 400 19 100 21 800 24 500 Choker hitch 570 710 890 1 120 1 390 1 600 2 960 2 280 2 630 2 960 3 340 4 170 5 080 6 040 7 130 8 200 9 540 10 900 12 200 ndless s Basket hitch Angle of rope horizontal 90 60 45 0 30 45 2 290 1 980 1 620 2 840 2 460 2 010 3 570 3 090 2 520 4 470 3 870 3 160 5 540 4 800 3 920 6 410 5 550 4 530 7 850 6 800 5 550 9 110 7 990 6 440 10 500 9 100 7 440 11 800 10 300 8 380 13 400 11 600 9 450 16 700 14 400 11 800 20 300 17 600 14 400 24200 20 900 17 100 28 500 24 700 20 200 32 800 28 400 23 200 38 200 33 100 27 000 43 600 37 700 30 800 49 000 42 400 34 600 30 60 1 140 1 420 1 780 2 230 2 770 3 200 3 920 4 550 5 260 5 920 6 680 8 330 10 200 12 100 14 300 16 400 19 100 21 800 24 500 75 76 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 19 Polypropylene Rope Slings Angle of rope to vertical shown in parentheses Eye and eye sling Endless sling Rope Nominal Basket hitch Angle of rope to Basket hitch Angle of rope to dia wt per Verti Choker horizontal Verti Choker horizontal hitch hitch 60 325 580 nominal 100 cal cal i 90 60 45 30 hitch 90 45 30 0 30 45 60 0 Gory 45 60 in hitch inches pounds 1 2 4 7 645 1 290 1 120 910 645 1 160 2 320 2 010 1 640 1 160 9 16 6 1 780 390 1 560 1 350 1 100
56. 780 1 400 700 2 810 2 430 1 990 1 400 5 8 7 5 950 475 1 900 1 650 1 340 950 1 710 855 3 420 2 960 2 420 1 710 3 4 10 7 1 300 650 2 600 2 250 1 840 1 300 2 340 1 170 4 680 4 050 3310 2 340 13 16 12 7 1 520 760 3 040 2 630 2 150 1 520 2 740 1 370 5 470 4 740 3 870 2 740 7 8 15 0 1 760 880 3 520 3 050 2 490 1 760 3 170 1 580 6 340 5 490 4 480 3 170 1 18 0 2 140 1 070 4 280 3 700 3 030 2 140 3 850 1 930 7 700 6 670 5 450 3 860 1 1 16 20 4 2 450 1 230 4 900 4 240 3 460 2 450 4 410 2 210 8 820 7 640 6 240 4 410 1 1 8 23 7 2 800 1 400 5 600 4 850 3 960 2 800 5 040 2 520 10 100 8 730 7 130 5 040 1 1 4 270 3 210 1 610 6 420 5 560 4 540 3 210 5 780 2 890 11 600 10 000 8 170 5 780 1 5 16 30 5 3 600 1 800 7 200 6 240 5 090 3 600 6 480 3 240 13 000 11 200 9 170 6 480 1 1 2 38 5 4 540 2 270 9 080 7 860 6 420 4 540 8 170 4 090 16 300 14 200 11 600 8 170 1 5 8 47 5 5 510 2 760 11 000 9 540 7 790 5 510 9 920 4 960 19 800 17 200 14 000 9 920 1 3 4 57 0 6 580 3 290 13 200 11 400 9 300 6 580 11 800 5 920 23 700 20 500 16 800 11 800 2 69 0 7 960 3 980 15 900 13 800 11 300 7 960 14 300 7 160 28 700 24 800 20 300 14 300 2 1 8 80 0 9 330 4 670 18 700 16 200 13 200 9 330 16 800 8 400 33 600 29 100 23 800 16 800 2 1 4 92 0 10 600 5 300 21 200 18 400 15 000 10 600 19 100 9 540 38 200 33 100 27 000 19 100 2 1 2 107 0 12 200 6 100 24 400 21 100 17 300 12 200 22 000 11 000 43 900 38 000 31 100 22 000 2 5 8 120
57. 7x19 Construction Galvanized Aircraft Grade Rope 7x6x19 IWRC Construction Improved Plow Steel Grade Rope dae 63 Table 6 6 Rated Capacities for Single Leg Slings Part and 6 Part Braided Rope 6x7 and 6x19 Construction Improved Plow Steel Grade Rope 7x7 Construction Galvanized Aircraft Grade Rope pret ote ee yes abe pibe Ie 64 4 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 7 Rated Capacities for 2 Leg and 3 Leg Bridle Slings 6x19 and 6x37 Classification Improved Plow Steel Grade Rope With Fiber Core FC 65 Table 6 8 Rated Capacities for 2 Leg and 3 Leg Bridle Slings 6x19 and 6x37 Classification Improved Plow Steel Grade Rope With Independent Wire Rope Core IWRC 66 Table 6 9 Rated Capacities for 2 Leg and 3 Leg Bridle Slings Cable Laid Rope Mechanical Splice Only 7 7 7 and 7x7x19 Constructions Galvanized Aircraft Grade Rope 7x6x19 IWRC Construction Improved Plow Steel Grade Rope eee 67 Table 6 10 Rated Capacities for 2 Leg and 3 Leg Bridle Slings 8 Part and 6 Part Braided Rope 6x7 and 6x19 Construction Improved Plow Steel Grade Rope 7x7 Construction Galvanized Aircraft Grade 68 Table 6 11 Rated Capacities for Strand Laid Grommet Hand Tucked Improved Plow Steel Grade ROPES DP ME 68 Table 6 12 Rated Capacities for Cable Laid Grommet Hand Tucked 7x6x7 and 7x6x19 Construction
58. 940 7 780 3 890 1 14 41 7 2430 1220 4860 4210 3 440 2 430 4370 2 190 8 750 4 370 1516 479 2 70 1350 5 400 4 680 3 820 2 700 4 860 2 430 9 720 4 860 1 172 599 3 330 1 670 6 600 5770 4710 3 330 5 990 3 000 12 000 5 990 1 58 746 4050 2 030 8100 7010 5 730 4050 7290 3 650 14 600 7 290 1 34 393 4 770 2390 9 540 8260 6 740 4770 8 590 4290 17 200 8 590 2 107 5 5 580 2 790 11 200 9 660 7 890 5 580 10 000 5 020 20 100 10 000 2 18 125 0 6 480 3240 13 000 11 200 9 160 6 480 11 700 5 830 23 300 11 700 2 1 4 146 0 7380 3 690 14 800 12 800 10 400 7 380 13 300 6 640 26 600 13 300 2 12 1667 8370 4190 16700 14 500 11 800 8 370 15100 7 530 30 100 15 100 2 5 8 V 190 8 19 360 4 680 18 700 16200 113 200 9 60 16 800 420 33 700 16 800 See Figures 6 1 and 6 2 for sling configuration descriptions 74 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 17 Nylon Rope Slings Angle of rope to vertical shown in parentheses Eye and Eye Sling Endless Sling Rope Nominal ug ego aid dia wt per Verti Vertical aus rd rad in 100 ft in hitch hitch Tm 30 hitch Y inches pounds 45 60 ha 45 p 1 2 6 5 635 320 1 270 1 100 900 635 1 140 570 2 290 1 980 1 620 1 140 9 16 8 3 790 395 1 580 1 370 1 120 790 1 420 710 2 840 2 460 2 010 1 420 5 8 10 5 1 030
59. AFOSHSTD91 46 1 FEBRUARY 1997 5 2 3 2 3 Before starting the hoist the operator will be certain all personnel are clear of the area 5 2 3 2 4 The operator will be familiar with the equipment and its proper care If adjustments or repairs are necessary or any damage is observed or suspected the operator will promptly report the problem to their supervisor 5 2 3 2 5 controls will be tested by the operator before beginning a shift If any controls do not operate properly they will be adjusted or repaired before operations are started Limit switches will be checked under no load conditions exercising care at slow speeds 5 2 3 2 6 The operator will make sure their hands are clear of all moving parts before operat ing the hoist 5 2 3 2 7 On chain hoists the operator will have safe access to the hand chain 5 2 3 2 8 Manual hoists will never be operated by other than hand power 5 2 3 3 Handling the Load 5 2 3 3 1 The rated load will not be exceeded except for properly authorized tests If at any time it is known or suspected that a nuclear certified hoist may have been overloaded other than a required and approved test load take action to ensure that all inspections daily through annual are completed prior to use with nuclear loads 5 2 3 3 2 The hoisting rope or chain will not be wrapped around the load 5 2 3 3 3 The load will be attached to the hook equipped with safety latch by means of slings or other devices
60. BY ORDER OF THE AIR FORCE OCCUPATIONAL SAFETY AND SECRETARY OF THE AIR FORCE HEALTH STANDARD 91 46 1 FEBRUARY 1997 Safety MATERIALS HANDLING AND STORAGE EQUIPMENT NOTICE This publication is available digitally on the SAF AAD WWW site at http afpubs hq af mil If you lack access contact your Publishing Distribution Office PDO HQ AFSC SEGO Certified by HQ AFSC SEG Richard L Baird Colonel John P Lucas Supersedes AFOSH Standard 127 46 Pages 147 15 December 1991 Distribution F The criteria in this standard are the Air Force s minimum safety fire protection and occupational health requirements Major commands MAJCOM direct reporting units and field operating agencies FOA may supplement this standard when additional or more stringent safety fire prevention and health criteria are required Refer to Air Force Instruction 91 301 formerly designated 127 12 Air Force Occupational and Environmental Safety Fire Protection and Health AFOSH Program for instructions on processing supplements or variances Report conflicts in guidance between this standard federal standards or other Air Force directives through MAJCOM DRU or FOA ground safety offices to Headquarters Air Force Safety Center Ground Safety Division Safety Engineering and Standards Branch HQ AFSC SEGS 9700 G Avenue SE Suite 222D Kirtland AFB NM 87117 5670 This standard establishes Air Force safety criter
61. Figure 3 15 Truck Hand Platform 4 Wheel Figure 3 16 Crane Truck Warehouse Electric AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 17 Crane Truck Warehouse Gasoline 37 38 AFOSHSTD91 46 1 FEBRUARY 1997 Chapter 4 CONVEYORS 4 1 Hazards and or Human Factors Hand and finger injuries are frequently sustained when person nel place their hands between boxes or other objects on conveyors or attempt to remove or unjam objects Injuries also occur from hand and or finger contact with conveyor rollers 4 2 Requirements 4 2 1 Acquisition 4 2 1 1 Ensure all chains sprockets belts couplings and other moving parts to drive conveyors are enclosed or guarded 4 2 1 2 Ensure a safety device is installed to prevent hands from being pinched between power and idler rollers 4 2 1 3 Ensure all electric motors controls wiring and their installation will conform to the specifications of NFPA 70 The National Electrical Code NEC 4 2 1 4 Ensure manually operated hinged sections are designed with spring tension to minimize the effort required to move them 4 2 1 5 Ensure mechanically operated sections have positive catches or stops to hold them 4 2 1 6 Ensure horizontally hinged sections are designed so they cannot roll vibrate or shift out of the intended position 4 2 1 7 Ensure all overhead conveyors have rails or roller guards to hold objects on the conveyor and sheet metal guards wire mesh or suitab
62. Inc DoD Department of Defense DRU Direct Reporting Unit F Fahrenheit FC Fiber Core FOA Field Operating Agency HQ Headquarters IWRC Independent Wire Rope Core JSA Job Safety Analysis JSM Joint Service Manual kV Kilovolts LP Liquid Petroleum MAJCOM Major Command MHE Materials Handling Equipment Mil Std Military Standard NDI Non Destructive Inspection NEC National Electrical Code NFPA National Fire Protection Association NS C wNational Safety Council OSHA Occupational Safety and Health Administration AFOSHSTD91 46 1 FEBRUARY 1997 AFOSHSTD91 46 1 FEBRUARY 1997 127 PPE Personal Protective Equipment SAE Society of Automotive Engineers Inc SA ALC San Antonio Air Logistics Center Technical Order Terms Shall Indicates a mandatory requirement Will Is also used to indicate a mandatory requirement and in addition is used to express a declaration of intent probability or determination Should Indicates a preferred method of accomplishment May Indicates an acceptable or satisfactory method of accomplishment Definitions Definition of terms used in the standard are included in this section VOTE Definitions of common usage terms not actually used in the standard but which may be encountered by materials handling and storage personnel in other documents are at Attachment 2 463L Equipment Specialized material handling equipment designed for on an
63. MERGENCY STOP Both arms extended palms down move arms back and forth MAGNET IS DISCONNECTED Crane operator spreads both hands apart palms up AFOSHSTD91 46 1 FEBRUARY 1997 91 Chapter 8 MOBILE AND LOCOMOTIVE CRANES 8 1 Hazards and or Human Factors 8 1 1 One of the greatest hazards associated with mobile crane operations is electrocution resulting from the equipment coming in contact with energized electric lines 8 1 2 Other potential hazards to personnel and property are overloading sideloading rope or hydraulic failure striking people or objects with moving loads or movable parts of the crane dropping or slipping of the load due to improper hitching or slinging failure to use outriggers floats blocks or mats operating on a surface that is not stable or level slipping or falling from equipment failure to use available safety devices such as brakes locks and warning signals failure to detect or correct equipment deficiencies or malfunctions ignoring inspection and maintenance requirements misuse of the machine and unqualified personnel operating the equipment 8 1 3 Where feasible safeguards have been built in to minimize the probability for human error but hazards that cannot be abated by mechanical means still exist It is important that supervisors select individuals who are physically and mentally fit to operate cranes Poor coordination or mental alert ness visual acuity depth perception peripheral vi
64. Plow Steel Grade Rope Horizontal angles shown in parentheses Rope Rated capacities tons 2 000 Lb Sieg Bride sing Dia In Constr 30 45 60 30 45 60 60 Angle 30 60 Angle 30 1 4 7 7 7 0 87 0 71 0 50 1 3 11 0 75 3 8 7 7 7 1 9 1 5 1 1 2 8 2 3 1 6 1 2 7 7 7 3 2 2 6 1 8 4 8 3 9 2 8 5 8 7 7 7 4 8 3 9 2 8 7 2 5 9 4 2 3 4 7 7 7 6 6 5 4 3 8 9 9 8 1 3 7 5 8 7 7 19 5 0 4 1 2 9 7 5 6 1 4 3 3 4 7 7 19 7 0 5 7 4 1 10 0 8 6 6 1 7 8 7 7 19 9 3 7 6 5 4 14 0 11 0 8 1 1 7 7 19 12 0 9 7 6 9 18 0 14 0 10 0 1 1 8 7 7 19 14 0 12 0 8 2 21 0 17 0 12 0 1 1 4 7 7 19 17 0 14 0 9 9 26 0 21 0 15 0 3 4 7x6x19 IWRC 6 6 5 4 3 8 9 9 8 0 5 7 7 8 7x6x19 IWRC 8 7 7 1 5 0 13 0 11 0 7 5 1 7x6x19 IWRC 11 0 9 0 6 4 17 0 13 0 9 6 1 1 8 7x6x19 IWRC 13 0 11 0 7 7 20 0 16 0 11 0 1 1 4 7 6 19 IWRC 16 0 13 0 9 2 24 0 20 0 14 0 1 5 16 7x6x19 IWRC 17 0 14 0 10 0 26 0 21 0 15 0 1 3 8 7x6x19 IWRC 19 0 15 0 11 0 28 0 23 0 16 0 1 1 2 7x6x19 IWRC 22 0 18 0 13 0 33 0 27 0 19 0 68 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 10 Rated Capacities for 2 Leg and 3 Leg Bridle Slings 8 Part and 6 Part Braided Rope 6x7 and 6x19 Construction Improved Plow Steel Grade Rope 7x7 Construction Galvanized Aircraft Grade Rope Horizontal angles shown in parentheses Rated capacitic On 000 Lh 2 Leg Bridle slings 3 Leg Bridle slings Dia Constr 30 60 45 ange 60 30 30 60 45 angle 60 30 n eren ope
65. SME Standard B30 10 Hooks ANSI Standard B30 11 Monorails and Underhung Cranes ANSI Standard B30 16 Overhead Hoists Underhung ANSI Standard B56 1 Low Lift and High Lift Trucks Department of Defense DoD 4145 19 R 1 Storage and Materials Handling Military Standard Mil Std 882 System Safety Program Requirements National Fire Protection Association NFPA 58 Storage and Handling of Liquefied Petroleum Gases 70 The National Electrical Code NEC AFOSHSTD91 46 1 FEBRUARY 1997 125 505 Industrial Trucks Powered National Safety Council NSC Accident Prevention Manual for Industrial Operations Engineering and Technology Occupational Safety and Health Administration OSHA Standard 29 Code of Federal Regulations CFR 1910 27 Fixed Ladders OSHA Standard 29 CFR 1910 107 Spray Finishing OSHA Standard 29 CFR 1910 108 Dip Tank Conveyors OSHA Standard 29 CFR 1910 176 Handling Materials General OSHA Standard 29 CFR 1910 177 Servicing Multi Piece and Single Piece Rim Wheels OSHA Standard 29 CFR 1910 178 Powered Industrial Trucks OSHA Standard 29 CFR 1910 179 Overhead and Gantry Cranes OSHA Standard 29 CFR 1910 180 Crawler Locomotive and Truck Cranes OSHA Standard 29 CFR 1910 184 Slings OSHA Standard 29 CFR 1910 218 Forging Machine Conveyors OSHA Standard 29 CFR 1910 251 Rigging Equipment for Material Handling OSHA Standard 29 CFR 1910 263 Bakery Equipment Conveyors OSHA
66. SURFACE WHICH SHALL HAVE A DIAMETER OF CURVATURE AT LEAST DOUBLE THE DIAMETER OF THE ROPE FROM WHICH THE SLING IS MADE REPRESENTS A CONTACT SURFACE WHICH SHALL HAVE A DIAMETER OF CURVATURE AT LEAST 8 TIMES THE DIAMETER OF THE ROPE REPRESENTS A LOAD IN A CHOKER HITCH AND ILLUSTRATES THE ROTARY FORCE ON THE LOAD AND OR THE SLIPPAGE OF THE ROPE IN CONTACT WITH THE LOAD DIAMETER OF CURVATURE OF LOAD SURFACE SHALL BE AT LEAST DOUBLE THE DIAMETER OF THE ROPE AFOSHSTD91 46 1 FEBRUARY 1997 Figure 6 2 Sling Configurations with Angled Legs FORM OF HITCH VERTICAL CHOKER BASKET HITCH HITCH HITCH Alternates have identical lead load ratings Eye anl See 94 6 1 dll Varta arit ES EYE AND NOT APPLICABLE NOT APPLICABLE KIND OF SLING ENDLESS NOT APPLICABLE APPLICABLE er NOTES 1 For vertical angles of 5 degrees or less refer to Figure 6 1 2 See Figure 6 1 for symbol explanation 57 58 AFOSHSTD91 46 1 FEBRUARY 1997 Figure 6 3 Basic Synthetic Web Sling Configurations FITTING EYE CHOKER SLOT TRIANGLE FITTING TRIANGLE CHOKER 2 LENGTH MEASURES PULL TO PULI WHEN FLAT TRIANGLE TRIANGLE TYPE 10 a EYE EYE AND EVE WITH FLAT ETES iin LENGTH MEN EYE AND EYE WITH TWISTED EYES TYPE W s LENGTH iar mns ENDLESS VI pm E LENGTH AETURN EYE vi
67. Standard 29 CFR 1910 265 Sawmill Conveyors OSHA Standard 29 CFR 1926 550 Cranes and Derricks OSHA Standard 29 CFR 1926 552 Material Hoists Personnel Hoists and Elevators OSHA Standard 29 CFR 1926 553 Base Mounted Drum Hoist Technical Order TO 00 11ON 16 Equipment Authorized for Use with Nuclear Weapons TO 00 20B 5 USAF Motor Vehicle and Vehicle Equipment Inspection TO 00 85 20 Engine Shipping Instruction TO 32 1 101 Use and Care of Hand Tools TO 36 1 23 Serviceability Standards USAF Vehicles TO 36C 1 4 Electrocution Protective and Proximity Warning Devices for Cranes Crane Shovels Line Maintenance Derrick Trucks and Dielectric Testing of Insulated Aerial Manlift Devices TO 36C 1 5 60 Rules on Safety TO 36M 1 141 463L Material Handling Equipment Systems Abbreviations and Acronyms AFI Air Force Instruction new designation AFM Air Force Manual old designation AFMANC Air Force Manual new designation 126 AFOSH Air Force Occupational Safety and Health AFPAM Air Force Pamphlet AFPD Air Force Policy Directive Force Regulation obsolete designation AFSC Air Force Safety Center Force Technical Order ANSI American National Standards Institute ASME American Society of Mechanical Engineers BE Bioenvironmental Engineering C Celsius CFR Code of Federal Regulations CG Center of Gravity CMAA Crane Manufacturer s Association of America
68. Truck truck powered by a gasoline diesel or liquid petroleum LP gas powered internal combustion engine Lay The linear distance for one strand to go completely around a rope Lift Section A mechanism which will lift a section of track out of alignment with a stationary track Limiting Device A mechanical or electrical device which is designed to limit motion Limit Switch A switch which is operated by some part of the hoist or equipment to alter the electrical circuit associated with the hoist or equipment to limit travel of lifting option to prevent hoist or equipment damage Load the total weight superimposed on the load block hook or carrier Load Block Lower The assembly of hook or shackle swivel sheaves pins bearings and frame suspended by the hoisting ropes or chains Load Block Upper The assembly of hook or shackle swivel sheaves pins and frame suspended from the boom point Load Hoist A hoist drum and rope reeving system used for hoisting and lowering loads Load Ratings Crane ratings in pounds established by the manufacturer as safe working loads at various boom radii Loading Platform A flat surface for loading or unloading cargo usually erected alongside warehouse approximately the same height as the bed of a truck or railcar Load Working The external load in pounds applied to the crane including the weight of load attaching equipment such as load blocks shackles
69. able laid rope with one or more metallic fittings Cable Laid Grommet Hand Tucked An endless wire rope sling made from one length of rope wrapped six times around a core formed by hand tucking the ends of the rope inside the six wraps Cable Laid Rope Sling Mechanical Splice A wire rope sling made from a cable laid rope with eyes fabricated by pressing or swaging one or more metal sleeves over the rope junction AFOSHSTD91 46 1 FEBRUARY 1997 129 Cable Laid Wire Rope wire rope composed of six wire ropes wrapped around a fiber or wire rope core Cab Operated Crane or monorail equipment the motions of which are controlled from an operator s cab Carrying Methods Following are descriptions of various types of carrying methods e Neck Carry Method In this method the material is carried on the back of the neck and shoulders with both arms lifted to shoulder height and the hands grasping the sides or top of the load e Shoulder Carry Method The load rests on one shoulder with the near arm helping to support the weight and the other arm brought across the body to steady the load e Side Hand Carry Method This is simply the suitcase method and can be used only where the load may be grasped by a handle or the equivalent e Tray Carry Method The material is carried in front of the abdomen with both hands placed under the bottom surface and the body serving as the balancer Two Person Carry Method A load is carried by
70. ads Cranes will not be used for dragging loads sideways 8 2 6 20 The crane will not be operated while anyone is on the load or hook MAJCOM DRU or FOA approved man rated cranes and work cages are permitted see paragraph 8 2 6 50 for hoist ing and or lowering personnel 8 2 6 21 The operator will not carry or swing a load over the heads of personnel 100 AFOSHSTD91 46 1 FEBRUARY 1997 8 2 6 22 On truck mounted cranes loads will not be lifted over the front area of the truck unless specifically allowed in the manufacturer s operating instructions 8 2 6 23 The operator will test the brakes each time a load is handled by raising the load a few inches and applying the brakes 8 2 6 24 Outriggers will be used When floats are used they will be securely attached to the out riggers Blocking used to support outriggers will be strong enough to prevent crushing not have defects and be wide enough and long enough to prevent shifting or toppling of the crane under load 8 2 6 25 Neither the load nor the boom will be lowered beyond the point where less than two full wraps of rope remain on their respective drums 8 2 6 26 When two or more cranes are used to lift one load one designated person will be responsible for the operation They will analyze the operation and instruct all personnel involved in the proper positioning rigging of the load and the movements to be made 8 2 6 27 Before any crane is moved to a new job sit
71. ailure to ensure that a pallet load is properly balanced and stacked 3 1 10 Failure to ensure that forks tines are fully under the load before lifting 3 1 11 Striking the pallet or the floor with the forks 3 1 12 Driving across bridge plates too fast and failure to observe load carrying capacity on bridge plates 3 1 13 Positioning empty forks too high when traveling no higher than 6 inches above the surface 3 1 14 Failure to release parking brake before traveling 3 1 15 Driving forward when vision is restricted by the load 3 2 General Requirements 32 1 Acquisition Commercially procured materials handling and lifting equipment or parts will conform to the specifications outlined in 29 CFR 1910 176 Handling Materials General 1910 177 Servicing Multi Piece and Single Piece Rim Wheels 1910 178 Powered Industrial Trucks American National Standards Institute ANSI B56 1 Low Lift and High Lift Trucks and National Fire Protec tion Association NFPA 505 Industrial Trucks Powered Local modifications of centrally procured materials handling equipment will be done only with the approval of the equipment item managers Local purchase acquisition requests should be coordinated with the installation ground safety staff Refer to Figure 3 1 through Figure 3 16 for examples of materials handling and lifting equipment 3 2 2 Inspection All materials handling and lifting equipment will be inspected prior to use by the opera
72. along the length of the conveyor Bracing Members used to stabilize the supporting structure Bridge Girder Crane member on which carriers or trolleys travel horizontally mounted between and supported by the end trucks Bucket Conveyor Any type of conveyor in which the material is carried in a series of buckets Bridle Wire Rope Sling A sling composed of multiple wire rope legs with the top ends gathered in a fit ting that goes over the lifting hook Bunker A large bin or compartment for the storage of bulk materials Capacity Rated Load Maximum load in tons of 2 000 pounds each for which the hoist is designed and built by the manufacturer Carrier e device of various types attached to or hung from trolleys to support the load receptacle in which objects are placed for transmittal through a pneumatic tube system Carrier Trolley An assembly with wheels which runs on monorail track or crane girders and supports the load and carries the hoisting mechanism 140 AFOSHSTD91 46 1 FEBRUARY 1997 Carrier and or Trolley Travel Clamp A suspension fitting used to support tracks from an overhead structure fastened to the structure by means of pressure rather than welding or direct bolting Car Unloader A type of conveyor in which one or more chains acts as the conveying element A British term for trolley conveyor Chain Guide A device that guides the load chain around the load sprocket Chute A trough through
73. an Factors 2120 91 AFOSHSTD91 46 1 FEBRUARY 1997 8 2 Requirements ence iet ar Chapter 9 RELATED HOISTING EQUIPMENT QDs Wire oit RB EIUS Uu a ARA i A UP ME 92 C CHANS EE 9 3 wSheaves and Equalizers pises eredt S esito e eoe iE E MM ROOKS aee 9 3 Hydrdsets and Load Cells ee ae 9 6 Personnel Hoists and Suspended Personnel Platforms eese Figure 9 1 Right and Wrong Way of Using Cable Clips eee Figure 9 2 Proper Method of Installing Cable Clips eee Figure 9 5 Double Base lamp ear Ligure 9 4L Joming Wire duode eie cta ode tia eee eee diu Figure 9 5 Correct and Incorrect Way to Measure Wire sese Figure 9 6 Wire Rope Wear Damage oed neret o ire ended siepe qe en Figure 9 7 Hook Inspection Areas d MN Figure 9 8 Hook Showing Block Interface Shank eere Table 9 1 Number of Spacing of Clips for Ropes of Various Sizes Chapter 10 INSPECTION TESTING AND MAINTENANCE OF DERRICKS IHSDOOGUORO conditus noo teamed tb pesa 10 2 Dercks Regular Uses i osi pu ao ute eite ec secca 10 3 tee RR Do RS
74. ance 9 1 2 1 Rope will be stored and handled in a manner which will prevent damage or deterioration 9 1 2 2 Unreeling or uncoiling of rope will be done as recommended by rope manufacturers and with extreme care to avoid kinking or inducing a twist 9 1 2 3 Before cutting a rope seizings will be placed on each side of the place where the rope is to be cut to prevent unlaying of the strands 9 2 4 During installation care will be observed to avoid dragging the rope in dirt or around objects which will scrape nick crush or induce sharp bends in it 9 1 2 5 Rope shall be maintained in a well lubricated condition It is important that lubricant applied as part of a maintenance program be compatible with the original lubricant The rope manufacturer s instructions will be consulted Lubricant applied will be of the type which does not hinder visual inspection Those sections of rope which are located over sheaves or difficult to see during inspection and maintenance procedures require special attention when lubricating the rope The object of rope lubrication is to reduce internal friction and to prevent corrosion EXCEPTION When used in clean rooms factory lubricant may be removed from stainless steel ropes to prevent contamination AFOSHSTD91 46 1 FEBRUARY 1997 105 9 1 2 6 When an operating rope shows greater wear at well defined localized areas than on the remainder of the rope rope life can be extended in some cases where a red
75. and the location of control and protective equipment shall be such that all operating handles are within convenient reach of the operator when facing the area to be served by the load hook or while facing the direction of travel of the cab The arrange ment shall allow the operator a full view of the load hook in all positions 7 2 2 7 Pendant and cab hoist controls for trolley and bridge movement shall use compass points north south east and west as the preferred identification whenever possible 7 2 2 8 Hoists utilizing synchronous controls for multiple point lifting movements shall be of fail safe design to preclude inadvertent operation which may be caused by malfunctions of selector switches power failure or improper sequencing of controls 7 2 2 9 Access to the cab or bridge walkway shall be by a conveniently placed fixed ladder stairs or platform requiring no step over any gap exceeding 3 inches Fixed ladders shall be designed and installed according to ANSI A14 3 Safety Requirements for Fixed Ladders and 29 CFR 1910 27 Fixed Ladders See AFOSH Standard 127 22 Walking Surfaces Guarding Floor and Wall Openings and Holes Fixed Industrial Stairs and Portable and Fixed Ladders 7 2 2 10 A carbon dioxide or dry chemical or equivalent at least 10 BC rated hand fire extin guisher shall be kept in the cab 7 2 2 11 Pendant control boxes and fixed control stations shall be constructed to prevent electri cal shock and be cle
76. arly marked for identification of functions and be legible 7 2 2 12 Except for floor operated cranes a gong buzzer or other effective warning signal shall be provided for each crane equipped with a power traveling mechanism 7 2 2 13 The hoisting motion of all electric traveling cranes shall be provided with an overtravel limit switch in the hoisting direction 82 AFOSHSTD91 46 1 FEBRUARY 1997 7 2 2 14 Emergency descent means shall be provided on all crane cabs Rope hand line is not acceptable Only approved control descent devices shall be used 7 2 2 15 Crane operators shall not be placed in a situation where there is a high probability that danger to life health or safety may suddenly develop 7 2 2 16 Lift eyes and or lift points used for the attachment of slings clevis shackles or hooks shall be constructed of forged or alloy steel Rebar steel shall not be permitted as attach points for any load 7 2 2 17 Refer to Chapter 9 for information on hoisting equipment sheaves ropes and equaliz ers 7 2 3 Qualification of Operators 7 2 3 1 Cab Operated and Pulpit Operated Equipment also see paragraph 5 2 3 1 3 7 2 3 1 1 Operators performing these duties will be qualified by either military and or Air Force specialty training or be able to furnish satisfactory evidence of prior qualification and experience Qualification will be limited to the specific type equipment for which examined 7 2 3 1 2 Operators
77. assen ger seat is provided 3 2 6 4 2 The operator will not extend any portion of body between the uprights of the mast or outside the running lines of the equipment 3 2 6 4 3 When leaving powered lifts unattended with the operator s seat vacated operators will fully lower the forks neutralize controls shut power off and set brakes They will chock the wheels if the vehicle is parked on an incline At the close of business each day LP powered and gasoline operated MHE will be parked on the warehouse ramp drip pans in place 3 2 6 4 4 Operators will use caution when traveling on docks or loading platforms and remain clear of the edge 3 2 6 4 5 Operators will not use forklifts to push or pull objects such as freight cars or to open and close freight and warehouse doors EXCEPTION When side loading vans are not available munitions containers with permanently installed skids may be pushed or pulled into end opening vans Ensure safety precautions such as keeping personnel clear of potentially hazardous areas have been considered and included in the procedure 3 2 6 4 6 Operators will set brakes and dock locks or put wheel chocks in place to prevent any movement of trucks trailers or railroad cars while loading or unloading Fixed jacks will be used to support semitrailers during loading or unloading when the trailer is not coupled to the tractor The operator will check the flooring of trucks trailers and railroad cars for break
78. ated load limit of the hook is not exceeded 9 5 Hydrasets and or Load Cells These devices are used to allow precision placement of heavy loads during mating and demating operations These precision positioners are especially valuable when handling critical high value items such as spacecraft payloads or astronautical optics Users of these types of materials handling equipment will develop inspection and testing procedures based upon the type of materials being lifted 9 6 Personnel Hoists and Suspended Personnel Platforms The use of a crane or derrick to hoist workers on a personnel platform is prohibited except when conventional means of reaching the worksite such as personnel hoist ladder stairway aerial lift elevating work platform or scaffold would be more hazardous or is not possible When absolutely necessary to hoist personnel the following shall apply 9 6 1 Cranes used for personnel hoisting shall have an anti two blocking device incorporated into its design and shall have a power controlled lowering system capable of handling rated loads and speeds as specified by the manufacturer See 29 CFR 1926 550 for additional information 9 6 2 Platforms used to suspend personnel shall be designed and used as follows see 29 CFR 1926 550 for additional information 110 AFOSHSTD91 46 1 FEBRUARY 1997 9 6 2 1 Be capable of supporting at least five times the maximum intended load 9 6 2 2 Be equipped with a guardrail system
79. ave a diameter of curvature meeting at least the minimums speci fied in Figure 6 1 and Figure 6 2 6 3 4 5 Natural and synthetic fiber rope slings except for wet frozen slings may be used in a temperature range from 20 degrees F 7 degrees Celsius C to 150 degrees F 66 degrees C without decreasing the working load For operations outside this temperature range and for wet 54 AFOSHSTD91 46 1 FEBRUARY 1997 frozen slings or where rope and slings have been stored in a chemically active environment the sling manufacturer s recommendations shall be followed 6 3 4 6 Spliced fiber rope slings will not be used unless they have been spliced according to the following minimum requirements and any additional recommendation of the manufacturer 6 3 4 6 1 In manila rope eye splices will consist of at least three full tucks Short splices will consist of at least six full tucks three on each side of the splice center line 6 3 4 6 2 In synthetic fiber rope eye splices will consist of at least four full tucks Short splices will consist of at least eight full tucks four on each side of the center line 6 3 4 6 3 Strand end tails will not be trimmed flush with the surface of the rope immediately adjacent to the full tucks This applies to all types of fiber rope and both eye and short splices For fiber rope under 1 inch in diameter the tail will project at least six rope diameters beyond the last full tuck For fiber rope 1 inch in d
80. cal Articulated Platform Conveyor A type of vertical conveyor in which sections of articu lated slat conveyor apron form rigid platforms for vertical movement in continuous flow The platforms are flexible in but one direction and they assume a vertical position on the non carrying run to minimize space requirements Vertical Chain Conveyor Opposed Shelf Type Two or more vertical elevating conveying units opposed to each other Each unit consists of one or more endless chains whose adjacent facing runs operate in parallel paths Thus each pair of opposing shelves or brackets receives objects usually dish trays and delivers them to any number of stations Vibrating Conveyor A trough tube or other device flexibly supported and vibrated at a relatively high frequency and small amplitude usually powered by an electrical or pneumatic impulse to convey bulk material or objects Wheel Conveyor A series of wheels supported in a frame over which objects are moved manually or by gravity Conveyor Screw The material propelling medium of a screw conveyor consisting of an assembly of heli cal flights mounted on a pipe or shaft Crane Double Girder A crane having two bridge girders mounted between and supported from end trucks Double Leg Gantry A crane whose bridge is supported on two or more legs running on fixed run ways Handpushed crane without mechanical or electrical power which is either pushed or pulled along the track
81. carrying load connecting and conveying elements such as chain cable or other linkage e unit carrying the hoist mechanism which travels on overhead bridge rails or Aframe on which a pair of load carrying wheels are mounted Trolley Conveyor series of trolleys supported from or within an overhead track and connected by endless propelling means such as chain cable or other linkage with loads usually suspended from the trolleys Truck e assembly which supports another unit in either a fixed or adjustable position and which pro vides mobility or A wheeled vehicle which can be detached from a conveying medium usually chain and pushed by hand Truck Crane crane consisting of a rotating superstructure with power plant operating machinery and boom mounted on an automotive truck equipped with a power plant for travel Some variations use a single engine in the truck which also is the power source for the superstructure or a single engine in the superstructure which also is the power source for the truck Turntable track device with a movable liner frame containing a straight section of track which can be rotated with a load carrier on it to align the section of track with other tracks for the transfer of carriers from one track to another Two Blocking When the lower load block comes in contact with the upper load block or boom point Vertical Reciprocating Conveyor A reciprocating power or gravity
82. ck bent knees free style and kinetic Each has advantages and limitations The kinetic method is the most widely accepted and taught because it provides more stability for the worker while reducing load on the back muscles and intervertebral disks Instructions how to lift properly follow 1 2 2 1 Position feet correctly Place feet far enough apart for balance with one foot to the rear of the object and the other foot slightly ahead of the other and to the side of the object refer to Fig ure 1 1 1 2 2 2 Crouch close to the load refer to Figure 1 1 Stay close to the load to minimize strain on the lower back Before beginning the lift be sure the back is straight as possible and back mus cles are tightened These steps prepare the body to accept the load 1 2 2 3 Pick up materials with a full palm grip Do not attempt to pick up weights with a fingertip grip Ensure the load is free of grease or sharp points which could cause injury Use suitable gloves when necessary 1 2 2 4 Always keep the back as straight as possible refer to Figure 1 1 It may not be possible to keep the back in the vertical plane but avoid arching the back Keep the back muscles tightened throughout the duration of the lift Do not relax the back until the load is released Bend from the hips and not from the middle of the back 1 2 2 5 With the arms slide the object toward the body to give it some motion kinetic energy At the same time use the legs t
83. coordinated operations of cranes which in turn will increase the mishap potential 7 1 7 Visual acuity depth perception color blindness poor hearing epilepsy or heart condition may result in poor coordinated control techniques This may be brought about when operators cannot dis tinguish the color of warning lights and required meanings and cannot relate equipment and load prox imity because of poor acuity and or depth perception refer to paragraph 7 2 3 Good physical condition is essential to ensure uninterrupted control and safe operations 7 1 8 Positive supervision and competent operators and qualified maintenance personnel are essen tial factors for safe operations of crane and or hoisting equipment 7 2 Requirements 7 2 1 Acquisition 7 2 1 1 All new overhead and gantry cranes constructed and installed on or after 31 August 1971 will meet the design specifications of ANSI ASME Standards B30 2 Overhead and Gantry Cranes Top Running Bridge Multiple Girders and B30 11 Monorails and Underhung Cranes Cranes constructed before 31 August 1971 will be modified to conform to those design specifica tions unless it can be shown the crane cannot feasibly or economically be altered and it substan tially complies with the requirements of this standard Contracts for procurement of overhead and gantry cranes shall mandate CMAA 70 or 74 as applicable and each of the appropriate ANSI ASME B30 series standards as compliance d
84. criptions of specific derricks Designated Selected or assigned by the employer or the employer s representative as being qualified to perform specific duties Dielectric Boom Shield An insulating device installed on booms to provide electrocution protection to operators and load handlers Drive An assembly of the necessary structural mechanical and electrical parts which provides the motive power for a conveyor monorail crane etc Drop Section A mechanism which will permit a section of track to be lowered out of alignment with a stationary track Drum 132 AFOSHSTD91 46 1 FEBRUARY 1997 e cylindrical or polygonal rim type of wheel around which cable chain belt or other linkage may be wrapped A drum may be driven or driving The face may be smooth grooved fluted or flanged e A cylindrical or bilged shipping container having straight sides and flat or bumped ends designed for storage and shipment as an unsupported outer package that may be shipped without boxing or crating Equalizer device which compensates for unequal length or stretch of a rope Exposed Capable of being contacted inadvertently applies to hazardous objects not adequately guarded or isolated Fabric Metal Mesh The flexible portion of a metal mesh sling consisting of a series of transverse coils and cross rods Fail Safe A provision designed to automatically stop or safely control any motion in which a malfunction occ
85. d be thoroughly familiar with pry bar use limitations and techniques to prevent internal damage to the aircraft 3 2 6 8 13 Do not allow personnel to position themselves between 3 2 6 8 13 1 Pallets that are locked in place 20 AFOSHSTD91 46 1 FEBRUARY 1997 3 2 6 8 13 2 Pallets being loaded and or unloaded or 3 2 6 8 13 3 The moving pallets and the materials handling equipment positioned outside the aircraft when off loading 3 2 6 8 14 To prevent damage to pallets or aircraft flooring check all floor areas prior to loading and or unloading to ensure loose items are removed Immediately report any dam ages resulting from aircraft loading and or unloading to the supervisor 3 3 Special Requirements 3 3 1 Material Handling Equipment Parked Inside Warehouses The decision to park gasoline and or diesel powered material handling equipment in general purpose warehouses is the responsi bility of the installation commander and shall be approved by local fire and ground safety officials The following safety operating rules shall be considered 3 3 1 1 The warehouse is equipped with a fire suppression system or heat sensor devices 3 3 1 2 Equipment will not block fire aisles fire fighting equipment fire alarm boxes stairways elevators or fire exits 3 3 1 3 Anoil absorbent compound is placed under any equipment leaking oil or grease A metal pan may be used in conjunction with the compound Corrective actions
86. d chain stretch 5 2 5 2 4 Hook retaining nuts on collar and pins welds or riveting used to secure the retain ing member 48 AFOSHSTD91 46 1 FEBRUARY 1997 5 2 5 2 5 Worn glazed or oil contaminated friction disc or worn pawls cams or ratchets on brake mechanisms corroded stretched or broken pawl springs 5 2 5 2 6 Worn cracked or distorted parts such as hook blocks suspension housing outrig ger hand chain wheels chain attachments clevises yokes suspension bolts shafts gears bearings pins rollers locking and clamping devices 5 2 5 2 7 Loose bolts nuts or rivets 5 2 5 2 8 Continued ability to support the imposed loads of supporting structure and trolley if used 5 2 5 2 9 Signs of pitting or any deterioration of controller contactors limit switches and push button stations on electrical apparatus 5 2 5 2 10 Additional annual requirements for nuclear certified hoists 5 2 5 2 10 1 Perform dye penetrant magnetic particle or other suitable Non Destructive Inspection NDI on the hook refer to paragraph 9 4 and Figure 9 7 5 2 5 2 10 2 Installation civil engineer or equivalent will perform an annual load test at 125 percent of the manufacturer s rated load 5 2 5 3 Hoists Not in Regular Use A hoist which has been idle for 6 months or more will be given a complete inspection conforming with the requirements of paragraph 5 2 5 2 5 2 5 4 Inspection Records A written dated and signed
87. d off loading cargo from aircraft It includes specially constructed pallet conveyor platforms Actuator A manually operated device used to initiate controls or operator action An actuator includes but is not limited to a push button toggle switch foot pedal hand lever and a hand set timer Administrative or Regulatory Authority Governmental agency or the employer in the absence of governmental jurisdiction Aisle Any passageway in the storage area Angle Indicator Boom An accessory which measures the angle of the boom to the horizontal Appointed Assigned specific responsibilities by the supervisor or the authorized user agency Approved Accepted as satisfactory by a duly constituted administrative or regulatory authority Attachment Forklift A device other than conventional forks or load back rest extension for handling the load mounted permanently or removable on the elevating mechanism of a truck Authorized Approved by a duly constituted administrative or regulatory authority Automatically Controlled Operation by the action of its mechanism being initiated by some design feature such as a conveyor which is started by a low level bin indicator Automatic Unit A unit which when activated operates through a preset cycle or cycles Auxiliary Hoist A supplemental hoisting unit of lighter load capacity and usually higher speed than provided by the main hoist Backrest Extension Forklift A
88. d report of the rope condi tion will be maintained by the user for a minimum of 1 year 9 1 4 4 replacement rope shall be of proper size grade and construction for the particular function it is to perform on the machine NOTE Discarded rope will not be used for slings 9 1 4 5 In order to establish data as a basis of judging the proper time for replacement a continu ing inspection record shall be maintained This record shall cover points of deterioration listed in paragraph 9 1 4 9 2 Chains 9 2 1 Welded Link Chain Inspection 9 2 1 1 Test the hoist under load in hoisting and lowering directions and observe the operation of the chain and sprockets Ensure the chain feeds smoothly into and away from the sprockets 9 2 1 2 If the chain binds jumps or is noisy first ensure it is clean and properly lubricated If the trouble persists inspect the chain and mating parts for wear distortion or other damage 9 2 1 3 Clean the chain for inspection Examine visually for gouges nicks weld splatter corro sion and distorted links Slacken the chain and move adjacent links to one side to inspect for wear AFOSHSTD91 46 1 FEBRUARY 1997 107 at the contact points If wear is observed or if stretching is suspected measure the chain accord ing to the hoist manufacturer s instructions If instructions are not available proceed as follows 9 2 1 3 1 Select an unworn unstretched length of the chain from the slack end 9 2 1
89. degrees F For operations outside these tempera ture ranges or for metal mesh slings impregnated with other materials the sling manufacturer s recommendations will be followed 6 3 3 8 Metal mesh slings will be removed from service if any of the following conditions are present 6 3 3 8 1 Broken weld or broken brazed joint along the sling edge 6 3 3 8 2 Reduction in wire diameter of 25 percent due to abrasion or 15 percent due to cor rosion 6 3 3 8 3 Lack of flexibility due to distortion of the fabric 6 3 3 8 4 Distortion of the female handle so the depth of the slot is increased more than 10 percent 6 3 3 8 5 Distortion of either handle so the width of the eye is decreased more than 10 per cent 6 3 3 8 6 Reduction of 15 percent of the original cross sectional area of metal at any point around the handle eye 6 3 3 8 7 Distortion of either handle out of its plane 6 3 3 8 8 Cracked end fitting 6 3 3 8 9 A broken wire in any part of the mesh 6 3 4 Natural and Synthetic Fiber Rope Slings 6 3 4 1 Fiber rope slings made from conventional three strand construction fiber rope will not be used with loads in excess of the rated capacities prescribed in Table 6 16 through Table 6 19 6 3 4 2 Cargo straps will not be used as a sling or part of a sling configuration 6 3 4 3 Slings not included in these tables will be used only according to the manufacturer s rec ommendations 6 3 4 4 Fiber rope slings will h
90. designed and permanently installed by the manufacturer are authorized 2 2 4 6 Manually operated lever hoists shall only be operated by personnel familiar with the use of the equipment Operator qualifications will be as determined by the facility and or shop super visor or designated representative 2 2 4 7 The rated load shall not be exceeded except for authorized proof tests 2 2 4 8 Hoists shall be attached to well defined dead end points capable of withstanding the intended load Note Lifeline attach points shall not be used for hoists AFOSHSTD91 46 1 FEBRUARY 1997 13 Chapter 3 POWERED INDUSTRIAL TRUCKS 3 1 Hazards and or Human Factors Mechanical assistance ranges from simple hand trucks to com plex powered forklift trucks The type of mishaps include dropped property bruises head injuries cuts and lacerations to personnel and fatalities due to turn overs Following are several common operator errors associated with the operation of powered industrial trucks 3 1 1 Jerky starts and stops 3 1 2 Failure to give proper signals when turning 3 1 3 Traveling too fast and turning too sharply 3 1 4 Failure to sound horn at intersections or when entering or exiting a building 3 1 5 Turning too wide on corners 3 1 6 Cutting corners too sharply 3 7 Forklift trucks carrying loads too high when traveling Tines should not be higher than 6 inches above the surface 3 1 8 Lowering loads too fast 3 1 9 F
91. designed specifically for the load being lifted 5 2 3 3 4 The slings or other devices will be seated properly in the saddle of the hook before operations begin 5 2 3 3 5 The load will not be moved or lifted more than a few inches until it is well balanced in a sling or lifting device and center of gravity is known 5 2 3 3 6 Care will be taken in hoisting to be certain that 5 2 3 3 6 1 Hoist ropes or chains are not twisted about each other 5 2 3 3 6 2 The load does not contact any obstruction 5 2 3 3 6 3 Ropes or chains are protected against sharp edges of the load 5 2 3 3 7 Before starting the hoist the operator will ensure that the rope or chain is properly seated on the drum sheaves or sprockets 5 2 3 3 8 A hoist will not be operated until the load is centered 5 2 3 3 9 Hoists will not be operated until the hoist unit is centered over the load 5 2 3 3 10 A hoist will not be used for hoisting personnel unless it has been specifically designed for this purpose and only if it is the safest means of accomplishing the work 5 2 3 3 11 The operator will not carry loads over personnel AFOSHSTD91 46 1 FEBRUARY 1997 45 5 2 3 3 12 The operator will test the brakes each time a load is handled by raising the load just enough to clear the floor or supports and check for brake action The lift should be con tinued only after the operator has ensured the braking system is operating properly 5 2 3 3 13 No loaded rope hois
92. dio voice remote hydraulic control etc Crane Storage Bridge A gantry type crane of long span usually used for bulk storage of material the bridge girders or trusses are rigidly or nonrigidly supported on one or more legs It may have one or more fixed or hinged cantilever ends e Crane Underhung A traveling bridge on two or more runway tracks on which hoists and carriers may travel for the purpose of lifting transporting and lowering loads It is suspended under its runway tracks system the trolley of which operates on the bottom flange of the track e Crane Wall A crane having jib with or without trolley and supported from a side wall or line of columns of a building It is a traveling type and operates on a runway attached to the side wall or columns Critical Loads Loads that include but are not limited to high value ordnance items missile or spacecraft hardware and components and any unique high value items identified by program or functional managers Crossover A connecting track with an interlock mechanism on both ends mounted between two interlocking cranes used to transfer a carrier from one bridge to the other Cross Rod A wire used to join spirals of metal mesh to form a complete fabric Derrick apparatus consisting of a mast or equivalent member held at its upper end by guys or braces with or without a boom for use with hoisting mechanism and operating ropes Refer to Attachment 4 for des
93. ditions will be guarded 8 2 1 2 7 Unguarded Machinery Conditions Crane operations have inherent hazards such as rotating equipment and or holes etc that cannot be mechanically safeguarded against To prevent severe injury to personnel they will exercise extreme care when they are exposed to unguarded and or rotating equipment and or holes Such conditions will be clearly marked with appropriate warning decals 8 2 1 2 8 Main Switch If the mobile crane is electrically powered separately and incorpo rates a main or master switch the switch will be designed so it can be locked in the open or OFF position 8 2 1 2 9 Operator Protection Cranes will be fitted with adequate equipment to protect oper ators from falling objects swinging loads and cable failures Where cranes are operated in inclement weather protection from the weather will also be provided 8 2 1 2 10 Warning An efficient audible warning device will be provided when hoisting operations or moving equipment might endanger personnel working in the area The control of the device will be within easy reach of the operator 8 2 1 2 11 Warning Sign A permanent sign will be posted in the cab of the equipment in full view of the operator This sign will read DANGER HIGH VOLTAGE Do Not Operate Within 10 Feet of Electric Power Lines If equipment will be expected to be operated in the vicinity of power lines the installation of a proximity device should be consider
94. e manufacturer of the crane in which the load is hoisted held for a predetermined time commonly 3 5 minutes raised again exercised through its operational envelope at the manufacturer s recommended boom angles lowered held again and then lowered to the ground Reach The effective length of an alloy steel chain sling measures from the top bearing surface of the upper terminal component to the bottom bearing surface of the lower terminal component Reach Truck self loading truck generally high lift having load engaging means mounted so it can be extended horizontally forward This permits a load to be picked up and deposited in the extended position and transported in the retracted position 136 AFOSHSTD91 46 1 FEBRUARY 1997 Reciprocating Conveyor Any conveyor that progressively advances material by a back and forth motion of its conveying medium It may be equipped with hinged flights or tilting dogs or pushers Reeving system in which a rope or chain travels around drums sheaves or sprockets Remote Control A control station or any system of controls in which the actuator is situated in a remote location and is not mechanically attached to the device being controlled Roller e Arevolving cylinder or wheel over which something is moved The face may be straight tapered crowned concave flanged corrugated ribbed or fluted component part of a roller chain which serves only to reduce frictional lo
95. e the route of travel will be checked to deter mine that adequate clearances exist along the entire route This survey will be conducted by the vehicle heavy equipment supervisor and crane operator The empty hook will be secured to pro hibit swinging and the boom will be lowered to the boom rest or travel position A red cloth or warning flag at least 12 inches square or a warning light will be carried at the end of any boom that extends more than 4 feet beyond the truck platform At night a warning light shall be used The superstructure will be secured to prohibit rotation except when there is an operator in the cab to ensure proper boom clearances around tight spots and corners Additional vehicles will be used to aid in warning other motorists if the crane boom or wide load poses a hazard to the front or rear 8 2 6 28 Before traveling a crane with a load a designated supervisor will be responsible for determining and controlling safety Decisions such as position of load boom location ground sup port travel route and speed of movement will be according to their determination Specified tire pressures will be maintained The boom will be carried in line with the direction of motion sudden starts and stops will be avoided and tag or restraint lines will be used to minimize swinging of the load 8 2 6 29 A crane will never travel with the boom so high that it may bounce back over the cab The manufacturer s operation manual will be consul
96. e as required 9 2 2 Roller Link Chain Inspection 9 2 2 1 Test the hoist under load in hoisting and lowering directions and observe the operation of the chain and sprockets Ensure the chain feeds smoothly into and away from the sprockets 9 2 2 2 If the chain binds jumps or is noisy first ensure it is clean and properly lubricated If the trouble persists inspect the chain and mating parts for wear distortion or other damage 9 2 2 3 If possible inspect the roller link chain while it is in the hoist With the hoist suspended in normal position apply a light load of approximately 50 pounds 9 2 2 3 Check chain for elongation following the hoist manufacturer s instruction In absence of specific instructions check the chain by determining the nominal pitch and measur ing a 12 inch section of chain that normally travels over the chain sprocket Using a vernier caliper check the dimension from the edge of one chain pin to the corresponding edge of another pin for the number of pitches per foot If elongation exceeds one fourth of an inch in 12 inches replace the chain For example a three fourths inch pitch chain should measure 12 inches over 16 pitches Reject chain if measurement over 16 pitches exceeds 12 25 inches 9 2 2 3 2 Check chain for twist Replace the chain if the twist in any 5 foot section exceeds 15 degrees 9 2 2 3 3 Check for camber Replace chain which has a side bow exceeding one fourth of an inch in any 5
97. e operator s station Roller Turn A series of vertical rollers mounted in a frame to guide conveyor chain around a horizontal curve Safety Lug A mechanical device fixed securely to the end truck which will prevent the crane from falling in the event of a wheel or axle failure Shear Point or Line The point at which or the line along which parts of the human body can be caught trapped or pinched between moving parts or objects Skip Bucket The tub or bucket used for containing the material conveyed by a skip hoist Skip Hoist A bucket or car operating up and down a defined path receiving elevating and discharging bulk materials Slack Cable Switch A device installed on skip hoists to automatically shut off the power supply when the hoisting cable becomes slack or has slack due to accident or jamming Slat A member supported between chains in a slat conveyor The series of slats form the conveying bed Span The horizontal distance between the centers of the runway tracks Speed The length of belt chain cable or other linkage which passes a fixed point within a given time It is usually expressed in terms of feet per minute meters per second etc In the case of a Rolling Chain Conveyor the load is moved at a rate double the chain speed In screw conveyors the speed is expressed in terms of revolutions per minute and the speed at which material is conveyed is dependent upon speed pitch of the screw type of flight a
98. e used The sling will not be loaded in excess of the rated capacity of the weakest component 6 3 1 2 Unauthorized makeshift links or fasteners such as those formed from bolts or rods will not be used 6 3 1 3 Each new repaired or reconditioned alloy steel chain sling including all welded compo nents in the sling assembly will be proof tested to 200 percent of rated capacity before being used 6 3 1 4 Alloy steel chain slings will not be used with loads more than the rated capacities pre scribed in Table 6 1 Slings not included in this table will be used only according to the manufac turer s recommendations 6 3 1 5 Alloy steel chain slings will be permanently removed from service if they are exposed to heat above 1 000 degrees Fahrenheit F When exposed to service temperature in excess of 600 degrees F maximum working load limits permitted in Table 6 1 will be reduced according to the chain or sling manufacturer s recommendations 6 3 1 6 Worn or damaged alloy steel chain slings and attachments will not be used until they are repaired or reconditioned and proof tested 6 3 1 7 Mechanical coupling links or low carbon steel repair links will not be used to repair bro ken lengths of chain 6 3 1 8 If the chain size at any point of any link is less than that stated in Table 6 2 the sling will be removed from service 6 3 1 9 Alloy steel chain sling with cracked or deformed master links coupling links or other compo
99. ed 8 2 1 2 12 Night Operations Cranes operated during darkness will have clearance lights installed The working areas will be illuminated so the designated signal person loads rig ging obstructions etc are readily visible 8 2 1 2 13 Man Rated Cranes Man rated cranes will be approved prior to acquisition or use The potential user will coordinate with the safety staff and submit the following for review see 29 CFR 1926 550 for additional information 8 2 1 2 13 1 Crane make model year and present modifications if applicable 8 2 1 2 13 2 Present safety devices limit switches dead man controls control lowering capabilities outriggers if applicable etc 8 2 1 2 13 3 Past major overhaul or repairs and dates of proof load or rated load test AFOSHSTD91 46 1 FEBRUARY 1997 93 8 2 1 2 13 4 Proposed method of use and working environment 8 2 1 2 13 5 Proposed work cage and or basket attachment points and methods of attachment for personnel 8 2 1 2 13 6 If necessary illustrated drawings or photographs 8 2 2 Inspections 8 2 2 New or Modified Cranes newly procured or modified cranes will be inspected prior to initial use to ensure compliance with this standard 8 2 2 2 Daily Inspections Every working day the following will be inspected by the operator 8 2 2 2 1 Hydraulic Hose Fittings and Tubing hydraulic hoses particularly those which flex in normal operation of crane functions
100. ed e iv D RU ated Maintenance eee ie to ette tese efe teen onde tete oda 10 5 Adjustments and noie tetuer des vet ebur EE TU 6 Qut ior c usc at d ta Meer ern ee eter 10 7 Rope Inspection Replacement and Maintenance eee Attachment 1 GLOSSARY OF REFERENCES ABBREVIATIONS ACRONYMS AND TERMS Attachment 2 SIGNIFICANT REFERENCES Attachment 3 CHECKLIST MATERIALS HANDLING AND STORAGE EQUIPMENT 91 104 104 106 108 108 109 109 111 112 113 114 115 116 117 117 118 120 120 121 121 121 122 122 123 124 139 146 6 AFOSHSTD91 46 1 FEBRUARY 1997 Chapter 1 MANUAL MATERIAL HANDLING 1 1 Hazards and or Human Factors Strains sprains hernias fractures and bruises are the com mon injuries associated with manual materials handling Lifting carrying dropping and lowering are the common physical acts responsible for these injuries Sprains account for approximately 30 percent of the lost time injuries in the Air Force Many of the strains are the direct result of improper lifting techniques lifting with no assistance or failure to use required and available material handling equipment 1 1 1 Individual Variables There are several variables which influence the ability of people to manually handle materials 1 1 1 1 Physical Age sex strength mobility fatigue and motor functions 1 1 1 2 Psychological
101. ement it is not termed a running sheave e Sheave Running A sheave which rotates as the load block is raised or lowered Shield full or partial enclosure or cover either framed or solid made from material sufficiently rigid to prevent accidental contact Side Loader truck generally a high lift having a load engaging means mounted in such a manner that it can be extended laterally to permit a load to be picked up and deposited in the extended position and transported in the retracted position Side Loading A load applied at an angle to the vertical plane of the boom AFOSHSTD91 46 1 FEBRUARY 1997 137 Side Pull That portion of the hoist pull acting horizontally when the hoist lines are not vertical Sling An assembly which connects the load to the material handling equipment Also known as bridle Spiral single transverse coil that is the basic element from which metal mesh is fabricated Sprocket A wheel with suitably shaped and spaced cogs or teeth to engage with the links of a chain Sprocket Load The hoist component that transmits motion to the load chain Component is sometimes called load wheel load sheave or chain wheel Standby Crane crane not in regular service but which is used occasionally or intermittently as required Standing Guy Rope A supporting rope which maintains a constant distance between the points of attachment to the two components connected by the rope Stop
102. emotely operated devices Switch Rotary A track switch with a movable inner frame containing straight or curved sections of track The inner frame can be rotated around a vertical axis to align these tracks with other tracks for rout ing carriers from one track to another Switch Tongue A track switch containing one straight section of track pivoted at one end which can be swung to various positions to connect with other tracks for transfer of carriers from one to the other Tackle An assembly of ropes and sheaves arranged for hoisting Tag line Electrical An electrical conductor system employing flexible cables Take Up The assembly of the necessary structural and mechanical parts which provides the means to adjust the length of belts cables chains etc to compensate for stretch shrinkage or wear and to main tain proper tension Tow Pin A movable or fixed member on a truck dolly or cart used to engage a pushing or pulling dog on a floor mounted tow conveyor Track Curves Curved sections of monorail track used to change the horizontal or vertical direction of carrier travel Track Hangers A suspension fitting fastened to the track Transit The moving or transporting of a crane from one job site to another Transfer Car Any wheeled device used for transferring loads from one conveyor line to another May be manually or automatically operated Transfer Mechanism Any mechanism that transfers objects onto or off a conve
103. en 1 and 12 months by a desig nated person who also maintains a record of the inspection The recommended intervals of the periodic inspections should be based on the type of use experienced by the equipment as follows Normal service yearly heavy service semiannually severe service quarterly If accomplished properly this inspection may require the removal of covers and or parts to gain access The level of disassembly required during this inspection will be determined by the manufacturer representa tive or the inspector Complete disassembly of the hoist or major components not designed to be removed or opened for the sole purpose of the inspection is not normally required However if the inspecting authority finds evidence of damage or wear that constitutes a potential hazard fur ther inspection to determine cause or to repair the system may be required and total disassembly or removal of major components may be necessary The periodic inspection includes items in para graph 5 2 5 1 plus the following NOTE For nuclear certified hoists the periodic inspection is required to be performed semi annually by the installation civil engineer or equivalent 5 2 5 2 1 Cracked unevenly worn or damaged drums or sheaves Sheave grooves will be smooth and free from surface irregularities which could cause rope damage 5 2 5 2 2 Excessive wear on motor or load brake 5 2 5 2 3 Excessive wear of chain rope load sprockets drums sheaves an
104. en the sling and load before the sling is tightened around the load 6 1 2 11 Sling failure caused by damage when slings are pulled from under a load 6 1 2 12 Improperly rigged loads 6 1 2 13 Use of unauthorized equipment such as cargo straps as slings 6 2 General Requirements 6 2 1 Acquisition Procurement of slings for use in the Air Force will comply with the design and manufacturing requirements for all slings and be according to 29 CFR 1910 184 Slings and ANSI B30 9 Slings Specifications for procurement of slings will contain enough information to ensure that manufacturers comply with all design construction and testing criteria in the references above 6 2 2 Inspection and Testing 6 2 2 1 Slings will be marked or identified on the sling or on durable and legible tags or labels as follows 6 2 2 1 1 Alloy steel chain slings are required to be marked with the size manufacturer s grade rated load and angle upon which the rating is based its reach number of legs and man ufacturer s name 50 AFOSHSTD91 46 1 FEBRUARY 1997 6 2 2 1 2 Wire rope slings should be marked to identify the rated load and manufacturer 6 2 2 1 3 Metal mesh slings will be marked with manufacturer s name or trademark and the rated load in vertical basket hitch and choker hitch 6 2 2 1 4 Synthetic webbing slings will be permanently marked to identify the name of the manufacturer the manufacturer s code or stock number the rated l
105. ensure that loads placed on the trailer directly behind the towing tractor are not stacked so high that they prevent or obstruct the operator s view of the remain ing trailers 3 2 6 7 7 Operators will reduce speeds on unlevel roadways to reduce jarring of material 3 2 6 7 8 When operating a straddle lift truck operators will 3 2 6 7 8 1 Ensure that all loads placed on trucks are blocked sufficiently to prevent any part of the cargo from coming in contact with the surface over which the cargo is trans ported AFOSHSTD91 46 1 FEBRUARY 1997 19 3 2 6 7 8 2 Use extreme caution any time the vehicle is being operated in congested areas 3 2 6 7 8 3 Carry hoist shoes in the up position to avoid striking any obstruction when the truck is not loaded 3 2 6 7 8 4 Operate vehicles on solid ground at all times 3 2 6 7 8 5 Avoid sudden stops especially when the truck is loaded 3 2 6 7 8 6 Ensure all guards and safety devices are in proper repair at all times and 3 2 6 7 8 7 Ensure straddle trucks operated on base roads at night or in periods of low visibility are equipped with head and tail lights 3 2 6 8 Operators who load and unload aircraft using materials handling and lifting equipment will ensure the instructions in TO 36 M 1 141 463L Material Handling Equipment Systems applicable aircraft Dash 9 and the following are complied with 3 2 6 8 1 Ensure the center of gravity of the cargo is as close to the forklift frame as po
106. equipment and when the load or hook approaches near personnel a warning signal is given 7 2 4 5 4 11 Appropriate clearance is maintained between any part of the crane and elec trical power sources 7 2 4 6 Signals and Instruction Standard signals given to the operator will be according to Fig ure 7 1 Voice communication equipment telephone radio or equivalent will be fully opera tional when used Signals and instructions will be distinct at all times Hand signals as illustrated in Figure 7 1 will be conspicuously posted on or immediately near all cranes 7 2 4 7 Personal Protective Equipment 7 2 4 7 1 Protective helmets hard hats will be worn if there is a potential for injury from falling objects or moving equipment AFOSHSTD91 46 1 FEBRUARY 1997 7 2 4 7 2 Safety toe shoes will be worn by all personnel involved in materials handling when there is a danger of injuries 7 2 4 7 3 Protective safety goggles will be worn when eye injury hazards such as work gen erated dirt dust or other airborne particles are present 7 2 4 7 4 Gloves will be worn by workers performing hooking unhooking loading handling tag lines or unloading operations when there is a potential for injury from punctures and severe cuts lacerations and abrasions 7 2 4 8 Miscellaneous Requirements 7 2 4 8 1 Ladders and Footwalks 7 2 4 8 1 1 The supervisor will ensure workers keep their hands free of encumbrance while they are using
107. er the load 1 2 10 2 The center of gravity of the load on both the handtruck and wheelbarrow will be kept as low as possible The weight should be forward so it will be carried by the axle not the handles If loaded correctly the handtruck and wheelbarrow should carry the load the operator need only balance and push 1 2 10 3 When a handtruck 1 loaded in a horizontal position proper lifting procedures discussed in paragraph 1 2 2 will be used to prevent operator injury 1 2 10 4 Loads will be positioned to prevent shifting or falling Bulky or hazardous items such as cylinders or drums shall be secured Additionally material shall not be positioned so it obstructs the worker s view 1 2 10 5 Handtrucks should be pushed not pulled after initially positioned for movement 1 2 11 Multi Wheel Trucks As with two wheeled equipment multi wheeled trucks and dollies vary greatly in design and use Most mishaps occur due to improper parking causing the worker to fall over the equipment or improper loading of material which causes the cart to tip Extra emphasis will be placed on worker training in these two areas along with frequent observation of work practices to immediately correct unsafe acts Figure 1 1 How to Lift Properly AFOSHSTD91 46 1 FEBRUARY 1997 11 Chapter 2 MANUAL HOISTING AND OR PULLING DEVICES 2 1 Hazards and or Human Factors Some common hazards associated with lever operated hoists can be attribu
108. er plants 8 2 2 4 8 Excessive wear of chain drive sprockets and excessive chain stretch 8 2 2 4 9 Cracks in crane hooks by magnetic particle or other suitable crack detecting inspec tion 8 2 2 4 10 Proper operation of travel steering braking and locking devices 8 2 2 4 11 Worn or damaged tires 8 2 2 4 12 Rust on hydraulic rods and control valves 8 2 2 4 13 Cleanliness of oil filters and oil strainers 8 2 2 4 14 For nuclear certified mobile hydraulic cranes complete a load test per the NOTE in paragraph 8 2 3 1 1 8 2 2 5 Cranes Not in Regular Use 8 2 2 5 1 A crane which has been idle for a period of 1 month or more but less than 6 months will be given an inspection conforming with requirements of paragraph and Chapter 9 8 2 2 5 2 A crane which has been idle for a period of over 6 months will be given a complete inspection conforming with requirements of paragraphs 8 2 2 2 and 8 2 2 3 and Chapter 9 before being placed in service 8 2 2 5 3 Standby cranes will be inspected at least semiannually according to the require ments of paragraphs 8 2 2 2 and 8 2 2 3 and Chapter 9 The need for more frequent inspec tions of cranes exposed to an adverse environment should be determined by the user 8 2 2 6 Inspection Records Inspection records will be maintained according to AFI 24 302 for merly designated AFM 77 310 Volume 2 Vehicle Maintenance Management or other appropri ate directives and their location will be de
109. eren enne enne etn nest en 36 Figure 3 17 Crane Truck Warehouse Gasoline enne enne ennt 37 Chapter 4 CONVEYORS 38 4 1 Hazards and or Human Factors een nnne ener nnne 38 2 Requitementsz eee e es e S E 38 Chapter 5 HOISTS 41 5 1 Hazards and or Human Factors eee nennen nennen 41 2 2 7 Reg itements gestattet cdit aen idus 41 Chapter 6 SLINGS 49 6 1 Hazards and or Human Factors eee nennen nennen 49 6 2 General Requiremiebts cite iis a 49 Gide Specifi Require Ments usen Soo LEE ruo Eus 51 Figure 6 1 Basic Sling Configurations With Vertical Legs eee 56 Figure 6 2 Sling Configurations with Angled Legs eene ene 57 Figure 6 3 Basic Synthetic Web Sling Configurations 58 Table 6 1 Maximum Safe Working Load A Type Alloy Steel Chain Single Vertical Sling 59 Table 6 2 Minimum Allowable Chain Size at Any Point of Link eee 60 Table 6 3 Rated Capacities for Single Leg Slings 6x19 and 6x37 Classification Improved Plow Steel Grade Rope With Fiber Core Pearce nores 61 Table 6 4 Rated Capacities for Single Leg Slings 6x19 and 6x37 Classification Improved Plow Steel Grade Rope With Independent Wire Rope Core IWRC s 62 Table 6 5 Rated Capacities for Single Leg Slings Cable Laid Rope Mechanical Splice Only 7x7x7 and
110. erials instead of lifting whenever possible 1 2 5 3 5 Use gravity assist in moving materials 1 2 5 3 6 Ensure adequate maneuvering space to eliminate the need to twist the body 1 2 5 3 7 Consider team lifting when items are known to weigh more than 25 pounds 1 2 6 Hand Tools Hand tools are discussed in detail in TO 32 1 101 Use and Care of Hand Tools personnel will be instructed in and will use the appropriate tools for each job Examples nail pull ers will be used for opening boxes strap or wire cutters for cutting strapping or wire etc 1 2 7 Inspection Prior to movement material will be examined for sharp edges protruding points and weak places When defects cannot be corrected additional steps will be taken to protect the worker This should be accomplished by isolating the unsafe condition for example using an enclosed cart when moving sheetmetal scraps 1 2 8 Personal Protective Equipment PPE Supervisors will conduct a job safety analysis JSA to evaluate each task and identify the need for PPE such as safety toed shoes gloves and eye protec AFOSHSTD91 46 1 FEBRUARY 1997 9 tion The installation ground safety staff and the bioenvironmental engineer BE are available to assist in this evaluation process AFOSH Standard 91 31 formerly designated AFOSH Standard 127 31 Personal Protective Equipment Department of Defense DoD 4145 19 R 1 Storage and Materials Handling and AFMAN 23 210 Joint Service Ma
111. et to running or on position 4 2 1 16 Ensure electrical or mechanical interlocking devices which will automatically stop a conveyor to prevent jam ups are provided 4 2 1 17 Ensure the open end of every roller conveyor is equipped with a stop that projects auto matically above the rollers when a hinged section is opened and retracts automatically when closed 4 2 1 18 Ensure retarders brakes or similar devices are used to prevent loads from running away at or near the end of an inclined reciprocating conveyor 4 2 1 19 Ensure hinged sections of a power conveyor are interlocked so they cannot be raised while the conveyor is in operation or so the conveyor will stop automatically when a section is opened 4 2 1 20 Ensure powered conveyors have lock out switches so power can be locked out during maintenance 4 2 2 Inspections The supervisor will ensure the entire conveyor system is inspected daily Defec tive parts that would affect the safe operation of the system will be replaced prior to continued opera tion Operators will ensure crossover walkway surfaces are in good condition 4 2 3 Maintenance No work will be done on a power conveyor until the power switch or discon nect has been locked in the off position and or tagged out 4 2 4 Training Personnel will be thoroughly trained on procedures for 4 2 4 Starting and stopping conveyors 4 2 4 2 Loading and unloading conveyors to prevent overloading and jamming
112. eved Gas Electric Truck An electric truck that uses a gasoline or LP gas engine driven generator Gate A device or structure which stops or regulates the flow of material Also a section of conveyor equipped with a hinge mechanism for movable service often called a hinged section Gondola An open top freight car with sides and ends Grating e coarse screen made of parallel or crossed bars to prevent passage of oversize material or e A series of parallel or cross bar units fastened to or propelled by the conveying medium used for carrying large lump sized bulk material or objects Usually used to permit passage of air for cool ing or heat to maintain temperature Hanger Rod Steel rods which together with other fittings are used to suspend the track from the sup porting structure Headroom Distances from saddle of load hook in highest position with full load to saddle of top hook Hopper A box having a funnel shaped bottom or a bottom reduced in size narrowed or necked to receive material and direct it to a conveyor feeder or chute Inactive Controls Those controls that are not a part of or contributing to the present or future contem plated use of the conveyor or system as presently installed and wired Jib An extension attached to the boom point to provide added boom length for lifting specified loads The jib may be in line with the boom or offset to various angles Lever Pull Average number of pounds of effo
113. eventing damage to the hoist rope or other machine components when hoisting the load extending the boom or lowering the boom on a machine having a stationary hoist mounted to the rear of the boom hinge 8 2 1 2 3 Boom Angle Indicator boom angle indicator shall be provided on all cranes 8 2 1 2 4 Overload Protection Devices such as Load Moment Indicators are commercially available and are designed to alarm the operator and or de energize the crane when attempt 92 AFOSHSTD91 46 1 FEBRUARY 1997 ing to lift a load that is beyond the capabilities of the crane Although these devices would be of minimal value in routine base level Air Force operations they may be of some value in operations involving construction where load may not be defined or identified or when a load has not been properly released from its transporter The user must evaluate the current and anticipated use of the crane to determine the need for such a device 8 2 1 2 5 Color Coding for Strike Hazard Those portions of crane cabs that extend beyond the main chassis when rotated will be color coded yellow and black on the lower areas to denote a strike hazard to personnel on the ground Colors will be reflective for night opera tions 8 2 1 2 6 Guarding of Machinery Exposed moving parts such as gears set screws projecting keys chains chain sprockets and reciprocating parts which might constitute a hazard to oper ating personnel under normal operating con
114. f Installing Cable Clips STEP 1 STEP 4 APPLY TENSION APPLY FIRST CLIP one base width from dead end of wire rope U Bolt over dcad and live end rests in clip saddle Apply tension and tighten all nuts to recommended Tighten nuts evenly to recommended torque torque STEP 5 STEP 2 APPLY TENSION APPLY SECOND CLIP nearest loop as possible U Bolt over dead end turn on nuts firm but DO NOT TIGHTEN STEP 3 ALL OTHER CLIPS Space equally between first two AFOSHSTD91 46 1 FEBRUARY 1997 Figure 9 3 Double Base Clamp 113 114 AFOSHSTD91 46 1 FEBRUARY 1997 Figure 9 4 Joining Wire Ropes WRONG AFOSHSTD91 46 1 FEBRUARY 1997 115 Figure 9 5 Correct and Incorrect Way to Measure Wire Rope Always read the widest diameter Correct Incorrect 116 Figure 9 6 Wire Rope Wear and Damage bird cage caused by sudden release of tension and resultant rebound of rope from overloaded condition These strands and wires will not return to their original position A wire rope which has been subjected to repeated bending over sheaves under normal loads This results in fatigue breaks in individual wires these breaks are square and usually in the crown of the strands An example of fatigue failure of a wire rope which has been subjected to heavy loads over small sheaves The usual crown breaks are accompanied by breaks in the valleys of the strands
115. ia for manual and powered materials handling require ments It implements portions of Occupational Safety and Health Administration OSHA Standard 29 Code of Federal Regulations CFR Part N Materials Handling and Storage and includes additional requirements not addressed by the OSHA standard The Air Force single point of contact to certify equip ment for use with nuclear weapons is HQ AFSC Nuclear Systems Engineering Division SEWA 9700 G Avenue SE Suite 120 Kirtland AFB NM 87117 5670 This office in coordination with the San Antonio Air Logistics Command Directorate of Nuclear Weapons SA ALC NWTD 413 North Luke Drive Building 1420 Kelly AFB TX 78241 5314 establishes the equipment as certified and ensures the equip ment is listed in Technical Order TO 00 110N 16 USAF Nuclear Certified Equipment and Software This standard applies to all US Air Force organizations including US Air Force Reserve personnel and when Air National Guard personnel are on Federal Service SUMMARY OF REVISIONS This revision implements regulatory federal requirements It adds training requirements for powered industrial trucks operators paragraphs 3 2 4 4 3 2 6 5 14 and 3 2 4 6 15 and certification records of inspections of hooks and hoist chains paragraphs 5 2 5 1 4 5 2 5 1 5 and 9 2 1 4 changes the fre quency of periodic inspection requirements paragraphs 5 2 5 2 and 7 2 5 7 2 modifies physical quali fications of operators and the req
116. iameter and larger the tail will project at least six rope diameters beyond the last full tuck Where a projecting tail interferes with the use of the sling the tail will be tapered and spliced into the body of the rope using at least two additional tucks which will require a tail length of approximately six rope diameters beyond the last full tuck 6 3 4 6 4 Fiber rope slings will have a minimum clear length of rope between eye splices equal to ten times the rope diameter 6 3 4 6 5 For all eye splices the eye will be sized to provide an included angle of not greater than 60 degrees at the splice when the eye is placed over the load or support 6 3 4 6 6 Only clamps specifically designed for fiber ropes will be used for splicing 6 3 4 6 7 Knots will not be used in lieu of splices 6 3 4 7 Fiber rope slings will not be used if end attachments that contact the rope have sharp edges or projections 6 3 4 8 Natural and synthetic fiber rope slings will be removed from service if any of the follow ing conditions are present 6 3 4 8 1 Abnormal wear 6 3 4 8 2 Powdered fiber between strands 6 3 4 8 3 Broken or cut fibers 6 3 4 8 4 Variations in the size or roundness of strands 6 3 4 8 5 Discoloration or rotting 6 3 4 8 6 Distortion of hardware in the sling 6 3 4 9 Only new rope will be used to make fiber rope slings Use of repaired or reconditioned fiber rope in slings is prohibited 6 3 5 Synthetic Web Slings
117. ical contacts in sets only Lubricate controller parts as recommended by the manufacturer 5 2 4 4 7 Keep pendant control stations clean and function labels legible 5 2 4 4 8 Adjust all functional operating mechanisms brakes and pawls limit switches and other limiting devices to ensure correct functioning of components 5 2 4 5 Lubrication All moving parts of the hoist for which lubrication is specified will be reg ularly lubricated Particular care should be taken to follow manufacturer s recommendations as to points and frequency of lubrication quantity and type of lubricant to be used Machinery will be stationary with the energy source locked out while lubricants are being applied See paragraph 5 2 4 3 3 5 2 4 6 Rope Replacement and Maintenance Refer to Chapter 9 5 2 5 Inspections The following items will be inspected for damage and or wear at intervals spec ified including observations during operation Deficiencies will be carefully examined and a determi nation made by the operator and the shop and or facility supervisor as to whether they constitute a safety hazard 5 2 5 1 Daily or Prior to Use Inspect AFOSHSTD91 46 1 FEBRUARY 1997 47 5 2 5 1 1 controls and operation mechanisms for proper operation On pendant controls inspect the electrical and support cable for condition and ensure all labels are present and leg ible 5 2 5 1 2 safety devices including the upper limit switches f
118. ick shall be performed at intervals as generally defined in paragraph 5 2 5 2 and in addition items such as the following will be inspected Deficiencies shall be carefully examined and a determination made as to whether they constitute a safety hazard AFOSHSTD91 46 1 FEBRUARY 1997 121 10 1 3 1 Structural members for deformations cracks and corrosion 10 1 3 2 Bolts or rivets for tightness 10 1 3 3 Parts such as pins bearings shafts gears sheaves drums rollers and locking and clamping devices for wear cracks and distortion 10 1 3 4 Gudgeon pin for cracks wear and distortion each time the derrick is erected 10 1 3 5 Power plants for proper performance and compliance with applicable safety require ments 10 1 3 6 Hooks for cracks and bends wear and deformations etc refer to Figure 9 7 10 1 3 7 Foundation or supports for continued ability to sustain the imposed loads 10 1 3 8 Derrick electrical pendant and or control box for proper grounding 10 2 Derricks Not in Regular Use 10 2 1 A derrick which has been idle for a period of 1 month or more but less than 6 months shall be given an inspection conforming with requirements of paragraph before placing in service 10 2 2 A derrick which has been idle for a period of over 6 months shall be given a complete inspec tion conforming with requirements of paragraph 5 2 5 2 before placing in service 10 2 3 Standby derricks shall be inspected at least
119. ided by timbers cribbing or other structural material sufficient to distribute the load and provide a level surface Outriggers on cranes so equipped will be fully extended per manufacturer s specifica tions 8 2 6 46 When small portable containers are used to refuel engines they will be approved safety containers with an automatic closing cap and flame arrester The crane will not be refueled when the engine is running or hot 8 2 6 47 A fire extinguisher rated for Class B and C fires will be provided at the operator s sta tion Operating and maintenance personnel will be familiar with the care and use of the extin guisher provided 8 2 6 48 Operation of locomotive cranes will cease when railway cars on adjacent tracks are in motion 8 2 6 49 hooks and hook blocks shall be permanently marked with the manufacturer s identi fication Load hooks shall be equipped with safety latches 8 2 6 50 The use of a crane or derrick to hoist workers on a personnel platform is prohibited except when conventional means of reaching the worksite such as personnel hoist ladder stair way aerial lift elevating work platform or scaffold would be more hazardous or is not possible See paragraph 9 6 8 2 6 51 The area in the rear in which someone could be struck or caught by the rotating super structure shall be barricaded 29 CFR 1926 550 AFOSHSTD91 46 1 FEBRUARY 1997 103 8 2 6 52 Chapter 9 will be referred to for information
120. ignated AFM 77 310 Vol 2 Vehicle Maintenance Management AFI 91 202 formerly designated AFR 127 2 The US Air Force Mishap Prevention Program AFI 91 301 formerly designated AFR 127 12 The Air Force Occupational and Environmental Safety Fire Protection and Health AFOSH Program Air Force Manual AFMAN 23 210 Joint Service Manual JSM for Storage and Materials Handling AFMAN 52 4 Special Purpose Vehicle Training Manual AFMAN 91 118 Safety Design and Evaluation Criteria for Nuclear Weapon Systems AFMAN 91 201 Explosives Safety Standards Air Force Occupational Safety and Health AFOSH Standard 48 2 formerly designated AFOSH Stan dard 161 2 Industrial Ventilation AFOSH Standard 91 31 formerly designated AFOSH Standard 127 31 Personal Protective Equipment AFOSH Standard 127 22 Guarding Floor and Wall Openings and Holes Fixed Industrial Stairs and Portable and Fixed Ladders AFOSH Standard 127 45 Hazardous Energy Control and Mishap Prevention Signs and Tags American National Standards Institute ANSI Standard A14 3 Safety Requirements for Fixed Ladders ANSI American Society of Mechanical Engineers ASME Standard B20 1 Safety Standards for Convey ors and Related Equipment ANSI ASME Standard B30 2 Overhead and Gantry Cranes Top Running Bridge Multiple Girders ANSI Standard B30 5 Mobile and Locomotive Cranes ANSI Standard B30 7 Base Mounted Drum Hoist ANSI ASME Standard B30 9 Slings ANSI A
121. including a top rail of 42 inches a midrail and a toe board and shall be enclosed at least from the toeboard to the midrail The guardrails shall be able to withstand at least 200 pounds applied in any direction A grab rail shall be installed inside the entire perimeter of the platform 9 6 2 3 Will limit to four the number of workers to be lifted to include tools Each worker shall be considered to weigh 250 pounds 9 6 2 4 Shall not be used during high winds electrical storms or any other adverse weather con dition which could endanger the workers using the platform 9 6 3 The lifting bridle used to suspend the working platform from the crane shall normally consist of four legs attached so the stability of the platform is ensured The lifting bridle shall be attached by a hook which can be closed and locked or secured by a shackle with a bolt nut and retaining pin These bridles and associated rigging shall not be used for any other purpose when not hoisting person nel 9 6 4 The total weight of the loaded personnel platform the related rigging to include the block ball and wire rope shall not exceed 50 percent or the rated capacity for the radius and configuration of the crane or derrick 9 6 5 The crane shall be uniformly level within 1 percent of level grade and located on firm footing If equipped outriggers shall be fully deployed according to manufacturer s specifications 9 6 6 Requirements for trial lift inspecti
122. ing configuration with one end of the sling passing under the load and through an end attachment handle or eye on the other end of the sling Used for turning an object e Vertical Hitch A method of supporting a load by a single vertical part or leg of the sling Hoist Includes only those components furnished by the hoist manufacturer such as drums tackle prime movers limiting device mounting bases etc When hoists are mounted as integral parts of more complex lifting equipment they become component parts of that equipment They are subject to the safety standards and inspection intervals established for the end item AFOSHSTD91 46 1 FEBRUARY 1997 133 Hoist Chain The load bearing chain in a hoist Hoist Motion That motion of a crane which raises and lowers a load Hook Latch Type safety hook incorporating a device to bridge the hook opening which requires manual movement to release the load from the hook Inclined Reciprocating Conveyor A reciprocating power or gravity actuated unit which receives only inanimate objects on a track roller conveyor or other form of carrying surface not designed to carry passengers or the operator These units operate on inclines generally in the range of 30 degrees to 70 degrees with the horizontal Interlock A mechanical device to align the adjacent ends of two cranes or a crane and spur track to permit the transfer of carriers from one to the other Internal Combustion Engine
123. internal combustion engines will not be refueled inside warehouses or while the engine is running Refueling will be accomplished in outside areas approved by local fire pro tection officials 3 3 4 2 When fuel is spilled during servicing operations will be stopped and equipment cleaned up according to local procedures prior to restarting fuel servicing operation The fire protection branch will be contacted if a significant spill is experienced 22 AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 1 Approved Safety Pallet NOTE The following correspond to the numbers 1 through 7 positioned around the figure 1 A 4 inch toeboard to prevent tools or small items from falling off 2 An expanded metal background to protect personnel from moving parts of forklift 3 Mitered corners 4 Handrail on backguard 5 Safety chains with the top chain 42 inches from the pallet surface and a second chain approximately midway between the pallet surface and the top chain to enclose the pallet area 6 Chains for securing the pallet to the fork truck 7 Checker plate flooring to prevent slippage of pallet AFOSHSTD91 46 1 FEBRUARY 1997 23 Figure 3 2 Extension Forks Used With the Safety Pallet NOTE Fork extensions are used to support larger type safety pallets A notice to this effect will be displayed prominently on the side of the pallet Use Fork Extensions 24 AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 3 High Lift Truck Also kno
124. ipment is listed in TO 00 11ON 16 Operational Test A test of mechanical and electrical controls limit switches and safety devices through the complete operational range without a load Operator s Station Location at which actuators are placed for the purpose of starting stopping reversing or otherwise controlling the conveyor or system of conveyors in the course of normal operation Order Stock Picker Truck High Lift A high lift truck with the operator s station attached to the forks The station and forks move as a unit The truck is intended for manual stock selection but may be capable of self loading or tiering Overhead Guard A protective framework fitted to a truck over the head of the operator Overload Device A mechanical or electrical device designed to disconnect the driven equipment from the motive power in the event of an overload on the conveyor Overtravel Restraint Any device used to prevent the slack load chain from inadvertently being lowered out of the load sprocket Outriggers Extendible or fixed metal arms attached to the mounting base which rest on supports at the outer ends Pallet A low portable platform of wood metal or fiberboard used to stack move store and transport supplies as a unit Pawl Dog A device for positively holding the mechanism drum etc against undesired rotation Pendant Station Controls suspended from the hoist for operating the unit from the floo
125. ity at least equal to the metal fabric and exhibit no defor mation after proof testing 6 3 3 2 The fabric and handles will be joined so that 6 3 3 2 1 The rated capacity of the sling is not reduced 6 3 3 2 2 The load is evenly distributed across the width of the fabric 6 3 3 2 3 Sharp edges will not damage the fabric 6 3 3 3 Coatings which damage the sling and diminish the rated capacity will not be applied 6 3 3 4 new and repaired metal mesh slings including handles will be proof tested at a min imum of one and one half times their rated capacity before they are used Elastomer impregnated slings will be proof tested before they are coated AFOSHSTD91 46 1 FEBRUARY 1997 53 6 3 3 5 Metal mesh slings will not be used to lift loads in excess of their rated capacities pre scribed in Table 6 15 Slings not included in this table will be used only according to the manu facturer s recommendations 6 3 3 6 Each metal mesh sling shall have a durable marking permanently attached that states the rated capacity for vertical basket hitch and choker hitch loadings and marked with the manufac turer s name 6 3 3 7 Metal mesh slings which are not impregnated with elastomers may be used in a tempera ture range from minus 20 degrees F to plus 550 degrees F without decreasing the working load limit Metal mesh slings impregnated with polyvinyl chloride or neoprene may be used only in a temperature range from zero degrees to plus 200
126. ks for deformations or cracks or having more than 15 percent in excess of normal throat opening or more than 10 degrees twist from the plane of the unbent hook refer to paragraph 8 2 3 3 4 8 2 2 3 4 Rope reeving for compliance with crane manufacturer s recommendation 8 2 2 3 5 Electrical apparatus for malfunctions signs of excessive deterioration or dirt and moisture accumulation 8 2 2 3 6 Hydraulic hoses fittings and tubing for deterioration refer to paragraph 8 2 2 2 1 8 2 2 4 Annual Inspections The Vehicle Maintenance Officer is responsible to ensure that plete inspections of the crane will be performed at intervals at least annually or as directed or recommended by the manufacturer These inspections will be performed by a qualified person and will include the requirements of paragraphs 8 2 2 2 and 8 2 2 3 and the following items 8 2 2 4 1 Deformed cracked or corroded members in the crane structure and boom 8 2 2 4 2 Loose bolts or rivets 8 2 2 4 3 Cracked or worn sheaves and drums 8 2 2 4 4 Worn cracked or distorted parts such as pins bearings shafts gears rollers and locking devices AFOSHSTD91 46 1 FEBRUARY 1997 95 8 2 2 4 5 Excessive wear on brake and clutch system parts linings pawls and ratchets 8 2 2 4 6 Any inaccuracies of load and check boom angle indicators and other indicators over their full range 8 2 2 4 7 Proper performance of gasoline diesel electric or other pow
127. l be given A list of approved instructors will be retained on file by the using activity and the vehicle operations activity 3 2 4 2 Training outlines for each piece of equipment will be accomplished by the unit according to instructions in AFI 24 301 formerly designated AFM 77 310 Volume 1 Vehicle Operations The training outline course content will include a written examination to evaluate the operator s knowledge of equipment operations and service instructions AFM 52 4 Special Purpose Vehicle Training Manual may aid in development of lesson plans for some types of equipment 3 2 4 3 The instructor will furnish the vehicle operations officer with written certification along with examination results prior to certification of an operator s qualification to operate equipment on the AF Form 171 Request for Driver s Training and Addition to U S Government Motor Vehicle Driver s License 3 2 4 4 In addition to initial training and certification a qualified instructor shall evaluate each operator annually and provide refresher or remedial training when there is reason to believe there is a need such as a near miss a reportable mishap or if the annual evaluation indicates that an operator is not capable of performing assigned duties 3 2 4 5 The base or unit explosives and or weapons safety manager will review course outlines to support the training of materials handling equipment operators according to requirements in AFI 91 202
128. l only use enough backward tilt to stabilize the load 3 2 6 6 5 The operator will not use more than the manufacturer s specified counterweight sys tem to increase lifting capacity 3 2 6 6 6 The operator will not align bump or push stacks with a lift 3 2 6 7 When operating warehouse tractor tug trailer trains 3 2 6 7 1 Tractor operators will obey all traffic regulations and will not exceed 15 miles per hour when towing trailers When traveling on base roads trains will keep to the extreme right and if operated at night or in periods of low visibility lights will be used The towing of air craft engines will be according to TO 00 85 20 Engine Shipping Instruction Chapter 4 3 2 6 7 2 The operator will not permit passengers to ride on tractors unless adequate seats have been installed 3 2 6 7 3 Operators will tow no more than four loaded or empty trailers with a tractor or tug EXCEPTION Six A M326 palletized cargo trailers may be towed behind one tractor 3 2 6 7 4 avoid jackknifing trailer trains the operator will ensure that the train is arranged with the most heavily loaded trailer next to the towing vehicle the next heaviest second in line and so on 3 2 6 7 5 The operator will make sure the couplings are secure before moving a trailer or train Pintle assemblies and towing connections will be secured with a pintle hook safety pin that will positively lock towing connections 3 2 6 7 6 The operator will
129. l powered industrial trucks or other material handling equipment pro vided appropriate parking and refueling areas Reference paragraphs 3 3 1 3 3 3 and 3 3 4 A3 6 Are battery charging areas for electrically powered material handling equipment designed accord ing to this standard and the NFPA 503 Section 5 3 Reference paragraph 3 3 2 A3 7 Do the conveyors have all of the required design and safety features required by this standard Reference paragraph 4 2 A3 8 Are all personnel trained on procedures for operating conveyors Reference paragraphs 4 2 4 and 4 2 5 A3 9 Are hoists operated only by qualified personnel who are trained and qualified to use the equip ment Reference paragraph 5 2 3 1 1 A3 10 Are there records of all operational rated and proof load tests Reference paragraph 5 2 4 1 A3 11 Have lockout and or tagout procedures been developed for use with maintenance activities Reference paragraph 5 2 4 3 and AFOSH Standard 127 45 A3 12 Are hooks used with hoisting equipment inspected daily or before each use Reference paragraph 5 2 5 1 A3 13 Are records of inspections of hoists chains and ropes maintained Reference paragraph 5 2 5 4 A3 14 Are slings inspected each month and documented Reference paragraph 6 2 2 A3 15 Are slings proof tested at 200 percent of rated capacity and a record of the most recent test main tained on file Reference paragraph 6 2 3 1 A3 16 Is
130. l times when personnel are on the safety plat form but will not move the forklift 3 2 5 8 Instructions prohibiting the movement of the forklift with personnel on the safety pallet should be posted on the pallet 3 2 6 Safe Operation Requirements 16 AFOSHSTD91 46 1 FEBRUARY 1997 3 2 6 1 Battery powered equipment will be used whenever possible When internal combustion engine equipment is used inside warehouses ventilation requirements will be determined by the installation BE to preclude exposure of workers to carbon monoxide gas Refer to AFOSH Stan dard 48 2 formerly designated AFOSH Standard 161 2 Industrial Ventilation See AFMAN 91 201 for operating in explosives and or weapons areas 3 2 6 2 Internal combustion engine equipment will not be warmed up inside a building and will be turned off when not in use 3 2 6 3 Liquid Petroleum LP gas fuel industrial trucks may be used in buildings or structures approved by the installation fire and ground safety officials If used inside buildings or structures there will be no more than two 10 gallon fuel containers on the truck and the truck will not be left unattended with the engine running Also see paragraph 3 2 6 1 3 2 6 4 Operation of high and or low lift trucks platform pallet trucks rider trucks reach trucks side loader trucks picker trucks straddle lift trucks etc 3 2 6 4 1 Personnel will not be permitted to ride on powered lift equipment unless a p
131. ladders 7 2 4 8 1 2 Articles which are too large to be carried in pockets or belts will be lifted and lowered by hand line 7 2 4 8 1 3 Footwalks will be kept free of loose tools parts or other tripping hazards 7 2 4 8 2 Cabs 7 2 4 8 2 1 Necessary clothing and personal belongings will be stored in a way that does not interfere with access or operation 7 2 4 8 2 2 Tools will be stored in approved tool boxes Wastes will be disposed of in appropriate containers No loose articles will be left in or about the cab 7 2 4 8 3 Fire Extinguishers Supervisors will ensure that operators are familiar with the operation and care of fire extinguishers provided See paragraph 7 2 2 10 7 2 5 Maintenance and Testing 7 2 5 1 Preventive Maintenance 7 2 5 1 1 A preventive maintenance program based upon the manufacturer s recommendation will be established Dated and detailed records will be maintained by the using agency and readily available 7 2 5 1 2 All replacement parts should be obtained from the original equipment manufacturer or a manufacturer approved source 7 2 5 2 Maintenance Procedures 7 2 5 2 1 Before adjustments and repairs are started the following precautions will be taken 7 2 5 2 1 1 Movable equipment shall be moved to a location where it will cause the least interference with other moving equipment on the system and operations in the area 7 2 5 2 1 2 All controllers will be placed at the off position
132. le for all pow ered hoists 5 2 3 Operations AFOSHSTD91 46 1 FEBRUARY 1997 43 5 2 3 1 Qualification of Operators 5 2 3 1 1 Manually operated hoists will be operated only by those personnel who are trained and qualified to use the equipment Power operated hoists will be operated only by qualified persons designated by the appropriate supervisor Operator qualifications will be determined by the successful completion of a practical operating examination administered by a qualified operator or an instructor Maintenance and test personnel and inspectors may also operate hoists in the performance of their duties 5 2 3 1 2 Operators of power operated hoists shall meet the following minimum qualifica tions 5 2 3 1 2 1 Have vision of at least 20 30 Snellen in one eye and 20 50 in the other with or without glasses 5 2 3 1 2 2 Be able to distinguish red green and yellow regardless of position of colors 5 2 3 1 2 3 Test for ordinary conversation in one ear with or without a hearing aid to ensure that there is adequate hearing for a specific operation 5 2 3 1 2 4 Have sufficient strength endurance agility coordination and speed of reac tion to meet the demands of equipment operation 5 2 3 1 2 5 Evidence of physical defect or emotional instability which could render the operator a hazard to himself or others or which in the opinion of the examiner or supervi sor could interfere with the operator s safe performance
133. le material under the conveyor line to guard against material falling from the conveyors 4 2 1 8 Ensure rails or guards are installed whenever there is danger of material falling from any conveyor 4 2 1 9 Ensure all conveyors installed within 7 feet of the floor or surface have crossovers or pas sages 4 2 1 10 If clear passageways cannot be provided under or around a conveyor ensure crossover stiles are installed if possible so workers don t have to climb on the conveyor Ensure stiles have stairs with nonslip treads standard handrails and 4 inch toeboards 4 2 1 11 If a crossover cannot be installed to clear objects on the conveyor ensure a hinge is installed so it can be swung out of the way when not in use 4 2 1 12 If crossover stiles are not feasible ensure metal plates with nonslip treads are installed in the conveyor just below and between the rollers Ensure handrails that clear the load on the con veyor are provided 4 2 1 13 Ensure all starting and stopping devices are clearly marked clear of obstructions and readily accessible 4 2 1 14 Ensure all starting and stopping devices are recessed or guarded to prevent accidental contact by persons or moving objects AFOSHSTD91 46 1 FEBRUARY 1997 39 4 2 1 15 If a conveyor has two or more stop switches ensure such switches are arranged so the conveyor cannot be restarted until the actuating stop switch the switch that originally broke the circuit has been res
134. ley carrier or truck from one track to another at a converging or diverging section Switch Limit A switch which is operated by some part or motion of a power driven machine or equipment to alter the electric circuit The purpose is generally to limit the travel of a machine or equipment component Switch Main A switch controlling the entire power supply to a system Switch Track A device with a moving section of track which can be moved to permit passage of a 138 AFOSHSTD91 46 1 FEBRUARY 1997 carrier from an incoming track to one of the various outgoing tracks Tag Line A manila or synthetic rope used to prevent a load from swinging or rotating Tiering The process of placing one load on or above another Track The structural member upon which the carriers or crane wheels operate Tracks The beams shapes or formed section on which trolleys rollers shoes or wheels roll or slide while being propelled Track Opener Sections of monorail track arranged to lift or swing out of the line of track to make an opening through which a door may pass Tramrail Same as Monorail Travel The function of the machine moving from one location to another Tread Plate A plate of suitable size fitted between conveyor rollers to permit persons to use it as a working or walking surface or safety guard Trolley e assembly of wheels bearings and brackets used for supporting and moving suspended loads or for
135. lly provided to connect the lower ends of the stiff legs to the top of the mast Drift Point A point on a travel motion controller which releases the brake while the motor is not ener gized This allows coasting before the brake is set Dynamic A method of controlling crane motor speeds when in the overhauling condition to provide a retarding force Dynamic Loading Loads introduced into the machine or its components by forces in motion Electrification The track mounted electrical conductor system by which the moving equipment receives its electrical power End Stop A positive device located at the end of a track or crane bridge to prevent the carrier from run ning off the end of the track or bridge End Truck The assembly consisting of the truck frame and wheels which support the crane girders and allow movement along the runway AFOSHSTD91 46 1 FEBRUARY 1997 143 Flange Load Carrying The lower flange of the monorail systems or underhung crane track on which the load bearing wheels roll Flight e or shaped plates suitable made for attachment to the propelling medium of a flight con Aterm applied to any conveyor in a tandem series Fork Safety A mechanical device for use on interlocking transfer equipment to mechanically prevent passage of a carrier when the elements are not securely locked Gantry A Frame A structural frame extending above the superstructure to which the boom support ropes are re
136. m running off the open ends of the fixed and movable track if they are not properly lined up with each other Conversely the track shall be interlocked with the bumpers so the track cannot move until the rail 42 AFOSHSTD91 46 1 FEBRUARY 1997 stops are in position Note The track and its support will be inspected at least monthly for signs of weakness wear and or misalignment If the monorail is located in a workplace not contin uously occupied such as a missile launch facility this inspection should be accomplished prior to use 5 2 2 8 Slack Chain In cases where the slack chain hanging from a hoist may be a hazard to the operation a chain container will be provided 5 2 2 9 Hooks Latch type safety hooks will be installed on all hoists 5 2 2 10 Load Rating The rated load will be permanently marked on the hoist and load block and will be clearly legible from the operating position 5 2 2 11 Warnings Information concerning operating procedures shall be either posted by all hoists or using a label affixed to the hoist controls or block see ANSI Standard B30 16 5 2 2 11 1 Lifting more than the rated load 5 2 2 11 2 Operating the hoist when the hook is not centered under the hoist 5 2 2 11 3 Operating the hoist with twisted kinked or damaged chain or rope 5 2 2 11 4 Operating a damaged or malfunctioning hoist 5 2 2 11 5 Operating a rope hoist with a rope that is not properly seated in its groove 5 2 2 11 6
137. main switch the operator will make certain all controllers are in the off position 7 2 4 4 9 If power goes off during operation the operator will immediately throw all control lers to the off position 7 2 4 4 10 The operator will be familiar with the equipment and its proper care If adjust ments or repairs are necessary or any damage is observed the operator will report it promptly to the appointed person and will also notify the next operator of the deficiencies upon chang ing shifts The results of the above shall be carefully recorded in the logbook in full detail and shall be dated and signed 7 2 4 4 11 Contacts with stops or other equipment will be made with extreme caution and only after all persons on or below equipment are aware of the action 7 2 4 4 12 Before departing the work area operators of outdoor cranes will secure them to prevent inadvertent movement 7 2 4 4 13 When the wind indicating alarm is given the bridge on the outside cranes will be anchored 7 2 4 4 14 Before performing any maintenance work on the equipment the operator and or maintainer will lock the main switch in the open position 7 2 4 4 15 All controls will be tested by the operator when beginning a new shift except when an operation is in progress If any controls do not operate properly they will be adjusted or repaired before operations begin 7 2 4 5 Handling the Load 7 2 4 5 1 The equipment shall not be loaded beyond
138. mined manner the electric power delivered to the apparatus to which it is connected Controller Spring Return controller which when released will return automatically to a neutral position Crane Any machine for lifting and or lowering of a load and moving it horizontally in which the lifting device is an integral part of the machine Refer to Attachment 2 for definitions of specific types of cranes not defined below e Crane Cantilever Gantry A gantry or semigantry crane in which the bridge girders or trusses extend transversely beyond the crane runway on one or both sides AFOSHSTD91 46 1 FEBRUARY 1997 131 Crane Crawler A crane consisting of a rotating superstructure with power plant operating machinery and boom mounted on a base equipped with crawler treads for travel e Crane Floor Operated A crane which is controlled by an operator on the floor or an independent platform by using a pendant or nonconductive rope Crane Gantry crane similar to an overhead crane except the bridge for carrying the trolley or trolleys is rigidly supported on two or more legs running on fixed rails or other runway e Crane Overhead A crane with a movable bridge carrying a movable or fixed hoisting mecha nism and traveling on an overhead fixed runway structure Crane Remote Operated crane controlled by an operator not in a cab or pulpit It is controlled by any method other than pendant or rope control for example ra
139. n CFan Part Srat Stan Srat atan 3 32 6x7 074 055 0 60 045 042 032 11 0 83 0 90 0 68 064 0 48 1 8 6 7 1 3 0 98 1 1 0 80 10 76 0 57 2 0 1 5 1 6 1 2 1 1 0 85 3 16 6x7 2 9 2 2 2 4 1 8 1 7 1 3 4 4 3 3 3 6 2 7 2 5 1 9 3 32 7 7 10 89 0 67 0 72 055 0 51 0 39 1 3 1 0 1 1 0 82 0 77 0 58 1 8 7 7 1 6 1 2 1 3 10 10 95 0 71 2 5 1 8 2 0 1 5 1 4 1 1 3 16 7x7 3 6 2 7 2 9 2 2 2 1 1 5 54 40 44 3 3 3 1 2 3 3 16 6x19 3 0 2 2 2 4 1 8 17 13 4 5 3 4 3 7 2 8 2 6 1 9 1 4 6x19 5 3 4 0 43 3 2 3 1 2 3 80 60 6 5 4 9 4 6 3 4 5 16 6x19 83 6 2 6 7 5 0 4 8 3 6 120 93 10 0 76 7 1 5 4 3 8 6x19 12 0 8 9 9 7 7 2 6 8 5 1 18 0 130 140 110 100 77 7 16 6x19 160 12 0 130 9 8 9 3 6 9 240 180 200 15 0 140 100 12 6 19 210 150 170 13 0 120 9 0 310 230 250 190 180 130 9 16 6 19 260 20 0 210 160 150 110 39 0 29 0 320 240 230 170 5 8 6x19 320 24 0 260 200 10 0 140 4 amp 0 36 0 400 300 280 210 3 4 6x19 460 35 0 380 280 270 200 69 0 520 1560 420 400 300 7 8 6 19 620 47 0 510 380 360 270 94 0 700 760 570 540 400 1 6x19 1810 61 0 66 0 500 470 35 0 1220 910 1990 74 0 1 700 53 0 Table 6 11 Rated Capacities for Strand Laid Grommet Hand Tucked Improved Plow Steel Grade Rope These values only apply when the D d ratio is 5 or greater where D Diameter of curvature around which rope is bent d Diameter of rope body AFOSHSTD91 46 1 FEBRUARY 1997 69 Table 6 12 Ra
140. n contained in paragraphs 3 2 4 6 3 2 4 7 and 3 3 3 2 5 Safeguarding Requirements 3 2 5 1 All materials lifting equipment powered by internal combustion engines will be equipped with fire extinguishers Type size and location will be determined by the local fire chief AFMAN 91 201 Explosives Safety Standards has requirements for explosives operations 3 2 5 2 The maximum capacity load will be posted on each piece of lifting equipment in view of the operator and will be kept current to reflect changes Any modifications or added attachments will be approved and load capacity posted on the items 3 2 5 3 All high lift equipment will be equipped and operated with overhead guards to protect the operator from falling objects The overhead guards will not be covered with material that could obstruct the operator s vision 3 2 5 4 Where steering must be accomplished with one hand and a steering handwheel is used steering knobs or equivalent may be used for safe and effective operation The steering knob will not protrude beyond the outside periphery of the handwheel 3 2 5 5 Load backrest extensions will be used whenever necessary to minimize the possibility of the load falling rearward 3 2 5 6 When a forklift is used to elevate personnel an approved safety pallet as illustrated in Figure 3 1 will be used It will be equipped with the features identified in the figure 3 2 5 7 The operator will remain at the controls at al
141. ncy and large amplitude of motion usually powered by a rotating eccentric Overland Conveyor single or series of belt conveyors designed to carry bulk material across country usually following the general contour of the land Portable Conveyor Any type of transportable conveyor usually having supports which provide mobility e Pusher Bar Conveyor Two endless chains cross connected at intervals by bars or rotatable push ers which propel the load along the bed or trough of the conveyor e Roller Slat Conveyor slat conveyor using rollers for slats e Screw Conveyor A conveyor screw revolving in a suitably shaped stationary trough or casing fit ted with hangers trough ends and other auxiliary accessories Shuttle Conveyor Any conveyor such as a belt chain apron screw etc in a self contained struc ture movable in a defined path parallel to the flow of the material e Slat Conveyor A conveyor employing one or more endless chains to which non overlapping non interlocking spaced slats are attached AFOSHSTD91 46 1 FEBRUARY 1997 141 Suspended Tray Conveyor vertical conveyor having one or more endless chains with suitable pendant trays cars or carriers which receives objects at one elevation and delivers them to another elevation Tow Conveyor An endless chain supported by trolleys from an overhead track or running in a track at the floor with means for towing floor supported trucks dollies or carts Verti
142. nents will be removed from service 6 3 1 10 Slings will be removed from service if hooks are cracked have been opened more than 15 percent of the normal throat opening measured at the narrowest point or twisted more than 10 degrees from the plane of the unbent hook 6 3 2 Wire Rope Slings 6 3 2 1 Wire rope slings will not be used with loads in excess of the rated capacities shown in Table 6 3 through Table 6 14 Slings not included in these tables will be used only according to the manufacturer s recommendations See paragraph 9 1 1 4 for proper wire rope attaching 6 3 2 2 Minimum sling lengths are determined as follows 6 3 2 2 1 Cable laid and 6 by 19 and 6 by 37 slings will have a minimum clear length of wire rope between splices sleeves or end fittings ten times the component rope diameter 6 3 2 2 2 Braided slings will have a minimum clear length of wire rope between splices sleeves or end fittings forty times the component rope diameter 6 3 2 2 3 Cable laid grommets strand laid grommets and endless slings will have a mini mum circumferential length of 96 times their body diameter 52 AFOSHSTD91 46 1 FEBRUARY 1997 6 3 2 3 Fiber core wire rope slings of all grades will be permanently removed from service if they are exposed to temperatures in excess of 200 degrees F When nonfiber core wire rope slings of any grade are used at temperatures above 400 degrees F or below minus 60 degrees F recommen dations
143. ngle of inclination and nature of material Spill Guard A stationary device of sufficient strength and capacity to catch retain and contain any spill age which might cause personal injury from a conveyor passing overhead Sprocket Idler A freely rotating device that changes direction of the load chain Spur Track A fixed track arranged to interlock with an adjacent crane girder to permit passage of carri ers from the spur track to the crane and vice versa Stacker A conveyor adapted to piling or stacking bulk materials packages or objects AFOSHSTD91 46 1 FEBRUARY 1997 145 Switch Baffle Electric A track switch wired in such a way that electric current is cut off from approach ing motor driven equipment unless the track switch is properly set for passage of the carrier Switch Cross track A track switch containing one straight section of moving track pivoted in the center which can be rotated to align it with other crossing tracks to allow passage of a carrier through the junc tion without changing the direction of the carrier motion Switch Glide and or Slide A track switch with a movable inner frame containing straight or curved sections of track The inner frame can be slid to align these sections of track with other tracks to permit routing carriers from one track to another usually changing the direction of motion of the carrier Switch Master A switch which dominates the operation of contactors relays or other r
144. nsist of hoisting 125 percent the rated load On hoists incorporating overload devices which prevent the lifting of 125 percent of the rated load the load will be at least 100 percent of the rated load after which the function of the overload device will be tested Use 110 percent in lieu of 125 percent for winches this applies also to paragraph 5 2 4 1 3 2 Nuclear certified hoists require annual proof load testing at 125 percent Do not use overload devices that prevent this testing 5 2 4 1 3 Hoists that are identified by the functional manager as being required to lift critical loads as defined in Attachment 1 will be tested as stated in paragraphs 5 2 4 1 1 and 5 2 4 1 2 and annually thereafter at 100 percent of the rated load NOTE For nuclear certified hoists perform a proof load test at 125 percent of the rated load annually 5 2 4 1 4 Test weights utilized for rated load tests shall be tagged or adequately marked indi cating total weight in pounds and owner and or agency identification number Reinforcing rebar steel shall not be used for test weight lift points 5 2 4 2 Preventive Maintenance The using organization concerned will establish a preventive maintenance program based on the manufacturer s recommendations These records should be maintained for the life of the equipment at the location determined by the unit 46 AFOSHSTD91 46 1 FEBRUARY 1997 5 2 4 3 Maintenance Procedures Before adjustments and repairs
145. ntacts limit switches and push button stations 7 2 5 7 2 7 Worn drive wheels and or tires and 7 2 5 7 2 8 Periodic inspection of overhead hoists according to Chapter 5 NOTE For suspended powered monorail systems inspect the following in addition to the require ments above 7 2 5 7 2 8 1 Power rails for misalignment at all splices switches and rail end joints 7 2 5 7 2 8 2 All rail hangers for security AFOSHSTD91 46 1 FEBRUARY 1997 7 2 5 7 2 8 3 Idlers at switches clean paths and lubricate as necessary 7 2 5 7 2 8 4 Switches throughout rail travel for alignment HOIST with forearm vertical Fore finger pointing up Move hand in small horizontal circle TROLLEY TRAVEL Palm up fingers closed thumb pointing in direction of motion jerk hand horizontally MULTIPLE TROLLEYS Hold up one finger For block marked 1 and two fingers For block marked 2 Rieqular signals Follow LOWER with arm extended down ward forefinger pointing down move hand in small horizontal circle STOP Arm extended palm down move arm back and forth MOVE SLOWLY Use one hand to give any motion signal and place other hand motionless in Front of hand giving the motion signal Hoist slowly shown as example Figure 7 1 Hand Signals for Controlling Overhead and or Gantry Crane Operations BRIDGE TRAVEL Arm extended forward hand open and slightly raised Make pushing motion in the direction of trael E
146. nual JSM for Storage and Materials Handling should be consulted when selecting PPE Note The BE will certify the applicability of chemical protective equipment respirators or other health related PPE 1 2 8 1 All personnel directly involved in the handling of supplies or material will wear approved safety shoes 1 2 8 2 Personnel will wear leather workman s gloves when manually handling objects that have sharp or burred edges or splintered surfaces 1 2 8 3 Personnel will wear appropriate ear protection when working in or visiting hazardous noise areas 1 2 8 4 Personnel will carry tools that have sharp edges in protective holders not unshielded in pockets 1 2 8 5 Personnel will wear appropriate protective clothing when transporting delivering or working with hazardous materials 1 2 8 6 Material handlers will not wear finger rings jewelry or loose clothing and will keep long hair completely covered when around moving conveyor belts open rotating shafts or other mov ing parts of machinery 1 2 8 7 Personnel will wear goggles and or safety spectacles with side shields and gloves when cutting strapping Personnel will stand out of the way so cut strapping does not contact them A board or other hold down device may be used to prevent the strapping from flying out from the material 1 2 9 Other Safety Requirements 1 2 9 1 Stack all materials neatly arrange them in an orderly manner and limit the stack height t
147. o minimize the chances they will fall 1 2 9 2 Remove repair or replace defective or broken strapping on material 1 2 9 3 Except when using approved chutes do not throw materials from elevated places Carry or lower them 1 2 9 4 If materials handling equipment MHE is not available and drums must be manually moved roll drums by pushing with the hands not the feet Ensure a minimum of two people upend them 1 2 9 5 If at all possible carry broken glass in a container other than a plastic bag or enclose the broken piece in cardboard or protective shield before placing in a bag This will reduce the possi bility of cuts from glass protruding from bags 1 2 9 6 Do not run when carrying materials 1 2 9 7 When unpacking materials follow good housekeeping rules for example discard band ing packing materials and empty cartons properly 10 AFOSHSTD91 46 1 FEBRUARY 1997 1 2 10 Two Wheeled Handtrucks and Wheelbarrows Two wheeled handtrucks and wheelbar rows are designed in a variety of shapes and sizes for both general and special purposes Preference will be given to procuring handtrucks and wheelbarrows equipped with knuckle guards Supervisors will instruct workers in their use To the new worker handtrucks and wheelbarrows look deceptively easy to use However mishaps occur because basic safe procedures are not followed 1 2 10 1 Material should be tipped slightly forward so the tongue of the handtruck will go und
148. o initial use all new and altered equipment or equipment which has not been used within the preceding 12 months will be tested for compliance with this standard including functions such as the following 7 2 5 6 1 1 1 Hoisting and lowering 7 2 5 6 1 1 2 Trolley travel 7 2 5 6 1 1 3 Bridge travel 7 2 5 6 1 1 4 Travel limiting devices 7 2 5 6 1 1 5 Locking and safety devices for interlocking mechanism track switches drop sections and lift sections 7 2 5 6 1 2 The trip setting of hoist limit switches will be determined by tests with an empty hook traveling in increasing speeds up to the maximum speed The actuating mech anism of the limit switch will be located so it will trip the switch under all conditions in sufficient time to prevent contact of the hook or load block with any part of the trolley 7 2 5 6 1 3 Ensure the following rules are obeyed on hoist limit switch 7 2 5 6 1 3 1 At the beginning of each operator shift during each periodic mainte nance and at any time a malfunction is suspected or after unusually heavy use the operator or maintainer will check the upper limit switch under no load Care will be exercised the block will be inched into the limit switch or run in at slow speed If the switch does not operate properly the operator will immediately notify the operation supervisor 7 2 5 6 1 3 2 The hoist limit switch which controls the upper limit of travel of the load block will never be used as an o
149. o lift the object and bring the back to a vertical position Keep the object close to the body while lifting refer to Figure 1 1 1 2 3 Team Lifting When required to manually move heavy or unusually shaped items always seek and obtain assistance When two or more people are required to move or carry an object adjust the load so each person carries an equal part Test lifts should be made before proceeding The key to lifts using two or more personnel is to make every move in unison The supervisor and workers are responsible for assessing all available methods to safely handle materials described above and use mechanical assistance whenever possible 1 2 4 Carrying Methods Acceptable carrying methods differ based upon the type of material dis tance and number of workers Workers should be instructed during initial training in each procedure for example neck shoulder side tray two person and under arm carry methods etc Some points to remember are 1 2 4 1 Use gloves to protect the hands and safety shoes to protect the feet 1 2 4 2 Inspect objects for slivers sharp edges and rough or slippery surfaces before attempting to lift AFOSHSTD91 46 1 FEBRUARY 1997 1 2 4 3 Keep fingers away from pinch and shear points 1 2 4 4 Do not carry a load that obstructs the view of the direction of travel Make sure that the path of travel is clear 1 2 4 5 Do not turn at the waist to change direction or to put an object down T
150. oad for types of hitches used and the type of synthetic material 6 2 2 2 Sling attachments or assemblies such as hooks rings oblong or pear shaped links or welded or mechanical coupling link will have a rated capacity at least equal to that of the sling rated capacity 6 2 2 3 The using organization will inspect each sling assembly as follows 6 2 2 3 1 A visual inspection will be made before the sling is used If evidence of damage or abuse is detected the sling will be removed from service repaired and tested before further use 6 2 2 3 2 Slings and attachments will be inspected monthly If a sling assembly is used less than once a month it will be inspected before each use The monthly inspection will be docu mented and the most recent month kept on file by the using organization 6 2 2 3 3 slings will be inspected once a year using the following procedures Note For nuclear certified slings and wire rope assemblies use the appropriate series TOs for inspection and maintenance criteria 6 2 2 3 3 Remove all dirt grease or oil from all components of the sling 6 2 2 3 3 2 Visually inspect all parts for excessive wear deformations fraying stretch ing and any other defects that may reduce the sling s rated capacity 6 2 2 3 3 3 Remove the sling from service if any component shows defects or deteriora tion 6 2 2 3 3 4 Update the sling identification tag to document the annual inspection 6 2 3
151. ocuments Nuclear certified hoists must meet require ments in AFMAN 91 118 AFOSHSTD91 46 1 FEBRUARY 1997 81 7 2 1 2 Hazards shall be identified by conducting System Safety Analysis as defined in Mil Std 882 or commercial equivalent The procuring activity shall specify the required analyses such as preliminary hazard analysis or operating hazard analysis The results of these analyses shall be included in applicable documents 7 2 2 General 7 2 2 1 Cranes may be modified and rerated if the modifications and the supporting structures are checked thoroughly for the new rated load by a qualified engineer or the equipment manufac turer The crane shall be tested according to paragraph 7 2 5 The new rated load shall be displayed on the crane or hoist 7 2 2 2 The rated load of the crane shall be plainly marked on each side of the crane If the crane has more than one hoisting unit each unit shall have its rated load marked on it or its load block and this marking shall be clearly visible from the floor or ground 7 2 2 3 minimum clearance of 3 inches overhead and 2 inches laterally shall be maintained between crane and obstructions 7 2 2 4 Where passageways or walkways are provided obstructions shall not be placed so the safety of personnel will be jeopardized by movements of the crane 7 2 2 5 Only properly trained and qualified personnel shall be permitted to operate a crane 7 2 2 6 The general arrangement of the cab
152. of the sling manufacturer regarding use at that temperature will be followed 6 3 2 4 End attachments except covers to thimbles will be welded before the sling is assembled 6 3 2 5 Welded end attachments will be proof tested at twice their rated capacity prior to initial use The owning agency shall maintain a record or certificate of proof test and make it available for inspection 6 3 2 6 Wire rope slings will be removed from service if any of the following conditions are present 6 3 2 6 1 Ten randomly distributed broken wires in one rope lay or five broken wires in one strand in one rope lay 6 3 2 6 2 Wear or scraping of one third the original diameter of outside individual wires 6 3 2 6 3 Kinking crushing bird caging or any other damage resulting in distortion of the wire rope structure 6 3 2 6 4 Evidence of heat damage 6 3 2 6 5 End attachments that are cracked deformed or worn 6 3 2 6 6 Hooks that have been opened more than 15 percent of the normal throat opening measured at the narrowest point or twisted more than 10 degrees from the plane of the unbent hook 6 3 2 6 7 Corrosion of the rope or end attachments 6 3 2 7 Only new rope shall be used to fabricate slings Use of repaired or reconditioned rope is prohibited 6 3 2 8 Slings used in choker hitch shall be long enough so the choke point is on the rope and never on a splice 6 3 3 Metal Mesh Slings 6 3 3 1 Handles will have a rated capac
153. olled stop holding traveling or traversing equipment in a selected location for preventing reverse travel and for controlling overspeed due to the action of gravity e Brake Drag A brake which provides retarding force without external control Brake Holding A brake that automatically prevents motion when power is off e Brake Travel brake that retards or stops motion in a horizontal direction Bridge That part of a crane consisting of girders trucks end ties footwalks and drive mechanism which carries the trolley or trolleys Bridgeplate A plate usually of metal and having a rated load capacity used to span the space between freight cars or trucks and the loading platform Also known as dockboard Bridge Travel Crane movement in a direction parallel to the crane runways Bumper Buffer An energy absorbing device for reducing impact when a moving crane or trolley reaches the end of its permitted travel when two moving cranes or trolleys come in contact Cab The operators compartment attached to the crane or monorail carrier in which the operator may ride and from which the motions of the crane or monorail equipment may be controlled housing which covers the rotating superstructure machinery or operators station On truck crane trucks a separate cab covering the driver s station Cable Laid Endless Sling Mechanical Splice A wire rope sling made endless by joining the ends of a single length of c
154. ollowing are examples 10 5 2 1 Hooks showing defects described in paragraph 9 4 shall be discarded Repairs by weld ing or reshaping are not generally recommended See Figure 9 6 10 5 2 2 critical parts which are cracked broken bent or excessively worn should be replaced 10 5 2 3 Pitted or burned electrical contacts should be corrected only by replacement and in sets Controller parts should be lubricated as recommended by the manufacturer 10 6 Lubrication AFOSHSTD91 46 1 FEBRUARY 1997 123 10 6 1 All moving parts of the derrick and hoist for which lubrication is specified including rope and chain shall be regularly lubricated Lubricating systems shall be checked for proper delivery of lubricant Particular care should be taken to follow manufacturer s recommendations as to points and frequency of lubrication and maintenance of lubricant to be used 10 6 2 Machinery shall be stationary while lubricants are being applied unless it is equipped for auto matic lubrication 10 7 Rope Inspection Replacement and Maintenance Refer to Chapter 9 Particular care shall be taken in the inspection of rotation resistant rope ORIN L GODSEY Brig General USAF Chief of Safety 124 AFOSHSTD91 46 1 FEBRUARY 1997 Attachment 1 GLOSSARY OF REFERENCES ABBREVIATIONS ACRONYMS AND TERMS References Air Force Instruction AFI 24 301 formerly designated 77 310 Vol 1 Vehicle Operations AFI 24 302 formerly des
155. on and proof tests follow 29 CFR 1926 550 for additional information 9 6 6 1 Trial lifts are required immediately before personnel are lifted A new trial lift will be per formed any time that the location or the route of the planned lift changes The platform will be inspected after the trial lift and before lifting personnel 9 6 6 2 The platform and rigging shall be proof load tested to 125 percent of the platform s rated capacity prior to lifting personnel at each job location and after any modifications or repairs have been made 9 6 7 Personnel work practices follow 9 6 7 1 Workers shall keep all parts of the body inside of the platform during lifts and except when over water shall wear and secure a safety belt and or harness with lanyard to an approved attach point within the platform The safety belt and or harness lanyard system must prevent a fall of over 6 feet and the attach point must be capable of supporting the fall impact of the worker 9 6 7 2 The crane or derrick operator shall remain at the controls when personnel are suspended Operations hoisting personnel will be terminated at the first sign of a potentially dangerous condi tion AFOSHSTD91 46 1 FEBRUARY 1997 111 Figure 9 1 Right and Wrong Way of Using Cable Clips U Bolt of all clips on deal end of Incorrect Do not stagger Incorrect U Bolt of all clips on live end of rope 112 AFOSHSTD91 46 1 FEBRUARY 1997 Figure 9 2 Proper Method o
156. on if an electric hoist is used 10 4 2 1 4 Warning or OUT OF ORDER signs shall be placed on the derrick and hoist 10 4 2 1 5 The repairs of booms of derricks shall either be made when booms are lowered and adequately supported or when safely tied off 10 4 2 1 6 A good communication system shall be set up between the hoist operator and the appointed individual in charge of derrick operations before any work on the equipment is started 10 4 2 2 Welding repairs shall be approved by the appointed person 10 4 2 3 After adjustments and repairs have been made the derrick shall not be operated until all guards have been reinstalled safety devices reactivated maintenance equipment removed and derrick electrical pendant and or control box checked for proper grounding 10 5 Adjustments and Repairs 10 5 1 Any unsafe conditions disclosed by the inspection and the requirements of paragraphs 10 3 and 10 4 shall be corrected before operation of the derrick is resumed Adjustments shall be main tained to assure correct functioning of components The following are examples 10 5 1 1 functional operating mechanisms 10 5 1 2 Tie downs or anchorages 10 5 1 3 Signal system 10 5 1 4 Brakes and clutches 10 5 1 5 Power plants 10 5 1 6 Guys 10 5 2 Repairs or replacements shall be provided promptly as needed for safe operation all replace ment and repair parts shall have at least the original safety factor The f
157. one to twelve month intervals or as specified by the manu facturer 10 1 2 Frequent Inspection Items such as the following shall be inspected for defects at intervals as defined in paragraph 5 2 5 1 or as specifically indicated including observation during operation for any defects which might appear between regular inspections Deficiencies as listed below shall be carefully examined and a determination made as to whether they constitute a safety hazard 10 1 2 1 Control Mechanisms Inspect daily for adjustment wear and lubrication 10 1 2 2 All Chords and Lacing Inspect daily 10 1 2 3 Tension in Guys Inspect daily 10 1 2 4 Plumb of the Mast Inspect daily 10 1 2 5 Leakage of Air or Deterioration of Hoses Seals and Rams of Hydraulic Systems Inspect daily 10 1 2 6 Derrick Hooks Inspect daily for deformations or cracks For hooks with cracks or hav ing more than 15 percent in excess of normal throat opening or more than 10 degree twist from the plane of the unbent hook refer to paragraphs 5 2 5 1 5 and 9 4 1 1 10 1 2 7 Rope Reeving Inspect for noncompliance with derrick manufacturer s recommenda tions 10 1 2 8 Hoist Brakes Clutches and Operating Levers Check daily for proper functioning before beginning operations 10 1 2 9 Electrical Apparatus Check for malfunction and signs of excessive deterioration dirt and moisture accumulation 10 1 3 Periodic Inspection Complete inspection of the derr
158. operator a hazard to himself or others or which in the opinion of the examiner or supervi sor could interfere with the operator s safe performance may be sufficient cause for dis qualification In such cases specialized clinical or medical judgments and tests may be required Note A history of epilepsy or a disabling heart condition may be sufficient reason for disqualification 8 2 4 1 3 Potential operator trainees will have good depth perception field of vision reaction time manual dexterity or coordination and no tendencies to dizziness or similar undesirable characteristics Physical defects such as loss of arm hand leg foot or gross loss of function 98 AFOSHSTD91 46 1 FEBRUARY 1997 thereof may be considered as cause for denial of acceptance into an entry level training pro gram for operators 8 2 5 Use Mobile cranes will be operated only by authorized qualified operators who possess valid AF Form 483 or by persons in training under the direct supervision of a designated operator The only other personnel who will enter a crane cab are persons such as oilers supervisors and inspectors whose duties require them to do so A list of qualified crane operators will be kept by the using orga nization and appropriate entries will be made in the individual s training records 8 2 6 Operating Practices 8 2 6 1 If the operator must divert their attention elsewhere while operating the crane they will stop the crane 8 2 6
159. or proper operation Block or hoist shall be inched into the limit switch to prevent possible damage 5 2 5 1 3 Air systems for deterioration or leakage 5 2 5 1 4 Load chain for wear twists breaks cracks or other damage to links Check chain also for deposits of foreign material which may be carried into the hoist mechanism At least monthly the person performing the inspection will document the date the identifier of the chain and sign the record of inspection The using organization will retain the record for a minimum of 1 year Also see paragraphs 9 2 1 3 and 9 2 1 4 5 2 5 1 5 Hooks for deformation chemical damage cracks or defective safety latches At least monthly the person performing the inspection will document the date the serial number or other identifier of the hook and sign the record of inspection The using organization will retain the record for a minimum of 1 year Replace hooks having more than 15 percent in excess of normal throat opening or more than 10 degrees twist from plane of the unbent hook Inspect if possible other load bearing components of the hoist for damage See paragraph 9 4 for more information on nuclear certified hoists and paragraph 9 6 for hoists approved for personnel lifts 5 2 5 1 6 Load carrying ropes for wear twist distortion broken wires or improper dead end ing to the hoisting drum and other attachments 5 2 5 2 Periodic A visual inspection performed at intervals betwe
160. osted in the cab of the equipment in full view of the operator This sign will read DANGER HIGH VOLTAGE Do Not Operate Within 10 Feet of Electric Power Lines 8 2 6 39 5 A dielectric boom shield and insulated link installed in the lifting line at the hook will provide some protection against electric shock if the crane accidentally comes in contact with energized electric lines Proximity warning devices are not fail safe and should be used in addition to but not as a replacement for other controls Even though shields insulated hooks and proximity warning devices are used the clearance criteria specified in paragraphs 8 2 6 39 2 and 8 2 6 39 3 shall be followed 8 2 6 39 6 If the boom of a rubber tired crane contacts an electric power line it is probable that the entire piece of equipment will be energized since the rubber tires may insulate the crane from the ground When this happens operators will not attempt to leave the crane until 102 AFOSHSTD91 46 1 FEBRUARY 1997 they are certain that either the line is clear of the crane or the line is de energized To make such an attempt might result in electrocution since the operator s body would complete the cir cuit to ground as he or she climbed or stepped from the crane If the fuel tank should become ignited or if for any other reason it is impossible for the operator to remain on the crane they should jump after first making sure that all parts of their body are clear of the
161. pe Length of Rope Turned Back inches Minimum Number of Clips Exclusive of Eye inches Torque ft lb 1 8 2 3 1 4 1 4 2 3 1 4 1 2 3 11 12 65 5 8 3 12 95 3 4 4 18 130 7 8 4 19 225 1 5 26 225 1 1 8 6 34 225 11 4 7 44 360 13 8 7 4 360 11 2 8 54 360 15 8 8 58 430 13 4 8 61 590 2 8 71 750 21 4 amp 73 750 lin 2 54cm ft Ib 1 36 newton meter The number of clips shown is based upon using right regular or Lang lay wire rope 6x19 class or 6x37 class fiber core or IWRC IPS or XIPS If Seale construction or similar large outer wire type construction in the 6x19 class 15 to be used for sizes 1 in 2 5 cm and larger add one additional clip The number of clips shown also applies to right regular lay wire rope 8x19 class fiber core IPS nominal sizes 1 1 2 in and smaller and right regular lay wire rope 18x7 class fiber core IPS or XIPS nominal sizes 1 3 4 in and smaller For other classes of wire rope not mentioned above it may be necessary to add additional clips to the number shown Turn back the specified amount of rope from the thimble Apply the first clip one base width from the dead end of the wire rope U bolt over dead end live end rests in clip saddle Tighten nuts evenly to rec ommended torque Apply the next clip as near the loop as possible Turn on nuts firm but do not tighten AFOSHSTD91 46 1 FEBRUARY 1997 119 Space additional clips if required equally between the first two Turn on nuts
162. perating control 7 2 5 6 2 Load Test 7 2 5 6 2 1 new hoists will have the manufacturer s certification that all proof load testing has been accomplished Prior to initial use all extensively repaired and altered equipment will be tested by or under the direction of a designated person and a written report furnished by such person confirming the load rating of the system Test loads will not be more than 125 percent of the rated load unless otherwise recommended by the man ufacturer These test reports will be maintained by the user and will be readily available 7 2 5 6 2 2 On hoists incorporating overload devices which prevent the lifting of 125 per cent rated load a load test will be accomplished with at least 100 percent of rated load after which the function of the overload device will be tested Nuclear certified hoists AFOSHSTD91 46 1 FEBRUARY 1997 89 require annual proof load testing at 125 percent Overload devices that prevent this testing will not be used 7 2 5 6 2 3 Test weights utilized for load testing shall be tagged or marked indicating total weight in pounds and owner and or agency identification number Rebar steel shall not be used for test weight lift points 7 2 5 7 Inspection 7 2 5 7 1 Frequent Visual inspections by the operator or designated person daily or prior to each use with no record of the inspection required The following items shall be inspected 7 2 5 7 1 1 Operating mechanisms for p
163. r or portable plug in pendant controls Platform A working space for persons who are elevated above the surrounding floor or ground such as a balcony for the operation of machinery and equipment Power and Free Conveyor A conveying system wherein the load is carried on a trolley or trolleys which are conveyor propelled through part of the system and may be gravity or manually propelled through another part This arrangement provides a means of switching the free trolley into and out of adjacent lines The spur or subsidiary lines may or may not be powered AFOSHSTD91 46 1 FEBRUARY 1997 135 Power Controlled Lowering system or device in the power train other than the load hoist brake which can control the lowering rate of speed of the load hoist mechanism Proof Load Crane A 110 percent test of the maximum load as designated by the manufacturer of a crane in which the proof load is hoisted held for a predetermined time commonly 3 5 minutes raised again held lowered held again and then lowered to the ground Proof Load Hoist A 125 percent test of the maximum load designated by the manufacturer of a hoist in which the proof load is hoisted held for a predetermined time commonly 3 5 minutes raised again held lowered held again and then lowered to the ground Proof Test nondestructive tension test performed to verify construction workmanship and load capability of a sling Proximity Warning Device
164. ravel with the load trailing 3 2 6 5 5 Operators will cross railroad tracks diagonally whenever possible to avoid jarring of the load 3 2 6 5 6 Operators will not park lifts closer than 8 feet from the center of railroad tracks 3 2 6 5 7 The operator will look in the direction of travel and keep a clear view 3 2 6 5 8 When traveling up or down ramps or grades the operator will drive a loaded lift with the load upgrade A spotter will be used if the operator s vision is obscured by the load Unloaded trucks will be operated on all grades with the forks downgrade Caution will be used on all grades The load on the forks will be tilted back as far as necessary to clear the road sur face 3 2 6 5 9 The operator will operate the lift at a speed that will permit it to be brought to a stop in a safe manner Horseplay or stunt driving will not be permitted 3 2 6 5 10 The operator will not travel with lift forks elevated more than 6 inches above the ground or surface or as necessary to clear any surface projections 3 2 6 5 11 When operating a mast with tilt capability the operator will tilt the mast back when transporting loads 3 2 6 5 12 Operators will make smooth starts turns and stops to prevent the load from shift ing or the truck from overturning 3 2 6 5 13 Prior to driving onto dockboards or bridge plates operators will ensure 3 2 6 5 13 1 Dockboards and or bridgeplates are anchored or equipped with stops at both
165. rds and or Human Factors 7 1 1 The most serious injury potential associated with the cranes and monorails described in this chapter are caused by permitting the loads to contact personnel Bruises lacerations pinching and fractures are associated with loading unloading and load transporting operations 7 1 2 Injuries and property damage are caused by striking personnel or objects with moving loads personnel falling from equipment and dropping or slipping loads Injury severity is increased by per sonnel not wearing required PPE such as hard hat gloves safety toe shoes and eye protection 7 1 3 Serious hazards are overloading obstruction to free passage of the load misuse of equipment and dropping or slipping of the load caused by improper hitching or slinging 7 1 4 Where feasible safeguards have been built in to minimize the probability for human error but hazards that cannot be met by mechanical means still exist for example moving ropes incomplete guarding which design alone prevents and being caught between exposed parts 7 1 5 Some mishap cause factors are inadvertent movement of equipment or loads failure to use available safety devices such as brakes locks and warning signals failure to detect equipment defi ciencies or malfunction acceptance of minor deficiencies and deviation from approved procedures 7 1 6 Lack of proper supervision and a lack of correct and adequate communication leads to poor un
166. record of all hoist chain and rope inspections will be maintained by the shop and or facility supervisor and be readily available 5 2 5 5 Rope Inspection Refer to Chapter 9 5 2 5 6 Welded Link Chain Inspection Refer to Chapter 9 and paragraph 5 2 5 1 4 AFOSHSTD91 46 1 FEBRUARY 1997 49 Chapter 6 SLINGS 6 1 Hazards and or Human Factors 6 1 1 Slings have the potential to cause injury death and property damage Mishaps are mostly caused by loads being dropped or slipping because either the sling or its attachments break or other wise fail The usual causes are inadequate design improper selection poor inspection failure to make sure that loads are properly attached and secured or improper storage and care 6 1 2 Human error contributes to most sling mishaps The most common is that supervisors allow untrained and unqualified people to use and maintain slings Other causes are 6 1 2 1 Use of damaged or defective slings 6 1 2 2 Unauthorized modifications to slings 6 1 2 3 Kinks in supporting ropes and cables 6 1 2 4 Overloaded slings 6 1 2 5 Improperly balanced loads which allows them to slip 6 1 2 6 Loads not securely attached to the slings 6 1 2 7 Sling failure caused by not using pads to protect the sling from being damaged by sharp edges or corners 6 1 2 8 Loads hitting obstructions 6 1 2 9 Personnel standing or walking under suspended loads 6 1 2 10 Personnel placing their hands betwe
167. rforming routine or high risk manual handling activities the importance of seeking ways to improve the methods used in accomplishing the work and eliminate manual material handling hazards and understanding of the stresses involved during manual handling which cause injuries This training should include both verbal and written materials that explain how to do the task correctly with practice and proper motions 1 2 1 1 Supervisors must train personnel who are required to regularly perform manual lifting Training will be documented on the AF Form 55 Employee Safety and Health Record or other AFOSHSTD91 46 1 FEBRUARY 1997 7 authorized methods refer to AFI 91 301 Information to assist the supervisor in establishing a program is located in this chapter and additional materials may also be found in the National Safety Council NSC Accident Prevention Manual for Industrial Operations Engineering and Technology When necessary the supervisor may contact the installation ground safety staff for assistance in developing the program and to review the NSC publication 1 2 1 2 The supervisor shall consider having personnel evaluated for physical fitness for duty when job task requires continuous manual lifting When required physical profile changes will be evaluated for possible reassignment actions to prevent recurring injuries to personnel 1 2 2 Lifting Methods There are three basic methods of lifting that is straight ba
168. roper operation proper adjustment and unusual sounds 7 2 5 7 1 2 Upper limit devices 7 2 5 7 1 3 Tanks valves pumps lines and other parts of air or hydraulic systems for leakage 7 2 5 7 1 4 Hooks and hook safety latches according to paragraphs 5 2 5 1 and 9 4 7 2 5 7 1 5 Hoists according to Chapter 5 7 2 5 7 2 Periodic Complete inspections of the crane shall be performed at intervals between 1 and 12 months by a designated person who makes records of the inspection The recom mended intervals for these inspections should be based upon the type of use experienced by the equipment as follows Normal use yearly heavy use semiannually and severe use quarterly Note For nuclear certified monorail systems the periodic inspection shall be performed semi annually by civil engineering or equivalent These inspections will include the requirements in paragraph 7 2 5 7 1 and in addition items such as the following 7 2 5 7 2 1 Deformed cracked or corroded members 7 2 5 7 2 2 Loose belts or rivets 7 2 5 7 2 3 Cracked or worn sheaves and drums 7 2 5 7 2 4 Worn cracked or distorted parts such as pins bearings wheels shafts gears rollers locking and clamping devices bumpers switch baffles interlock bolts and trolley stops 7 2 5 7 2 5 Excessive wear on brake system parts 7 2 5 7 2 6 Signs of any deterioration of electrical apparatus including but not limited to controllers master switches co
169. rt exerted by the operator on the end of the lever to raise or move the rated load Lift Distance between the upper and lower limits of travel of the load hook Lift Out Section A section of track which can be raised out of the line of the track to make an opening through which a door can pass Load Carrying Flange The lower flange of the monorail or underhung crane track on which the load bearing wheels roll Load Center The point at which the rated capacity can be carried commonly 2 inches from the fork tips Main Hoist The hoist mechanism provided for lifting the maximum rated load 144 AFOSHSTD91 46 1 FEBRUARY 1997 Man Trolley A trolley which has an operator s cab attached Master Switch A switch which dominates the operation of contactors relays or other remotely operated devices Railing Guard A structure consisting of rails and posts including top rail center rail posts and where required toeboards Rail Joint The point at which two sections of track are joined together Rated Speed The speed of the conveyor as established by the manufacturer or a qualified engineer at which safe and satisfactory service can be expected Regenerative A form of dynamic braking in which the electrical energy generated is fed back into the power system Remote Location Any location with respect to the conveyor from which the presence or position of personnel relative to the conveyor cannot be readily determined from th
170. ructor 7 2 3 2 2 Qualification will be limited to the specific type of equipment for which examined 7 2 4 Operations 7 2 4 1 Cab Operated and Pulpit Operated Equipment 7 2 4 1 1 Equipment will be operated only by the following personnel AFOSHSTD91 46 1 FEBRUARY 1997 83 7 2 4 1 1 1 Designated operators 7 2 4 1 1 2 Trainees under the direct supervision of a designated operator 7 2 4 1 1 3 Maintenance and test personnel when it is necessary in the performance of their duties 7 2 4 1 1 4 Inspectors 7 2 4 1 2 No one other than personnel specified above will enter a cab or pulpit with the exception of persons such as oilers and supervisors whose duties require them to do so and then only in the performance of their duties and with the knowledge of the operator or other appointed person 7 2 4 2 Floor Operated Equipment Equipment will be operated by the following personnel 7 2 4 2 Designated personnel 7 2 4 2 2 Inspectors 7 2 4 2 3 Maintenance and test personnel when it is necessary in the performance of their duties 7 2 4 3 Remote Operated or Automatic Equipment The use of remote control or automatic equipment involves such a wide variety of service requirements and conditions that each installa tion will be carefully analyzed and the operation reviewed at least monthly for the first 6 months of operation to determine whether paragraph 7 2 4 1 or 7 2 4 2 will apply 7 2 4 4 Operating Practices 7
171. s Current Contacting devices for collecting current from runway or bridge conductors Collector Shoe That portion of a current collector that makes contact by sliding on the conductor bar wire Conductor 4A substance or device that readily conducts heat electricity sound etc Definitions of specific conductors follow 130 AFOSHSTD91 46 1 FEBRUARY 1997 e Conductors Bridge The electrical conductors located along the bridge structure of a crane to pro vide power to the trolley e Conductors Enclosed Bar or wire used to transmit electricity enclosed to minimize the possibil ity of accidental contact with the conductor e Conductors Open Bar or wire not enclosed used to transmit electrical current and provide power frequently used with the crane or monorail carrier e Conductors Runway Main The electrical conductors located along a crane runway to provide power to the crane Conveyor horizontal inclined or vertical device for moving or transporting bulk material packages or objects in a path predetermined by the design of the device and having points of loading and discharge fixed or selective Included are skip hoists and vertical and inclined reciprocating conveyors Typical exceptions are those devices known an industrial trucks tractors and trailers tiering machines cranes hoists power shovels power scoops bucket drag lines platform elevators designated to carry passengers or the operator
172. s Improved Plow Steel Grade Rope 7x7x7 Construction Galvanized Aircraft Grade EI m 69 Table 6 13 Rated Capacities for Strand Laid Endless Slings Mechanical Joint Improved Plow Steel GIPAGE aoi iei E tee C LUE UE 70 Table 6 14 Cable Laid Endless Slings Mechanical Joint 7x7x7 and 7x7x19 Construction Galvanized Aircraft Grade Rope 7x6x19 IWRC Construction Improved Plow Steel Grade Rope 71 Table 6 15 Rated Capacities Carbon Steel and Stainless Steel Metal Mesh Slings 72 Table 6 16 Manilla 73 Nylon Rope SHES us Essi pen tg 74 Table6 15 Polyester Rope Ee OGNI I 75 Table 6 19 Polypropylene Rope Slings 1525 e rA Aided e dac pee pad dd 76 Table 6 20 Synthetic Web Slings 1 000 Pounds Per Inch of Width Single Ply 77 Table 6 21 Synthetic Web Slings 1 200 Pounds Per Inch of Width Single Ply 78 Table 6 22 Synthetic Web Slings 1 600 Pounds Per Inch of Width Single Ply 79 Chapter 7 OVERHEAD GANTRY UNDERHUNG CRANES AND MONORAIL SYSTEMS 80 7 1 Hazards and or Human Factors nennen enne enhn nennen 80 7 25 Requirements C M 80 Figure 7 1 Signals for Controlling Overhead or Gantry Crane Operations 90 Chapter 8 MOBILE AND LOCOMOTIVE CRANES 91 8 1 Hazards and or Hum
173. s and weakness before driving onto them Loads will not be transferred across the tailgate when it is supported solely by its chain The tailgate must be supported by the mating surface across its entire width or a bridgeplate will be used Also see paragraph 3 2 6 5 13 3 2 6 4 7 Operators will ensure sufficient head room or clearance under overhead installa tions lights pipes sprinkler system etc 3 2 6 4 8 Personnel will not stand or pass under the elevated portion of a lift whether the lift is loaded or empty 3 2 6 5 When traveling AFOSHSTD91 46 1 FEBRUARY 1997 17 3 2 6 5 1 While operating inside warehouses operators will observe all established driving procedures and will not exceed 5 miles per hour Under normal traffic conditions operators will keep to the right maintain a safe distance approximately three truck lengths from the truck ahead and will keep the truck under control at all times especially during turns and while traveling over slippery or wet floors and rough surfaces 3 2 6 5 2 Operators will not pass other vehicles or pedestrians at intersections blind corners or at other dangerous locations 3 2 6 5 3 Operators will slow down and sound the horn at cross aisles warehouse entrances and exits or at other dangerous locations where vision is obstructed Operators will be pre pared to stop and will not proceed until the way is clear 3 2 6 5 4 When loads obstruct the forward view operators will t
174. s by welding or reshaping shall only be done by certified personnel Repairs will be inspected by suitable crack detecting methods and shall be proof tested to 125 percent Hooks should not be painted see paragraph 5 2 5 1 5 Note Repairs to hooks used on nuclear certified hoists are not authorized 9 4 1 2 Hooks shall be examined for the following see Figure 9 7 9 4 2 1 Distortion such as bending twisting or increased throat opening 9 4 1 2 2 Wear 9 4 1 2 3 Cracks severe nicks gouges 9 4 1 2 4 Safety latch engagement and damaged or malfunctioning latch 9 4 1 2 5 Hook attachment and securing means 9 4 1 2 6 Lubrication of swivel point 9 4 1 2 7 On nuclear certified hoists perform dye penetrant magnetic particle or other suit able NDI on the hook in addition to the above NOTES 1 If the hook retaining nut is welded to the hook shank removal of the hook for inspection is not required In this case a visual inspection of the inside of the block assembly shall be performed Figure 9 8 If the block is designed such that disassembly is not feasible this inspection is not required 2 See additional annual requirements for nuclear certified hoists in paragraph 5 2 5 2 10 9 4 2 Rated Load Rated load for a hook when used in the manner for which intended shall be equal to other suspension members to which it is attached When this is not feasible special precau tions shall be taken to ensure that the r
175. sion color vision and reaction time can be contrib uting factors to mishaps Refer to paragraph 8 2 4 1 2 for operator physical qualifications 8 2 Requirements 8 2 1 Acquisition 8 2 1 1 All crawler locomotive and truck cranes will meet the design specifications characteris tics and rules of ANSI ASME B30 5 Mobile and Locomotive Cranes 8 2 1 2 All new mobile hydraulic cranes constructed and used on or after 25 January 1982 will meet the safety code requirements of ANSI ASME B30 5 Equipment manufactured prior to the effective dates of the referenced ANSI Standard and still in replacement codes A through J as of the date of this AFOSH Standard need not be modified or retrofitted to conform to this standard Following are general design considerations which shall be included in procurement documents 8 2 1 2 1 Load Ratings and Charts A substantial and durable rating chart with clearly legible letters and figures will be provided with each crane and securely fixed to the crane cab in a location easily visible to the operator while seated at the control station A duplicate load rat ing chart legible from the ground should also be provided on the outside of the crane The load rating chart for truck cranes may list loads for the crane operating both with and without counterweights 8 2 1 2 2 Two Blocking Prevention On telescoping boom cranes a two blocking damage preventive feature shall be provided It shall be capable of pr
176. ss occurring as the chain passes over the sprockets Rollers may also serve as the rolling support for the chain and the load being conveyed or e The rotating element upon which a conveyor belt or chain or the object being transported is car ried refer to belt idler Roller Conveyor e A series of rollers supported in a frame over which objects are advanced manually by gravity or by power e A series of rollers over which objects are moved by the application of power to all or some of the rollers The power transmitting medium is usually belting or chain Rope Refers to wire rope unless otherwise specified Runway The track and supports rails beams girders brackets and framework system upon which the crane or trolley travels Safety Device A mechanism or an arrangement placed in use for the specific purpose of preventing an unsafe condition preventing the continuation of an unsafe condition warning of an unsafe condition or limiting or eliminating the unsafe effects of a possible condition Selvage Edge tThe finished edge of synthetic webbing designed to prevent unraveling Seizing The cord tape or wire wrapped around a rope to prevent it from unraveling when it is cut in two Sheave grooved wheel or pulley used with a rope to change direction and point of application of a pulling force e Sheave Non running A sheave used to equalize tension in two parts of the rope Because of its slight mov
177. ssible but no further than one half the length of the tines raise the load until clear of the surface and tilt the tines backward prior to transporting 3 2 6 8 2 When leaving powered lifts unattended with the operator s seat vacated fully lower the forks neutralize the controls shut the power off and set the brakes Chock the wheels if the vehicle is parked on an incline 3 2 6 8 3 When it is necessary for a K loader and or forklift operator to approach an aircraft in near proximity use a spotter 3 2 6 8 4 Do not pitch K loader cargo platforms forward to aid the on or off loading of cargo 3 2 6 8 5 Ensure that loads on the K loader are secured by chains forward and aft 3 2 6 8 6 Secure dunnage to equipment prior to transport 3 2 6 8 7 Never leave cargo loading equipment on the ramps or taxiways where it will be a hazard to taxied or towed aircraft 3 2 6 8 8 Do not exceed 5 miles per hour around aircraft and 10 miles per hour on ramps 3 2 6 8 9 Remove ice or snow from equipment before loading or unloading 3 2 6 8 10 When cargo loading equipment is left unattended on a flight line set the hand brake lower the forks shut off the ignition place the transmission in the lowest gear or park if automatic transmission and chock the vehicle 3 2 6 8 11 When using hand pallet trucks inside an aircraft use at least two people 3 2 6 8 12 Exercise extreme care when using pry bars to move cargo inside an aircraft an
178. supervisor or the person who originally attached the device 8 2 6 8 Before closing the switch or starting the engine the operator will ensure all controls are in the OFF position and all personnel are clear of the crane 8 2 6 9 If power fails during operation the operator will 8 2 6 9 1 If practical lower to the ground the suspended load under brake control If not prac tical to land the load shut down the crane and completely rope off and or barricade the area around the suspended load 8 2 6 9 2 Set all brakes and locking devices AFOSHSTD91 46 1 FEBRUARY 1997 99 8 2 6 9 3 Move all clutch or other power controls to the OFF position 8 2 6 10 The operator will be familiar with the equipment and its proper care If adjustments or repairs are necessary or any damage is known they will report them promptly to the supervisor and will record them on Air Force Technical Order AFTO Form 89 Daily Inspection Worksheet for Locomotive Cranes Other Than Steam or other appropriate inspection and maintenance forms 8 2 6 11 controls will be tested by the operator at the start of a new shift If any controls do not operate properly they will be adjusted or repaired before continuing operation 8 2 6 12 Booms which are being assembled or disassembled on the ground with or without sup port of the boom harness should be securely blocked to prevent dropping of the boom and boom sections 8 2 6 13 Booms which are being
179. t drum will be rotated in the lowering direction beyond the point where less than two wraps of rope remain on the drum Distinctive rope markings may be used to warn the operator the rope wrap limits are being reached 5 2 3 3 14 The operator will inch the hoist upward to engage a load and avoid unnecessary stops and starts 5 2 3 3 15 The operator will not leave a suspended load unattended 5 2 3 3 16 The upper limit device will not be used as a normal operating control except to inch the hook into place for storage between use 5 2 3 3 17 If a load must remain suspended for a considerable time a pawl or other equiva lent means rather than the brake alone shall be used to hold the load The ground area below the suspended load shall be barricaded to prohibit entry of personnel or equipment 5 2 4 Maintenance and Testing 5 2 4 1 Operational and Load Tests All new hoists or those which have had load sustaining parts altered replaced or repaired will be tested before use by the owner agency as outlined below A record of all tests will be maintained by the using agency and the agency responsible for hoist maintenance and inspections NOTES 5 2 4 1 1 The operational test will consist of operating all functions of the hoist under no load condition to test all functions of the hoist including hoisting and lowering operation of brakes and testing of limit locking and safety devices 5 2 4 1 2 The proof load test will co
180. take up rope slack tighten all nuts evenly on all clips to recommended torque NOTES 1 Apply the initial load and retighten nuts to the recommended torque The rope will stretch and shrink in diameter when loads are applied Inspect periodically and retighten 2 The efficiency rating of a properly prepared termination for clip sizes 1 8 to 7 8 in is approximately 80 percent and for sizes 1 to 3 in is approximately 90 percent This rating is based upon the catalog breaking strength of wire rope If a pulley is used in place of a thimble for turning back the rope add one additional clip 120 AFOSHSTD91 46 1 FEBRUARY 1997 Chapter 10 INSPECTION TESTING AND MAINTENANCE OF DERRICKS 10 1 Inspection 10 1 1 Inspection Classification 10 1 1 1 Prior to initial use all new and altered derricks shall be inspected to ensure compliance with the provisions of this standard 10 1 1 2 Inspection procedure for derricks in regular service is divided into two general classifi cations based upon the intervals at which inspections shall be performed The intervals in turn are dependent upon the nature of the critical components of the derricks and the degree of their expo sure to wear deterioration or malfunction The two general classifications are herein designated as Frequent and Periodic with respective intervals between inspection as follows 10 1 1 2 1 Frequent Inspection daily or prior to use 10 1 1 2 2 Periodic Inspection
181. ted 8 2 6 30 When rotating the crane sudden starts and stops will be avoided Rotational speed will be such that the load can be controlled A tag line will be used when rotation of the load is hazard ous 8 2 6 31 When a crane is to be operated at a fixed radius the boom hoist pawl or other positive locking device will be engaged on rope supported booms 8 2 6 32 Ropes will not be handled on a winch head without the knowledge of the operator While a winch head is being used the operator will be within convenient reach of the power unit control lever 8 2 6 33 On cranes having a powered telescoping boom the hook is drawn closer to the boom head when hoisting extending the boom or lowering a boom on machines where the winch is mounted stationary to the rear of the boom hinge If the machine is not equipped with a AFOSHSTD91 46 1 FEBRUARY 1997 101 two blocking damage preventive feature rope will be let out from the load hoist mechanism so the hook will not be jammed two blocked against the boom head The jammed condition may cause overload and result in rope or other component failure 8 2 6 34 Telescoping boom sections will be telescoped in the manner and sequence specified by the manufacturer 8 2 6 35 While holding the load 8 2 6 35 The operator will not leave his or her position at the controls when the load is sus pended 8 2 6 35 2 No person will be permitted to stand or pass under a suspended load 8
182. ted Capacities for Cable Laid Grommet Hand Tucked 7x6x7 and 7x6x19 Constructions Improved Plow Steel Grade Rope 7x7x7 Construction Galvanized Aircraft Grade Rope Rated capacities tons 2 000 Lb 7x6x7 7x6x7 7x6x7 7 7 7 7 7 7 7 7 7 7x6x19 7x6x19 7x6x19 7x6x19 7x6x19 7x6x19 7x6x19 7x6x19 7x6x19 7x6x19 These values only apply when the D d ratio is 5 or greater where D Diameter of curvature around which cable body is bent d Diameter of cable body 70 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 13 Rated Capacities for Strand Laid Endless Slings Mechanical Joint Improved Plow Steel Grade Rope Rope Body Rated capacities tons 2 000 Lb Vertical Dia inches Constr Vertical Choker basket 19 IWRC 6 x 19 IWRC 6 x 19 IWRC 6 x 19 IWRC 6 x 19 IWRC 6 x 19 IWRC 6 x 19 IWRC 6 x 19 IWRC 6x37 IWRC 6 x 37 IWRC 6 x 37 IWRC These values only apply when the D d ratio is 5 or greater where D Diameter of curvature around which rope is bent d Diameter of rope body AFOSHSTD91 46 1 FEBRUARY 1997 71 Table 6 14 Cable Laid Endless Slings Mechanical Joint 7x7x7 and 7x7x19 Construction Galvanized Aircraft Grade Rope 7x6x19 IWRC Construction Improved Plow Steel Grade Rope Cable body Rated capacities tons 2 000 Lb Vertical Dia inches Constr Choker 1 4 7 7 7 3 8 7 7 7 12 7 7 7 5 8 7 7 7 3 4 7 7 7 5 8 7 7 19 3 4 7 7 19 7 8 7 7 19
183. ted to misuse due to the use of extensions cheater bars and indirect pulls Injury can also be caused by the lack of proper storage and maintenance procedures 2 2 Requirements 2 2 1 Acquisition Lever operated hoists shall meet the requirements and specifications of recog nized industry standards 2 2 1 Capacity of all lever operated devices shall be permanently and conspicuously marked in an easily visible place on the hoist 2 2 1 2 Only ratchet and pawl and load brake hoists which include a means to prevent a sus pended load from self lowering will be procured Lowering under load shall be by operation of the hoist lever 2 2 2 Inspections 2 2 2 1 Daily or prior to each use lever operated hoists shall be inspected for 2 2 2 1 1 Loose or worn parts nuts bolts etc 2 2 2 1 2 Cracked or broken welds or parts 2 2 2 1 3 Deformed or damaged hooks see paragraph 5 2 5 1 5 2 2 2 1 4 Bent or deformed pawls and 2 2 2 1 5 Lubrication 2 2 2 2 Annual inspection shall include 2 2 2 2 1 Complete inspection of all wire rope chain and fittings or attachments 2 2 2 2 2 Inspection of brakes pawls or other holding features 2 2 2 2 3 Inspection of the chain length Chains that have elongated more than one fourth of an inch in 12 inches shall be removed from service 2 2 2 3 Identification tags shall be attached to all hoists Tags shall include the following infor mation 2 2 2 3 1 Date of inspection 2
184. termined by the user 8 2 3 Maintenance and Testing 8 2 3 1 Load Test 8 2 3 1 1 Prior to initial use extensively repaired or modified cranes will be load tested to 110 percent of rated capacity by the owning activity Upon completion of the test the weight load test date will be stenciled on the lower boom assembly as per TO 00 20B 5 USAF Motor Vehicle and Vehicle Equipment Inspection new crane will have the manufacturer s certifi cation that all load testing has been accomplished NOTE For nuclear certified hydraulic mobile cranes perform an annual load test of 100 percent of the rated capacity 8 2 3 1 2 Test loads will not exceed 110 percent of the rated load at any selected working radius 8 2 3 1 3 If it is determined that rerating is necessary crawler truck and wheel mounted mobile cranes will be tested according to Society of Automotive Engineers Inc SAE Rec ommended Practices Crane Load Stability Test Code J765 Locomotive cranes will be rerated 96 AFOSHSTD91 46 1 FEBRUARY 1997 according to manufacturers specifications A copy of the rerating test report will be provided to Vehicle Maintenance Control and a copy posted in the cab of the crane 8 2 3 1 4 Cranes will not be rerated in excess of the original load ratings unless such rating changes are approved by the crane manufacturer 8 2 3 1 5 A record of all tests will be maintained by the owning and or using agency 8 2 3 1 6 Test weights utilized
185. the rated load plainly marked on each crane Reference paragraph 7 2 2 2 A3 17 Do the pendant or cab hoist controls use the compass points for directional identification Ref erence paragraph 7 2 2 7 A3 18 Is there an approved hand fire extinguisher located in the cab of the crane Reference paragraph 7 2 2 10 AFOSHSTD91 46 1 FEBRUARY 1997 147 A3 19 Are personnel trained and identified to operate cab and pulpit cranes Reference paragraph 7 2 4 1 A3 20 Are the standard hand signals posted on or near all cranes Reference paragraphs 5 2 2 2 and 7 2 4 6 and Figure 7 1 A3 21 Are hazardous energy control lockout and or tagout procedures developed and used during maintenance activities Reference paragraph 7 2 5 and AFOSH Standard 127 45 A3 22 Have all cranes received the required load tests and are these test reports documented and avail able Reference paragraph 7 2 5 6 2 A3 23 Is there a clearly legible rating chart located in view of the operator in the crane cab Reference paragraph 8 2 1 2 1 A3 24 Is there a warning permanently posted in the cab of the crane which states DANGER HIGH VOLTAGE DO NOT OPERATE WITHIN 10 FEET OF ELECTRIC POWER LINES Reference para graph 8 2 1 2 11 A3 25 Have man rated cranes been approved prior to acquisition Reference paragraph 8 2 1 2 13 A3 26 Are daily monthly and annual inspections being conducted and documented Reference para graph 8 2 2
186. tic web slings of polyester and nylon shall not be used at temperatures in excess of 180 degrees F Polypropylene web slings will not be used at temperatures in excess of 200 degrees 6 3 5 8 Each repaired sling will be proof tested to twice the rated capacity before it is returned to service 6 3 5 9 Slings including webbing and fittings with temporary or makeshift repairs will not be used 6 3 5 10 Synthetic web slings will be removed from service if any of the following conditions are present 6 3 5 10 1 Damage from acid or caustic materials 6 3 5 10 2 Melting or charring of any part of the sling surface 6 3 5 10 3 Snags punctures tears or cuts 6 3 5 10 4 Broken or worn stitches 6 3 5 10 5 Distortion of fittings 6 3 5 11 When not in use slings will be kept in clean dry storage areas that will protect the sling materials 56 AFOSHSTD91 46 1 FEBRUARY 1997 Figure 6 1 Basic Sling Configurations With Vertical Legs OF SLING NOTES EYE AND EVE ENDLESS VERTICAL CHOKER HITCH HITCH 5 MAX 5 MAX t BASKET HITCH Alternates have identical lead load ratings 5 MAX he 5 MAX 5 MAX 1 Angle 5 degrees or less from the vertical may be considered vertical angles 2 For slings with legs more than 5 degrees off vertical the actual angle as shown in Figure 6 2 must be considered EXPLANATION OF SYMBOLS MINIMUM DIAMETER OF CURVATURE e REPRESENTS A CONTACT
187. tor Equipment will be kept clean When inspecting equipment operators will use AF Form 1806 Operator s Inspection Guide and Trouble Report for industrial tractors and or tugs and AF Form 1810 Operator s Monthly Report for forklifts Equipment with safety defects will be imme 14 AFOSHSTD91 46 1 FEBRUARY 1997 diately removed from service until such defects are corrected Examples of safety defects are mal functioning brakes steering mechanisms control mechanisms warning devices lights lifting mechanisms guards or tilt mechanisms fuel leaks worn or damaged tires or damaged exhaust sys tems 3 2 3 Maintenance 3 2 3 1 Repairs to the fuel electrical or ignition systems will be accomplished by qualified per sonnel only in locations approved for such repairs Deviations to this requirement will be approved by the installation fire chief through coordination with the responsible ground safety manager 3 2 3 2 Equipment will be cleaned in designated locations and only with cleaning agents approved by fire and BE personnel 3 2 4 Training 3 2 4 1 Each activity requiring training on powered materials handling and lifting equipment will designate qualified personnel as instructors to train and supervise the operator trainee The names and grades of instructors will be forwarded to the vehicle operations officer who will thoroughly screen each for background and experience in the type of equipment of which instruction wil
188. trapped air removed from hydraulic system safety devices reactivated and maintenance equipment removed 8 2 3 2 3 Warning tags and or locks will only be placed or removed by the maintenance supervisor or his or her representative 8 2 3 3 Adjustments and Repairs 8 2 3 3 Any unsafe conditions disclosed by the inspection requirements of paragraph 8 2 2 will be corrected before the crane is operated again Adjustments and repairs will be done only by designated personnel 8 2 3 3 2 Adjustments to all functional operating mechanisms safety devices control sys tems and power plants will be maintained to ensure correct functioning of components AFOSHSTD91 46 1 FEBRUARY 1997 97 8 2 3 3 3 critical parts of functional operating mechanisms or crane structures which are cracked broken bent corroded or excessively worn will be repaired or promptly replaced to ensure safe operation 8 2 3 3 4 Crane hooks showing defects described in paragraph 8 2 2 3 3 will be discarded Field repairs by welding or reshaping will not be permitted EXCEPTION See ANSI B30 10 8 2 3 3 5 All replacement parts or repairs will have at least the original manufacturer s design safety factor 8 2 3 4 Lubrication 8 2 3 4 1 moving parts of the crane for which lubrication is specified will be regularly lubricated Care should be taken to follow manufacturer s recommendations or TO procedures as to points and frequency of lubrication
189. two people who use oral signals to coordinate their movements They decide on appropriate emergency signals to be given if the grasp of either person should slip They walk in step to coordinate their movements e Under Arm Carry Method The material is carried under one arm with the other arm brought across in front of the body to steady and balance the load Also called Side Under Arm Carry Method Chain A series of links pivotally joined together to form a medium for conveying or transmitting motion or power General classes of chain common to the conveyor art are detachable pintle combination roller rivetless coil inverted tooth and bar link chains Chain Roller Link chain consisting of a series of stamped steel plates fastened with pins bush ings and rollers giving articulation in only one plane e Chain Welded Link A chain consisting of a series of interwoven links formed and welded from round bar stock Checker Plate Flooring Metal flooring embossed with high and low points pressed into metal to create a non skid surface Clearance The distance from any part of material handling equipment to a point of the nearest obstruction Coaming Toeboard Raised sides on a platform installed to prevent tools and small items from falling off Coating An elastomer or other suitable material used to impart physical electrical or other desired properties when applied to a sling or sling component Collector
190. uced rope length is adequate by cutting off a section at one end thus shifting the wear to different areas on the rope 9 1 2 7 Wherever exposure to temperatures at which fiber cores would be damaged are antici pated rope having an independent wire rope or wire strand core or other temperature damage resistant core will be used 9 1 2 8 Replacement rope will be the same size grade and construction as the original rope fur nished by the crane manufacturer unless otherwise recommended by a wire rope manufacturer due to actual working condition requirements Also see paragraphs 9 1 2 4 and 9 1 4 4 9 1 3 Inspection 9 1 3 1 All running ropes in service shall be visually inspected once each work day A thorough inspection of all ropes will be made at least once each month and a full written dated and signed report of rope condition kept on file for a minimum of 1 year by the user and readily available such inspections shall be performed by a designated person Any deterioration resulting in appre ciable loss of original strength such as described below and in paragraph 9 1 4 will be carefully noted and should be considered for rejection 9 1 3 1 1 Reduction of rope diameter below nominal diameter due to loss of core support internal or external corrosion or wear of outside wires Rope calipers and micrometers are normally used to determine changes in wire rope diameters See Figure 9 5 9 1 3 1 2 A number of broken
191. uirements for annual physical examinations are revised paragraphs 2 AFOSHSTD91 46 1 FEBRUARY 1997 5 2 3 1 deletes Chapter 12 Operations Using Nuclear Certified Hoists Overhead Gantries or Mono rails and moves required guidance for nuclear certified equipment to the main text and adds a glossary of definitions references abbreviations acronyms and terms Attachment 1 A indicates revisions from previous edition of AFOSH Standard 127 46 The use of illustrations in the standard are to aid in recognition of equipment only and does not imply endorsement by the Air Force NOTE AFRs are now Air Force Policy Directives AFPD AFIs and or AF Pamphlets AFPAM In addition AF Manuals AFM are changing to AFMAN AFOSH 127 series standards are changing to 91 series when revised and 161 series standards will become 48 series When known the new number of each AFPD AFI AFPAM AFMAN and AFOSH standard is provided along with a reference to the previous number Chapter 1 MANUAL MATERIAL HANDLING 6 1 1 Hazards and or Human Factors eene eene steer 1 20 Regie He TES a eeiam e Lp odii estando tero 6 Proure Lb How to Lift Properly occ he he ee a oie is Sales 10 Chapter 2 MANUAL HOISTING AND OR PULLING DEVICES 11 2 1 Hazards and or Human Factors cccccccccccccccecesssssscecececeeeesensaaeceseceeseeensnseseeeeeeseeees 11 2 2 R guirem nts ORE ARAS SAL AAT INTERN Se AUNT MER
192. ure around which the body of the sling is bent d Diameter of rope 5 0 41 0 64 0 91 1 2 12 6 2 0 2 5 3 6 4 8 6 3 7 9 9 2 11 0 13 0 15 0 18 0 23 0 Vertical Basket HT MS 0 99 1 0 1 5 1 6 2 1 2 2 2 9 3 0 3 7 3 9 4 6 5 0 5 6 6 2 7 8 8 8 10 0 12 0 13 0 15 0 17 0 19 0 20 0 22 0 24 0 27 0 28 0 32 0 33 0 27 0 38 0 43 0 49 0 55 0 1 1 1 7 24 3 3 43 5 4 6 7 9 5 13 0 17 0 21 0 25 0 30 0 35 0 41 0 48 0 62 0 61 62 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 4 Rated Capacities for Single Leg Slings 6x19 and 6x37 Classification Improved Plow Steel Grade Rope With Independent Wire Rope Core IWRC Rated Capacities Tons 2 000 Lb Dia Inches Constr 1 4 5 16 3 8 7 16 1 2 9 16 5 8 Hand Tucked Splice For hidden tick splice IWRC use values in HT columns MS Mechanical Splice S Swaged or Zinc Poured Socket These values only apply when the D d ratio for HT slings is 10 or greater and for MS and Slings is 20 or greater where D Diameter of curvature around which the body of the sling is bent d Diameter of rope AFOSHSTD91 46 1 FEBRUARY 1997 63 Table 6 5 Rated Capacities for Single Leg Slings Cable Laid Rope Mechanical Splice Only 7x7x7 and 7x19 Construction Galvanized Aircraft Grade Rope 7x6x19 IWRC Construction Improved Plow Steel Grade Rope 1 4 3 8 1 2 5 8 3 4 1 1 8 1 1 4 1 15 16 1 3 8 1 1
193. urn the whole body and crouch down to lower the object 1 2 4 6 When carrying items up or down stairways 1 2 4 6 1 Adhere to the guidance provided by the supervisor 1 2 4 6 2 Try to reduce the bulk or size of the object carried to allow for maximum visibility 1 2 4 6 3 Use assistance when required and available 1 2 5 Minimizing Manual Material Handling Hazards 1 2 5 1 Engineering Controls When other methods are not practical consider using engineering controls such as employing mechanical assists to decrease the force the repetition distance of travel and frequency of the manual handling activities Some examples include scissor tables lev elators conveyors and gravity chutes 1 2 5 2 Administrative Controls Job rotation schedules and mandatory work rest cycles can be useful to reduce hazards but do not eliminate the hazard and are not as reliable as engineering controls 1 2 5 3 Work Design Principles Conduct a job safety analysis identify potential hazards and when practical arrange tasks and select workstations using the following principles 1 2 5 3 1 Place objects to be lifted at the approximate height of the knuckles when the arms dangle at side of the body 1 2 5 3 2 Limit stack height to shoulder level If items must be stacked higher provide step up access to eliminate lifting above shoulder level 1 2 5 3 3 Use grips handles and other devices to provide better control of items 1 2 5 3 4 Slide mat
194. urs Footwalk 4A walkway with handrail attached to the bridge or trolley for access purposes Fork Extensions Steel extensions which fit over the forks to extend the reach of the forklift The use of extension extends the reach but reduces the capacity of the forklift Fork Height The vertical distance from the ground to the load carrying surface adjacent to the heel of the forks with the mast vertical and forks extended Forks and or Tines Horizontal steel projections normally suspended from the carriage of a forklift truck used to engage loads Handle A terminal fitting to which metal mesh fabric is attached Hand Chain Wheel A wheel with formed pockets on its periphery to allow torque to be transmitted to the hoist when a force is applied to the hand chain High Lift Platform Truck A truck equipped with a load platform intended primarily for transporting and tiering loaded skid platforms High Lift Truck truck designed to permit stacking material in tiers Types in this category are high lift fork truck high lift ram truck high lift boom truck high lift clamp truck and high lift platform truck Hitch sling configuration whereby the sling is fastened to an object or load either directly to it or around it e Basket Hitch sling configuration where the sling is passed under the load and has both ends end attachments eyes or handles on the hook or single master link e Choker Hitch A sl
195. which could cause rope damage 9 3 1 2 Sheave carrying ropes which can be momentarily unloaded will be provided with close fitting guards or other suitable devices to guide the rope back into the groove when the load is applied again Note Equalizers at which ropes are terminated shall be specified to have suf ficient adjustment space for block leveling as the rope stretches 9 3 1 3 The sheaves in the bottom block will be equipped with close fitting guards that will pre vent ropes from becoming fouled when the block is lying on the ground with loose ropes 9 3 1 4 Pockets and flanges of sheaves used with hoist chains will be of such dimensions that the chain does not catch or bind during operation 9 3 1 5 All running sheaves will be equipped with means for lubrication Permanently lubricated sealed bearings meet this requirement 9 3 1 6 When chain is replaced the mating parts chain sprockets guides stripper will be disas sembled and inspected for wear and replaced if necessary 9 3 2 Equalizers 9 3 2 1 If aloadis supported by more than one part of rope the tension in the parts will be equal ized 9 3 2 2 Equalizers shall be readily accessible for maintenance lubrication and inspection 9 4 Hooks AFOSHSTD91 46 1 FEBRUARY 1997 109 9 4 1 Inspection 9 4 1 1 Hooks with more than 15 percent of normal throat opening or more than 10 degree twist from the plane of the unbent hook shall be discarded Repair
196. will be done only by designated personnel 7 2 5 3 2 Adjustments will be made to ensure correct functioning of all components such as 7 2 5 3 2 1 Control systems 7 2 5 3 2 2 All operating mechanisms 7 2 5 3 2 3 Limit switches 7 2 5 3 2 4 Drive wheels squaring shafts couplings roller chain drives bumpers and stops 7 2 5 3 2 5 Interlocks crossovers track switches track openers 7 2 5 3 2 6 Collector shoes or wheel limit switches electrical control systems pushbut ton stations or controllers 7 2 5 3 2 7 Brakes hoist mechanisms hydraulic units hydraulic or pneumatic valves and controls 7 2 5 3 2 8 Power source 7 2 5 3 3 Repairs or replacements will be provided promptly as needed for safe operation The following are examples 7 2 5 3 3 1 Hoist mechanisms showing defects as described in Chapter 5 7 2 5 3 3 2 Hooks showing damage as described in Chapter 9 7 2 5 3 3 3 Damage to components listed in paragraph 7 2 5 3 2 which have been deter mined to constitute a safety hazard 7 2 5 3 3 4 Load attachment chains and rope slings showing defects AFOSHSTD91 46 1 FEBRUARY 1997 7 2 5 3 3 5 All critical parts which are cracked broken bent or excessively worn 7 2 5 3 3 6 Dirty pendant control stations and illegible function labels 7 2 5 4 Rope Maintenance Refer to Chapter 9 7 2 5 5 Rope Replacement Refer to Chapter 9 7 2 5 6 Testing 7 2 5 6 1 Operational Tests 7 2 5 6 1 1 Prior t
197. will be visually inspected Any deterioration should be examined and determination made whether further use of the component would con stitute a safety hazard Conditions such as the following should be sufficient reason for consid eration of replacement 8 2 2 2 1 1 Any evidence of hydraulic oil leakage at the surface of the flexible hose or any excessive leakage at its junction with the metal end couplings 8 2 2 2 1 2 Any blistering or abnormal deformation to the outer covering of the hydraulic hose 8 2 2 2 1 3 Hydraulic oil leakage at any threaded or clamped joint that cannot be elimi nated by normal tightening or recommended procedures 8 2 2 2 1 4 Evidence of excessive abrasion or scrubbing on the outer surface of a hose rigid tube or hydraulic fitting Action will be taken immediately to eliminate or correct the cause or otherwise protect the components from additional damage 8 2 2 2 2 Pumps and Motors The following may be reason for replacement or repair 8 2 2 2 2 1 Loose bolts or fasteners 8 2 2 2 2 2 Leaks at joints between sections 8 2 2 2 2 3 Shaft seal leaks 8 2 2 2 2 4 Unusual noises or vibration 8 2 2 2 2 5 Loss of operating speed 8 2 2 2 2 6 Suspected overheating of the hydraulic oil 8 2 2 2 2 7 Inability to hold proper pressure 8 2 2 2 3 Valves The following may be reason for replacement or repair 8 2 2 2 3 1 Cracks in valve housing 8 2 2 2 3 2 Improper return of spool to neutral position 8
198. wn as Counterbalanced Truck Cantilever Truck Rider Truck or Forklift Truck AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 4 High Lift Truck Also known as a High Lift Platform Truck 25 26 AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 5 Low Lift Truck Also known as a Low Lift Platform Truck AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 6 Motorized Hand Truck Also known as Pallet Truck 27 28 AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 7 Industrial Tractor AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 8 Motorized Hand and or Rider Truck 29 30 AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 9 Reach Truck 32 AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 11 Order Picker Truck High Lift NOTE Required guards to prevent truck movement when the operator extends beyond the truck have not been shown AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 12 Narrow Aisle Truck Also Known as Straddle Truck oo Y r ae drm EIER o t n L mrt m enim riim un made wee in de dn Bem m te Se w ae 34 AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 13 Truck Straddle Carry AFOSHSTD91 46 1 FEBRUARY 1997 Figure 3 14 Truck Warehouse Double Handle Type 2 Wheel Solid Rubber Tires 35 36 AFOSHSTD91 46 1 FEBRUARY 1997
199. y AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 1 Maximum Safe Working Load A Type Alloy Steel Chain Single Vertical Sling Double Sling Triple and Quadruple Sling 3 al Angle Chain Vertical Angle Size i 30 deg 45 deg 60 deg Inches Horizontal Angle 2 i 60 deg 45 deg 1 4 5 650 4 550 3 250 8 400 6 800 4 900 3 8 11 400 9 300 6 600 17 000 14 000 9 900 1 2 19 500 15 900 11 250 29 000 24 000 17 000 5 8 16 500 28 500 23 300 16 500 43 000 35 000 25 500 3 4 23 000 39 800 32 500 23 000 59 500 48 500 39 500 7 8 28 750 49 800 40 600 28 750 74 500 61 000 43 000 1 38 750 67 100 5 800 38 750 101 000 82 000 58 000 1 1 8 44 500 77 000 63 000 44 500 115 500 94 500 66 500 1 1 4 57 500 99 500 61 000 57 500 149 000 121 500 86 000 1 3 8 67 000 116 000 94 000 67 000 174 000 141 000 100 500 1 1 2 80 000 138 000 112 500 80 000 207 000 169 000 119 500 1 3 4 100 000 172 000 140 000 100 000 258 000 210 000 150 000 NOTES 1 Rating of multileg slings adjusted for angle of loading measured as the included angle between the inclined leg and the vertical as shown in Figure 6 2 2 Rating of multileg slings adjusted for angle of loading between the inclined leg and the horizontal plane of the load as shown in Figure 6 2 3 Quadruple sling rating is the same as triple sling because normal lifting practice may not distribute load uniformly to all four legs 60 AFOSHSTD91 46 1 FEBRUARY 1997 Table 6 2 Minimum Allowable Chain Size at Any Point
200. yor line or from one con veyor line to another Tray A car carrier or pallet usually suspended from the moving element of the conveyor Whipline Auxiliary Hoist A separate hoist rope system of lighter load capacity and higher speed than provided by the main hoist to provide crane dexterity 146 AFOSHSTD91 46 1 FEBRUARY 1997 Attachment 3 CHECKLIST MATERIALS HANDLING AND STORAGE EQUIPMENT This is not an all inclusive checklist It simply highlights some critical items in this standard Other requirements exist in the standard that are not included in the checklist whereappropriate MAJCOMs DRUs FOAs local safety staffs and supervisors will add to this checklist to include command mission and or work area unique requirements or situations A3 1 Has a training program been developed on manual listing and carrying methods and techniques and is this training documented according to AFI 91 301 Reference paragraph 1 2 1 A3 2 Are annual inspections of manual hoisting or pulling devices documented with identification tags and include appropriate information Reference paragraph 2 2 2 3 A3 3 Have training outlines been developed qualified personnel identified as instructors and has train ing on the operation of powered industrial trucks been conducted Reference paragraph 3 2 4 4 Are safety pallets used to lift personnel designed correctly Reference paragraph3 2 4 6 A3 5 Are gasoline and or diese

AFOSHSTD91-46, Materials Handling and Storage Equipment

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