Overhead and gantry cranes - Pennsylvania

Pennsylvania follows federal OSHA regulations for overhead and gantry cranes.   

However, there are also the following state-specific requirements.   

General safety and health requirements

All cranes used for moving, lifting, lowering, and transporting material must be designed, constructed, equipped, and operated to eliminate dangerous conditions (43 P.S. § 25-2).

General requirements for all cranes

• Construction:
  • Factor of safety. The structural steel members must be designed to conform with the A.I.S.C. Code. All other apparatus must be designed with not less than a factor of safety of five under static full-rated load conditions, based on the ultimate strength of the material used:
    • Cast iron – 12
    • Cast steek – 8
    • Forged steel – 5
    • Cables and hooks - 5
  • Capacity notices. A notice must be placed on every crane and hoist showing the maximum allowable load in pounds or tons. This notice must be placed so as to be clearly legible from the floor.
  • Lubrication. The construction of cranes must be such that all parts may be lubricated and inspected safely when cranes are not in operation. No cranes may be manually lubricated while in operation.
  • Tool boxes. Where a toolbox or receptacle is used for the storing of oil cans, tools, and the like, it must be permanently secured in the cage or on the foot-walk of outside cranes, and on the foot-walk of inside cranes. Toolboxes of hot metal cranes must be constructed of metal.
  • Guarding of gears. All gears on cranes must be provided with suitable guards at points of danger to prevent contact.
  • Projecting keys. Keys projecting from revolving shafts must be guarded.
  • Brakes. A braking apparatus must be provided on every type of crane and be so designed and installed as to be capable of stopping a moving weight of at least 1 1/2 times the full rated load of the crane.
  • Unauthorized operators. Means must be provided to prevent the starting of equipment by unauthorized persons.
  • Control levers. The control levers of traveling cranes must be located so that the operator faces the direction of travel.

(34 Pa. Code § 25.41)

• Electrical equipment
  • Guarding current-carrying parts. All exposed current-carrying parts except conductors, connected to circuits above 300 volts to ground, must be isolated, insulated or guarded. Exposed parts less than 300 volts must be suitably insulated or guarded to prevent possible accidental contact. Exposed metallic parts of conduit armored cable as malding must be permanently grounded. Current-carrying parts of electrical equipment such as controllers, motors, transformers, automatic cut-outs, circuit breakers, switches and other like devices must be guarded either by locating them so as to be inaccessible to the operator or routine maintenance personnel, or by enclosing these devices in cabinets, casings, or shields of permanently grounded metal or of substantial insulating material.
  • Suddenly moving parts. All parts of electrical equipment, such as fuses and the handles and arc chutes of circuit breakers, must be isolated or guarded so that the possibility of persons being stuck or burned is reduced to a minimum.
  • Noncurrent-carrying parts. All exposed noncurrent-carrying metal parts of electrical equipment must be permanently grounded. A grounded connection through well bonded track rails will be considered satisfactory.
  • Operations near electric lines. No one must operate a crane or hoist so that any part thereof, including the load, is within 6 feet of an electric line, unless either adequate mechanical barriers have been erected or the line has been de-energized.
  • Warning signs. Warning signs must be provided as follows:
    • The owner, lessee or employer responsible for the operation of any crane or hoist must post and maintain a durable warning sign, legible at 12 feet by the operator in his normal operating position.
    • The warning sign must consist of white lettering on a red background with at least a 1/4-inch-wide white border. The minimum overall dimensions of the sign must be 10 inches horizontally and 6 inches vertically. Lettering must follow the horizontal dimensions. The word ‘‘unlawful’’ must stand alone at the top with letters at least 1 inch in height. The remaining wording must be printed and spaced on four lines with lettering 5/8 inch in height.
  • Exception. The above rules on operation near electric lines and warning signs may not apply to the following:
    • The owner or lessee of overhead electric lines and equipment and his authorized representatives.
    • Overhead traveling cranes.
  • Disconnecting source of energy. Readily accessible means must be provided whereby all conductors and equipment located in cranes can be completely disconnected from the source of energy at a point as close as possible to the main current collectors.
  • Electrical circuits. The electrical circuit for electric magnets must be maintained in good condition. Means for taking up the slack cable must be provided.
  • Fuses. All fuses must be of the enclosed arcless type.

(34 Pa. Code § 25.42).

• Chains and cables
  • Inspection. All hoist chains including end fastenings should be inspected once every working day. A thorough inspection must be made at least once a month and a signed report of same kept on file. After a shutdown of a month or more, a thorough inspection must be made before use. Special attention must be given to detecting defective welds.
  • Double chains. Bolts or nails may not be placed between two chain links to shorten chains.
  • Splicing chains. Chains may not be spliced with other than approved splicing devices.
  • Annealing of chains. Whenever annealing of chains is attempted, it must be done in properly equipped annealing furnaces and under the direct supervision of a competent person thoroughly versed in heat treating.
  • Inspection of wire ropes. All running ropes should be inspected every working day by a crane operator. A thorough inspection of ropes must be made at least once a month and a fully written and signed report of rope condition must be kept on file, and readily available to the Department and its authorized representative. Ropes used on equipment which has been shut down for a period of one month or more must be given a thorough inspection and full release by the inspector before the equipment is permitted to be used. A report on the rope condition must be filed.
  • Renewal of cables. Whenever the design factor of safety of any cable has been reduced by 15 percent, the cable must be immediately removed.
  • Wraps of cable on drums. There may be not less than two full wraps of hoisting cable on the drums of cranes and hoists at all times of operation.
  • Flanges on drums. Cables must not be allowed to pile on drums of cranes. The drums must have a flange at each end to prevent the cables from slipping off the drums.
  • Bottom sheaves. Bottom sheaves must be protected by close-fitting guards to prevent the rope from being misplaced.
  • Reaving. The reaving must be of a type and so arranged that ropes will not chafe or abrade while in use.

(34 Pa. Code § 25.43).

• Floor operated overhead traveling cranes
  • Aisles. An unobstructed aisle not less than three feet wide must be maintained for travel of the operator except in cases where the control handles are hung from the trolleys of traveling cranes.
  • Control ropes. The direction of all movements of the crane must be clearly indicated so that the operator may become readily familiar with them.

(34 Pa. Code § 25.44).

• Operators
  • Authorized operators. Cranes, derricks and hoists must be operated only by experienced operators, learners under the supervision of an experienced operator, a crane repair man, or an inspector. Only an authorized person may enter a crane cab.
  • Mental requirements. No crane may be operated by any person who is unable to read and understand the signs, notices, and operating instructions and who is not familiar with the signal code used by the floormen.
  • Physical requirements. Cranes must not be operated by any person having seriously defective eyesight or hearing or suffering from heart disease or similar ailments that may cause fainting as determined by the examining physician. All regular crane operators must be examined by a physician at least annually.
  • Ascending and descending ladders. Hands must be kept free when going up and down ladders. Articles which are too large to go into pockets or belts must be lifted to or lowered from the crane by hand line, except where stairways are provided.
  • Cages. Cages must be kept free of clothing and other personal belongings. Tools, extra fuses, oil cans, waste and other articles necessary in the crane cage must be stored in a tool box.
  • Crane rules. The operator must completely familiarize himself with all crane rules and with the crane mechanism and its maintenance. If adjustments or repairs are necessary, he must report them at once to the proper authority.
  • Eating, reading while on duty. The operator may not eat or read while engaged in the operation of a crane, nor may he operate the crane when he is physically or mentally unfit.
  • Lubrication. The operator or someone specially designated must properly lubricate all working parts of the crane.
  • Daily inspection. On each day of use, cranes must be examined by the operator for loose parts or defects.
  • Cleaning cranes. It is the responsibility of the operator to clean his respective crane.
  • Carrying loads over people. Operators must avoid, as much as possible, carrying loads over people. Carrying molten metal or metal with a magnet over people must be absolutely avoided. If loads have to be carried over people, a warning must be given. No person may be permitted to stand or pass under an electric magnet in use.
  • Closing emergency switch. When the operator finds the main or emergency switch open, he may not close it, even when starting on regular duty, until he has made sure that no one is on or about the crane. If there is a ‘‘Man Working’’ sign on the switch, he shall not remove it unless placed there by himself; he may not close the switch unless the warning sign has been removed by the man placing it there. He may not oil or repair the crane unless the main switch is open.
  • Power off. If the power goes off, the operator must immediately throw all controllers to ‘‘off’’ position until power is again available.
  • Closing main switch. Before closing the main switch, the operator must make sure that all controllers are in ‘‘off’’ position until power is again available.
  • Tripping limit switches. When long hitches are made, the operator must pay special attention to the block, to avoid tripping the limit switch. The operator must never depend on the limit switch to stop the hoists but must control the movement from the cab. At the beginning of his tour of duty, the operator must test the upper limit switch, under no load. If it does not operate properly, he must immediately notify the foreman or inspector.
  • Signals. If a warning gong is furnished, it must be sounded each time before traveling.
  • Trolley placement. Before starting to hoist, the operator must place the trolley directly over the load to avoid swinging it when being hoisted. This precaution is especially important in the handling of molten metal.
  • Side pulls. Cranes may not be used for side pulls unless authorized by a responsible person who has determined that the stability is thereby not endangered and that the various parts of the crane will not be overstressed. A monorail hoist must never be used for this purpose.
  • Testing hoist brakes. When handling maximum loads, particularly ladles of molten metal, the operator must test the hoist brakes after the load has been lifted a few inches; if the brakes do not hold, the load must be lowered at once and the brakes adjusted or repaired.
  • Bumping runway stops or cranes. Bumping into runway stops or other cranes must be avoided. When the operator is ordered to engage with or push other cranes, he must do so with special care for the safety of persons on or below cranes.
  • Lowering loads. When lowering a load, the operator must proceed carefully to ensure that he has the load under safe control.
  • Leaving the cage. When leaving the cab or cage of any equipment, the operator must place all controls in neutral or ‘‘off’’ position and open the main switch or disengage the master clutch.
  • Locking the crane. Before leaving a crane unattended, the operator must lock the crane to prevent movement in any direction. This requirement may not apply to overhead traveling cranes inside industrial buildings.
  • Riding on hooks. Operators may not permit anyone to ride on the load or hooks.
  • Age and sex requirements. A male under 18 years of age or female under 21 years of age may not be permitted to operate a crane. Application for permission to employ women as crane operators must be filed with the Department.

(34 Pa. Code § 25.45).

• Floormen
  • Signals. Floormen must give all signals to the operator in accordance with the established standards.
  • Condition and use of hoisting accessories. Floormen are responsible for the condition and use of all hoisting accessories and hitches.
  • Empty chain slings. Before the operator moves a crane from which an empty chain sling is hanging, the floormen must hook both ends of the sling to the block.
  • Walking ahead of loads. Floormen must walk ahead of the moving load to warn people to keep clear and to ensure that the load is carried high enough to clear all obstructions.
  • Extra heavy loads. Floormen must notify the foremen in advance when an extra heavy load is to be handled.

(34 Pa. Code § 25.46).

• Repairmen
  • Crane location. When repairs are necessary, repairman must move the crane to a location where the repair work will least interfere with other cranes and operations.
  • Controllers in ‘‘off’’ position. Before starting repairs, repairmen must see that all controls are placed in ‘‘off’’ position, and that the main switch or emergency switch is opened. Either the main switch or emergency switch shall be locked or a ‘‘Man Working’’ sign attached.
  • Out of order signs. Repairmen must immediately place warning signs or ‘‘out of order’’ signs on a crane to be repaired and either on the floor beneath or hanging from the crane to be easily seen from the floor. If other cranes are operated on the same runway, repairmen must also place rail stops at a safe distance or make other safe provisions.
  • Repairing runways. When repairing runways, repairmen must place rail stops and warning signs or signals to protect both ends of the section to be repaired.
  • Loose parts. Repairmen must take care to prevent loose parts from falling or being thrown to the floor beneath.
  • Replacement of guards and safety devices. Repairs may not be considered complete until all guards and safety devices are put in place and the block and tackle and other loose material are removed.

(34 Pa. Code § 25.47).

Overhead traveling cranes

• Scope. The regulations relating to overhead traveling cranes will also govern in the cases of single I-bean and transfer cranes, except when the construction of the cranes precludes compliance (34 Pa. Code § 25.51).

• Construction requirements
  • Overhung gears. No overhung gears may be used unless provided with an effective means of keeping them in place. Keys must be secured in an approved manner to prevent gears from working loose.
  • Outriggers for repairs. If there are no members above an outside overhead traveling crane that are suitable for attaching blocks for repair work and another crane is not available, a structural steel or aluminum outrigger of strength sufficient to lift the heaviest part of the trolley must be provided.
  • Locking of cranes. Approved locks must be installed to prevent outside overhead traveling cranes from being blown along or off the tracks by severe winds.
  • Brakes for bridge travel. Foot brakes, or other effective means, must be provided to control the bridge travel of all overhead traveling cranes.

(34 Pa. Code § 25.52).

• Platforms and foot-walks
  • Changing truck wheels. Platforms must be provided for changing and repairing truck wheels on end trucks.
  • Access to crane cages. A platform or foot-walk must be located on the crane or crane runway to give access to the crane cage, and it must be accessible from one or more stairways or fixed ladders. This platform or foot-walk may be not less than 18 inches wide.
  • Stairways and ladders. When stairways are used to give access to platforms, they must make an angle of not more than 50 degrees with the horizontal and must be equipped with substantial railing. If ladders are used to give access to platforms, they may extend not less than 36 inches above the platform. Railed stairways or ladders used as means of ingress and egress to crane cages must be located to prevent the operator or other persons from meeting live lines feeding runway or other parts of the crane equipment.
  • Foot-walks—clearances. A foot-walk must be placed along the entire length of the bridge on the motor side, and a short platform twice the length of the trolley placed at one end of the girder on the opposite side, with a vertical clearance of at least 6 feet 6 inches when the design of the crane or building permits, but in no case may there be less than 4 feet clearance. For hand operated cranes, the foot-walk may not be required to be installed on the bridge of the crane, but there must be a repair platform, equal in strength and design to that required for motor operated cranes, installed on the wall of the building or supported by the crane runway at a height equal to the lower edge of the bridge girder to facilitate necessary repairs.
  • Width of foot-walks. The clear width of foot-walks must be not less than 18 inches except around the bridge motor where it may be reduced to 15 inches.
  • Construction. Foot-walks for outside service must be constructed so as to provide proper drainage, but the openings between the boards, sections of metal decking or floor plates must not be wider than 1/4 inch.
  • Railings and toe-boards. Railings and toe-boards must conform with the following:
    • Railings must be capable of safely sustaining a vertical load of 80 pounds per linear foot and a horizontal thrust of 25 pounds per linear foot.
    • The suggested inside diameter for pipe railings may not be less than 1 1/4 inches.
    • Railings may be not less than 42 inches in height, with an additional rail midway between the top rail and the floor.
    • Pipe railings may be not less than 1 1/4 inches inside diameter if of iron or be not less than 1 1/2 inches outside diameter if of brass tubing.
    • Posts or uprights must be spaced not more than 8 feet center to center.
    • Toe-boards must be not less than 6 inches in height.
    • Toe-boards must be constructed so as to be permanent and made of metal, wood or other substantial material. If made of wood, toe-boards must be at least equal in cross section to 1 inch by 6 inches; if made of steel at least 1/8 inch by 6 inches; and if made of other construction at least equal to the requirements for steel. Perforations up to 1/2 inch are permissible in metal toe-boards.
  • Openings between foot-walks and crane girders. No opening may be permitted between the bridge foot-walk and the crane girders. If wire mesh is used to fill this opening, the mesh openings must not be greater than 1/2 inch.
  • Platform strength. All foot-walks and platforms must be designed so as to be capable of sustaining a uniformly distributed live load of 100 pounds per square foot.

(34 Pa. Code § 25.53)

• Cages
  • Means of escape. Means of escape must be provided for operators of hot metal cranes. This will consist of a walkway accessible from the cage when in any position, or some other approved arrangement.
  • Location and size of cages. The cage of the operator must be located at a place from which signals may be clearly understood and securely fastened in place and well braced to minimize vibration. The cage must be large enough to allow ample room for the control equipment and the operator. The operator may not be required to step over an open space of more than 18 inches when entering the cage.
  • Fire extinguisher. An approved fire extinguisher must be carried in the cage.
  • Warning device. In establishments where continuous loud noises prevail, such as caused by the operation of pneumatic tools, steam exhausts from boilers, and the like, audible type signaling devices must be installed on cranes or one or more employes must be placed on the floor for each crane operated to warn other employes of the approach of a crane with a load. If there are more than two cranes on the same runway or within the same building structure, signaling devices may not be required if a man is placed on the floor for each crane to give warning to other employes of the approach of a crane with a load.
  • Protection from heat. Cages of cranes subjected to heat from below must be of noncombustible construction and have a steel or aluminum plate shield not less than 6 inches below the bottom of the floor of the cage. If necessary, approved heat insulating material must be provided in this space.
  • Outside cages. Outside crane cages must be enclosed and properly heated. There must be windows on three sides of the cage. The windows in the front and the side opposite the door must be the full width of the cage.
  • Cage floor extensions. The floor of the cage on outdoor cranes must be extended to form an entrance landing which must be equipped with a handrail and toe-board of standard construction.
  • Rules for operators. A durable copy of the rules for operators must be permanently posted and maintained in the cages of all cage-operated cranes.

(34 Pa. Code § 25.54).

• Rail stops, bumpers and fenders
  • Rail stops and bumpers. Rail stops must be provided at both ends of the crane runway and at the ends of the crane bridge. When two trolleys are operated on the same bridge rails, bumpers must be provided between trolleys.
  • Heights. Bumpers and rail stops must extend at least as high as the centers of the wheels.
  • Fastening of rail stops. Rail stops must be fastened either to the girders or to girders and rails, but not to the rails alone. This does not apply to portable rail stops.
  • Rail stop construction. Rail stops must either be built up of plates and angles or be made of cast steel.
  • Fenders. Fenders must be installed which extend below the lowest point of the treads of the outside bridge truck wheels. They must be of a shape and form that will push or raise the hand, arm or leg of a man off the rail and away from the wheel.

(34 Pa. Code § 25.55)

Gantry Cranes

• Special requirements
  • Fenders. All bridge truck wheels must be equipped with fenders which should project in front of the wheels and extend slightly below the top of the rail in the same groove as the wheel flange or flanges.
  • Passageway. An unobstructed passageway not less than 30 inches wide must be maintained parallel to and extending the entire length of the tracks upon which any gantry crane is operated.
  • Stairways to platforms. Where stairways are used to give access to platforms they must be equipped with a substantial handrail.
  • Warning device. An automatically operated bell or other effective warning device, which must operate at all times while the crane is traveling, must be provided on all gantry cranes. In addition, each trolley or similar part of a gantry crane must be equipped with a manually operated bell, or other effective warning device, in all cases where persons may be endangered by the movement of a trolley or similar part.
  • Rail stops. Rail stops must be provided at both ends of the crane runway. The rail stops must extend at least as high as the center of the wheels.

(34 Pa. Code § 25.61).