Professional Documents
Culture Documents
Peer-Reviewed
Construction Hoists
Understanding Exposures & Controls
By Sathy Rajendran and Brian Clarke
C
onstruction hoists, also known as man- safe operation; therefore, the controlling
lifts, personnel hoists and construction contractor should implement a compre-
elevators, are commonly used when con- hensive construction hoist safety program.
structing high-rise buildings to transport person- Subcontractors should address hoist oper-
nel, tools, equipment and materials between floors ations in their safety planning when their
(Photo 1). Incidents involving construction hoists work is performed near a hoist.
caused 93 deaths among construction workers be- Failure to follow proper safety pro-
tween 1992 and 2003 (ASSE, 2010). Table 1 pres- cedures during a hoist’s life cycle could
ents deaths from hoist-related injuries by major result in severe personal injury, death or
construction occupation. Despite the number of property damage. This article provides in-
fatalities associated with hoist operations and the formation to help contractors and SH&E
similarity of hoists to tower cranes in terms of tall professionals develop proactive construc-
mast sections, building tie-ins and public exposure, tion hoist safety programs.
construction hoist installation and operation have Hoists have either one or two cars that
received little attention. travel vertically along stacked mast tower
Over the past few decades, hoists sections. The base of the mast is connect-
and tower cranes have made construc- ed to a structural concrete foundation.
IN BRIEF tion material handling easier and safer. Mast sections are tied-in to the building at
•Construction contractors who However, the hoist itself introduces regular intervals determined by the hoist
use construction hoists on several hazards and exposures that manufacturer. The manufacturer typically
their sites should implement a must be mitigated during its life cycle provides the different forces generated by
proactive comprehensive hoist on a project (Figure 1, p. 30). A hoist the hoist on the building. Based on these
safety program. is erected on site from several com- data, the structural engineer (with a P.E.
•Failure to follow proper safety ponents, usually with the help of an license) designs or verifies the tie-in con-
procedures during a hoist’s life on-site tower crane. If a jobsite has no nection point to the building to withstand
cycle on a project could result tower crane or if tower crane opera- the load imposed on the building.
in severe personal injury, death tions are limited, a mobile crane (an as-
or property damage. sist crane) is used. Construction Hoists: Existing Practices
A hoist is typically rented by a gen- The authors conducted an extensive
eral contractor from a lessor (rental or manufactur- search of the existing literature to locate
er), although some large contractors own hoists as articles, reports, regulatory standards and other
part of their equipment fleet. In either case, as the documents that address best practices related to
controlling contractor, a general contractor that uses construction hoists. Minimal guidance was found.
a construction hoist on its site is responsible for its This section summarizes current industry best
practices pertaining to construction hoists.
OSHA Subpart N, Cranes, Derricks, Hoists, El-
Sathy Rajendran, Ph.D., M.S., CSP, LEED AP, CRIS, is a construction safety evators and Conveyors, §1926.552 titled “Material
specialist with Hoffman Construction Co. of Oregon. He has managed safety
hoists, personnel hoists and elevators” covers the
programs for medium and large construction projects, and his experience includes
a wide variety of buildings, including hospitals, a biopharmaceutical facility, high- regulatory requirements for construction hoists. It
rise condominiums and office buildings, airport projects, parking garages and a directs employers to “manufacturer specifications”
hotel. Rajendran holds a Ph.D. and M.S. in Civil Engineering from Oregon State and provides limited guidance on hoist operation
University and a B.E. in Civil Engineering from Anna University in India. safe practices. According to this regulation:
Brian Clarke, CSP, is managing partner, G.E.W llc Safety Solutions. Prior to [T]he employer shall comply with the manu-
this, he was corporate safety director for Hoffman Construction Co. and a senior facturer’s specifications and limitations ap-
loss control representative for Continental Insurance. A professional member of plicable to the operation of all hoists and
ASSE’s Columbia-Willamette Chapter, Clarke was on ASSE’s Board of Directors elevators. Where manufacturer’s specifica-
from 1999 to 2003. He received the Gary Bird Horizon Award from the Interna- tions are not available, the limitations as-
tional Risk Management Institute in 2003 for “Excellence in Innovative Risk Man- signed to the equipment shall be based on
agement Techniques and Processes in the Construction Industry. Clarke holds a
B.S. in Occupational Safety and Health from Central Washington University. the determinations of a professional engi-
neer competent in the field. (OSHA, 2006b)
28 ProfessionalSafety JULY 2011 www.asse.org
Table 1
Deaths Resulted
From Hoist-Related
Injuries
Crane Representative
The crane representative/operator plays a critical
role throughout the process. The site tower crane is
typically used to erect/dismantle a hoist. However, Note. Used with permission from Hoffman Construction Co. of Oregon safety
as noted, based on tower crane limitations, a mo- program. This is only part of the preerection meeting checklist.
bile crane may be erected on site to install the hoist.
www.asse.org JULY 2011 ProfessionalSafety 31
•Inform the crane tercoms and floor door limit switches. Ask the
operator and oiler subcontractor to verify that all safety devices are
that they are re- reinstalled and checked for proper operation.
sponsible for ensur- •Conduct a final preoperation walkthrough with
ing that all involved all parties involved to ensure safe operation of the
in assembly/disas- hoist. Look for items such as hoistway protection,
sembly of the erec- gaps between landing area and floors, and related
tion crane use all issues.
PPE and adhere to •Ensure that bolt retorquing is scheduled per
all safety precau- manufacturer specifications.
tions. •Provide a make-/model-specific self-inspection
•Discuss the type checklist.
of rigging that will •Verify make/model operator training, including
be used, rigging that for back-up operators (during breaks).
owner, rigger and
signaler qualifica- Hoist Operator Training Program
tion, and related The next critical step is the safe operation of the
topics (Photo 4). hoist at the construction site. A hoist should be
controlled by operators trained on hoist operation
Photo 2 (top, left).
Project Superintendent (General Contractor) (general and make-/model-specific), inspection
Ironworkers install-
During construction hoist erection/dismantle, and maintenance.
ing the hoist mast
complacency is a concern. Crews may rush to Some employers have operators read the hoist
sections in place
complete a job, and the repetition of assembling operations and maintenance manual, then have
with 100% tie-
and disassembling an erection crane as well as the them sign a form that states “read and understood
off. Photo 3 (top,
hoist can lead to overconfidence and a failure to the manual.” Although this form may satisfy reg-
right). A city street
take necessary precautions. This is dangerous work ulations, these operators are being set up to fail.
blocked off during
and all involved must continuously watch for any Most equipment operators will not read the man-
a hoist dismantle
and all hazards. ual and, therefore, will not have the knowledge to
operation. Photo 4
The superintendent must address several key el- operate the hoist safely.
(above). Hoist mast
ements. On several sites, to test compliance with “read
dismantle in prog-
•Discuss pedestrians (“sidewalk superinten- and understood the operator’s manual,” business
ress with an assist
dents”) who may become curious about the con- cards were inserted deep within manuals for aerial
mobile crane.
struction activity and enter the work area to ask lifts and cranes with the note, “When you get this
questions. card call the safety department for a company jack-
•Ensure that the hoist foundation is poured and et.” Not a single jacket was given out during this
finished per design, and has attained its required period. This reinforces the fact that simply having
strength before hoist installation. operators “read and understand” a manual is not
•Locate a travel path for trucks to give them the an effective way to provide training.
best route to/from the work area. Rental companies (lessors) and manufacturers
•At the safety meeting the week before work were contacted to inquire about hoist operator
begins, inform workers where and when the assist training. Most did not have a training program, al-
crane will be assembled. Direct them to find an al- though some lessors had a multiday class at their
ternate route to avoid walking through this area. shops that covered everything about a hoist. How-
•Ensure that electrical disconnect and power are ever, it often is not practical or economical to send
available before work commences. operators to a manufacturer’s site because of fac-
•Verify that the connection points between the tors such as cost, high turnover among operators
hoist and the building are installed per the struc- that requires training several operators during a
tural engineer’s approved design. short period, and availability of training when it is
•When the erection team is finished, make sure needed (schedule).
all safeguards are working, including all floor in- The authors’ firm created its own short training
32 ProfessionalSafety JULY 2011 www.asse.org
program that covers all major elements associated Emergency Photo 5 (left). Con-
with hoist operation, inspection and maintenance. If an operator finds any defect (e.g., faulty inter- struction hoist with
With guidance from in-house staff (experienced su- locks, damaged structural items) during the daily hoistway protec-
perintendents, SH&E professionals, operators and inspection that poses an imminent risk, s/he should tion on each floor.
maintenance staff), insurance companies and the shut down and secure the hoist to prevent unau- Photo 6 (right).
literature, a 45-minute PowerPoint presentation thorized personnel from operating it. The operator Operators should
was developed. The training is based on manufac- should then contact a supervisor or the designated maintain clear path
turers’ manuals, OHSA regulations and ANSI/ASSE technician to fix the defect prior to operation. during loading
standards. It helps ensure that operators know the operations.
safe procedures to follow during daily operations Hoistway Protection
and what to look for during daily inspections. Such All employees should stay clear of a moving car
training sets operators up for success. In addition, and counterweight (Photo 5). All activities (e.g.,
operators complete make-/model-specific training crane work, aerial lifts) performed near the hoist
for each hoist to which they are assigned. shall be coordinated with the operator.
Training should be delivered by a qualified in- In one incident, an employee was attempting to
structor, such as an SH&E professional, manu- install exterior sheathing to the face of a building.
facturer/rental company representative and/or At ground level, the employee had maneuvered
maintenance staff. The trainer should clearly com- and parked his scissor lift adjacent to the plywood
municate that safe hoist operation and inspection safety barrier created at the base of the construction
is the sole responsibility of the operators. In ad- hoist. The employee elevated the scissor lift to his
dition to operators, all workers should be briefed desired work height, then extended the platform so
about hoist safety during new employee site-spe- he could easily reach the work area in front of him.
cific orientation. The hoist operator, starting his normal opera-
Next, let’s discuss critical issues to be addressed tions for the day, looked up and noticed the scis-
during hoist operation, inspection and mainte- sor lift in close proximity to the hoist’s mast. He
nance. For SH&E professionals or company super- traveled slowly upward and talked to the scissor lift
visors who perform site audits of hoist compliance, operator, asking, “You in the clear?” (referring to
these items serve as a checklist. The elements the proximity of the counterweight). The response
highlighted are based on industry literature (CPA, was “Yes” (this worker recognized the proximity to
2004; 2006) and the authors’ experience. the hoist car, but apparently not the counterweight
above). The hoist operator proceeded toward the
Daily Inspection top of the building. The hoist’s counterweight trav-
The operator should conduct a daily inspection eling downward struck the scissor lift basket, caus-
using the hoist make-/model-specific checklist. A ing extensive damage. The 6,000-lb counterweight
copy of the checklist should be maintained at the missed striking the scissor lift operator by a matter
site at all times. If the hoist is older and does not of inches.
have a model-specific inspection checklist, con- In this case, the employee, his supervisor and the
tact the lessor/manufacturer to see whether one is operator failed to recognize the serious danger that
available. exists near an in-service personnel hoist. Compa-
If not, SH&E professionals and lessors can de- nies should direct all hoist operators to suspend
velop one. This checklist should then be sent to the all operations and report to their immediate su-
manufacturer for review (although some manufac- pervisor whenever they deem people, equipment
turers are no longer in business). Additionally, the or materials to be in the hoist’s safety zone. Before
project management team must read inspection any work is allowed in the safety zone, the electri-
reports and correct any deficiency noted. cal system must be deenergized, locked and tagged
An operator should not be allowed to handle or out-of-service.
use the hoist before reading the operator’s manual.
During audits, ensure that operators are perform- Structural Examination
ing their inspections and that the operator’s manu- During every inspection, the operator should ex-
al is kept in the car at all times. amine load-bearing items such as masts, mast bolts,
www.asse.org JULY 2011 ProfessionalSafety 33
ties, fixing anchors, the load carrying device (load/ all electrical interlocks by making test runs. In ad-
platform) and the base support. The operator should dition, the operator should check the function of
ensure that no cracking or deformation has occurred control devices, alarm signal, lighting, automatic
and that no connections have become loose or been stop at landings, emergency light functions, and
damaged. In the case of a large building, additional the condition and operation of the main isolator
qualified individuals can inspect the connections. switch each day.
This inspection is critical because any structural fail-
ure can result in catastrophic incidents. Housekeeping
All debris should be removed from the base
Material Handling enclosure, cage and roof floor. All landing areas
All loads transported in the hoist (e.g., drywall should be free of materials/debris to prevent trip
on carts) should be secured properly. Improperly hazards.
secured loads can become dislodged easily dur-
ing travel and pinch against users. Maintain a clear Extreme Weather
path during loading operations to avoid pinch- A hoist must not be used when wind velocities
point/crush-point hazards (Photo 6, p. 33). Make exceed 40 mph. When velocity surpasses 20 mph,
sure users never exceed the hoist’s loading capac- do not operate the lift past last tie-in. An operator
ity. Users should be required to provide calculated also must know to not attach any materials to the
loads for materials and equipment transported in inside of the car, such as plastic to protect against
the hoist. Hoist operators must know they have the rain, since such materials increase the possible
authority to refuse unsafe loads and that they will forces to the structure.
be held accountable if they do. In case of storms, tornadoes, hurricanes or earth-
quakes, all of a hoist’s vital parts must be inspected
Operator Safety and tested by an expert or manufacturer-autho-
When workers are loading large loads (tight- rized representative before the hoist is used. Where
fit), the operator should stay clear from the load icing can occur, the hoist should be parked at the
to avoid pinchpoint hazards between the load and ground landing upon completion of work. If the
the car. The operator should never help with un- mast or power cables are covered with ice, remove
loading/loading because it is not part of their job ice before using the hoist.
function and they could be injured trying to help.
An analogy would be a surveyor trying to help Conclusion
an ironworker lift a piece of I beam. Hoist users A construction hoist safety program must be an
should provide enough personnel to safely load integral component of a construction company’s
and unload their cargo. safety program. Failure to follow proper safety pro-
cedures during a hoist’s life cycle on a project could
Mechanical Inspection cause injury, death or property damage. This expo-
The hoist operator should examine racks and pin- sure demands some needed attention. PS
ions, drive drums, pulleys, gear boxes, transmission
motors, brakes, guide rollers, drive shafts and emer- References
gency lowering system to detect undue wear or mal-
ANSI/ASSE. (2007). Safety requirements for person-
function. When inspecting gears, check oil level and nel hoists and employee elevators: American national
refill as necessary. Leaking seals must be replaced. standard for construction and demolition operations
All repair and maintenance must be performed only (ANSI/ASSE A10.4-2007). Des Plaines, IL: Author. Re-
by manufacturer-approved representatives. trieved Oct. 11, 2010, from www.asse.org/shoponline/
An operator also should inspect lubrication on products/A10_4_2007.php.
racks, safety devices and the trolley system, and ASSE. (2010). Occupational deaths related to hoists
check the condition and function of cable guides, in construction, 1992-2003. Des Plaines, IL: Author.
guide rollers and roller assemblies. The operator Retrieved Oct. 11, 2010, from http://www.asse.org/
also should perform a detailed examination of wire publications/standards/a10/a10_3804_occdeaths.php.
Construction Plant-Hire Association (CPA).
ropes to identify broken wires, surface wear, exces- (2004). Best practice guide: Construction hoists mainte-
sive stretching, unequal rope tensions, variations nance, inspection and thorough examination. London,
in diameter, kinks, localized crushing, “birdcag- U.K.: Author, Construction Hoist Interest Group.
ing” (wire rope strands are forcibly untwisted and CPA. (2009). Best practice guide: Working at height
become spread outward) due to misspooling, and on construction hoists. London, U.K.: Author, Construc-
surface rust and corrosion. tion Hoist Interest Group.
For the counterweight (where applicable), the OSHA. (2006a). Re: Construction requirements for
operator should check the cathead arrangement personnel hoists; applicability of ANSI A10.4-2004 (Letter
for possible wear and damage, and confirm that all of interpretation). Washington, DC: U.S. Department of
Labor, Author. Retrieved Oct. 11, 2010, from www.osha
screw joints are properly tightened.
.gov/pls/oshaweb/owadisp.show_document?p_table
=INTERPRETATIONS&p_id=25315.
Safety Devices OSHA. (2006b). Cranes, derricks, hoists, elevators
The operator must ensure that all emergency and conveyors. Washington, DC: U.S. Department of
stop switches, the final limit switch and electric Labor, Author, Construction Safety and Health Out-
motor brakes are working. S/he also should check reach Program.
34 ProfessionalSafety JULY 2011 www.asse.org