3.3 Special Requirements Under 230 CMR 6.09: Cranes, Derricks, Pile Drivers, Forklifts & Excavators
Key Takeaways
Boom crane rating plates or load charts must show the safe load for maximum and minimum boom positions and at least two intermediate positions (230 CMR 6.09(1)(a)).
Cranes must have devices that keep the boom from falling over backward, and cable boom stops alone are not adequate (230 CMR 6.09(1)(b)).
All parts of a crane and its supports must be designed, built and maintained with a safety factor of not less than two (230 CMR 6.09(1)(h)).
Tower crane foundations must be designed by the manufacturer or a registered professional engineer, and wind speed must not exceed the manufacturer's limits (230 CMR 6.09(1)(j)–(k)).
Pile drivers must not be used with a jib attached, and the hammer must be chocked, blocked in the leads or lowered to the ground when not in use (230 CMR 6.09(3)).
Read 6.09 as preconditions
230 CMR 6.09 opens with: "The operator shall not operate the hoisting machinery unless the following requirements are met." Each item is a condition that must be met before operation. An operator who sees one is missing has a reason under 6.08(2)(c)11 to stop and refuse until it is fixed.
Cranes (230 CMR 6.09(1))
| Paragraph | Requirement | What it means on the job |
|---|---|---|
| (a) Loading | Load per the manufacturer's specifications. Load-rating plates or load charts are kept in the cab in clear view of the operator. Boom crane charts show the safe load for maximum and minimum boom positions and at least two intermediate positions. Instructions, recommended operating speeds, special hazard warnings and the operator's manual are in the cab | No chart in the cab means no lift. If ratings exist only electronically and the display fails, cease operations immediately or follow safe shutdown procedures until the ratings are available again |
| (b) Boom stops | Devices that prevent the boom from falling over backward; cable boom stops alone are not adequate | On lattice boom cranes this means a rigid boom stop such as telescoping struts; OSHA 1926.1415(a)(2) likewise requires boom stops except on derricks and hydraulic booms |
| (c) Speed controls and stops | Machines on rails, tracks or trolleys have speed controls and positive stops or limiting devices | Applies to rail-mounted and travelling cranes |
| (d) Modifications | Keep at least the original factor of safety; the owner keeps a record of the differences; done with the manufacturer's written approval or, if that is unavailable, under a procedure created and certified by a professional engineer added to the permanent record | Unapproved modifications violate 230 CMR |
| (e) Operator protection | A cab or equivalent cover when exposed to overhead hazards or weather, without blocking the view of the load; safety glass (or equivalent) with no distortion | Cracked or distorting cab glass is a deficiency (see also OSHA 1926.1412(d)(1)(xii)) |
| (f) Required presence | Operators remain at the controls while the load is suspended, except on loss of power (then follow 6.08(2)(c)13). The operator shall not leave the machine while the master clutch is engaged | Covers friction machines with a master clutch, and the general rule against leaving a hanging load |
| (g) Erection or dismantling | Per the manufacturer's specifications and 29 CFR 1926, under the supervision of the manufacturer's representative or others experienced in erecting or dismantling that equipment. Attachments may not exceed the manufacturer's capacity, rating or scope | OSHA 1926.1403–1404 adds an assembly/disassembly (A/D) director and procedures (Section 4.1) |
| (h) Factor of safety | All crane parts and supports designed, built and maintained to withstand all stresses of intended use with a safety factor not less than two | Applies to structural design and maintenance; it does not permit loading beyond the chart |
| (i) Capacity schedule | Each crane model keeps a schedule of load capacities in the operator's station at all times | Same idea as (a) |
| (j) Tower crane foundations | Designed by the manufacturer or a registered professional engineer | Foundations are engineered, never improvised |
| (k) Wind speed | Must not exceed the manufacturer's recommendations for continued work | The manufacturer's wind limit is the limit (Section 7.3) |
| (l) Tower crane safety devices | All required safety devices installed and functioning | — |
| (m) Tower crane operational aids | All required operational aids installed and functioning, or approved temporary alternative measures in place | Matches OSHA 1926.1416 temporary alternative measures |
Derricks (230 CMR 6.09(2))
- Guys, cable clamps and other rigging are visually checked by the operator at the beginning of each work day, before any lift near the rig's capacity, and as the manufacturer requires.
- A licensed person frequently checks the lead cables and mast foot blocks so cables are not crossed or fouled, and checks that lead line blocks are secure. Leads are arranged to minimize tripping hazards.
- Derricks (guy derricks, stifflegs, Chicago booms and gin poles) fall under the 1A restriction (Section 2.1).
Pile drivers (230 CMR 6.09(3))
| Rule | Detail |
|---|---|
| Daily inspection | All pile driving equipment is inspected daily before work by a licensed operator of that equipment; unsafe conditions and defective parts are corrected first |
| Not in use | The hammer is chocked or blocked in the leads, or lowered to the ground |
| Interruptions | The operator stays at the post until the hammer is chocked or blocked, or lowered and resting on a driven pile or the ground |
| Jibs | Pile drivers must not be used with a jib attached |
| Stop blocks | Stop blocks on the leads keep the hammer from being raised against the head block |
Pile drivers are the 4B restriction, which is also covered by 1A and 1B.
Fork lifts (230 CMR 6.09(4))
- Only a duly licensed operator, or an apprentice under the direct supervision of a licensed operator, may operate a fork lift. No fork lift may be loaded beyond its capacity rating.
- Every power-operated fork lift has adequate wheel brakes.
- No fork lift is operated at unsafe speeds, and no other person except the licensed operator or supervised apprentice may ride on it while it operates.
- The company-property forklift exemption in 230 CMR 6.06(2)(e) still applies where its conditions are met (Section 2.3).
Excavating machines, backhoes and front-end loaders (230 CMR 6.09(5))
- Dig Safe first: meet all Dig Safe obligations before any excavation, notify utilities not covered by Dig Safe, and record the Dig Safe permit number, start date and time (Chapter 6).
- Cab protection is required where the operator is exposed to weather or overhead hazards.
- Operated only by a licensee, temporary permit holder, or apprentice under direct supervision.
- SAE hand signals are used with excavating machinery (Appendix B; Section 10.1).
- No one except the operating crew or a supervised apprentice rides on the machine. No one other than the pitman and excavating crew may stand within the full working radius of an excavator or backhoe while it operates.
- Excavating machinery shall not straddle an open trench.
Suspended personnel platforms (230 CMR 6.09(6))
Hoisting personnel on a crane- or derrick-suspended platform has its own detailed rules: 1% level, 50% of rated capacity, wire rope safety factors of 7 and 10, trial lifts and proof tests. These are covered in Section 10.2.
Scenario practice
- The electronic chart goes dark. Midway through a pick, the crane's display, the only copy of the load chart in the cab, reboots and stays blank. Under 6.09(1)(a) the operator must immediately cease operations or follow safe shutdown procedures until the rated capacities are available again.
- A boom-stop cable only. A lattice crawler arrives with only a cable boom stop rigged. 6.09(1)(b) says cable stops alone are not adequate, so the machine does not meet the precondition.
- The pile hammer at lunch. The crew breaks with the hammer hoisted halfway up the leads. 6.09(3)(b) requires it to be chocked or blocked in the leads or lowered to the ground.
- Excavator over the trench. To reach a manhole, the operator wants to straddle the open trench with the tracks. 6.09(5)(c) prohibits this.
Under 230 CMR 6.09(1)(a), what must a boom crane's rating plate or load chart show?
Only the maximum capacity at the shortest radius
Safe loads for the maximum and minimum boom positions and at least two intermediate positions
Only the capacities for the boom length currently installed
A single capacity figure valid at all radii
Which statement about pile drivers is correct under 230 CMR 6.09(3)?
A jib may be attached if the hammer weighs less than 5,000 pounds
The hammer may be left raised in the leads during short breaks
Daily inspection may be done once a week if the rig is new
Pile drivers must not be used with a jib attached
Under 230 CMR 6.09(1)(h), what minimum safety factor applies to the design, construction and maintenance of crane parts and supports?
Not less than two
Not less than five
Not less than seven
Not less than ten
Sections you finish are checked off in the contents.