1. Tower Crane Accidents: Causes, Concerns, and Correct Procedures
Michigan Safety Conference
April 7, 2009
Tower Crane Accidents: Causes, Concerns, and Correct Procedures
Presented By: Jim Getting, Ph.D. Consultation Education & Training (CET) Division
Michigan Occupational Safety & Health Administration Michigan Department of Energy, Labor & Economic Growth
(517)

2. Michigan Safety Conference
April 7, 2009
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3. MIOSHA Training Institute Certification
Michigan Safety Conference
April 7, 2009
MIOSHA Training Institute Certification
What is it?
Through this certification you will begin the process of developing a safety and health management system while becoming familiar with MIOSHA Standards and other relevant topics.
Also refer to CET #0160.

4. MIOSHA Training Institute Certification
Michigan Safety Conference
April 7, 2009
MIOSHA Training Institute Certification
What are the benefits?
Conducted by credible MIOSHA consultants
CEUs, CSPs, Maintenance points
Validation of a set of knowledge
Standardized curriculum path
Increased recognition for employee & employer
Tracking of course completion
MIOSHA consultants teaching MIOSHA topics
Compared with others charging more and not as experienced with MIOSHA standards
Validation of an increased level of awareness of health and safety management systems and MIOSHA standards
Like a diploma
Provides a curriculum path for developing a set of knowledge related to safety and health
Like a college degree path
Increased recognition for proceeding through a standardized certification along with the industry specific CEUs
Similar to other certifications & degrees
Tracking of course completion through Macomb’s database

5. Michigan Safety Conference
April 7, 2009
Objectives
Analyze the scope and magnitude of the problem.
Summarize recent tower crane accidents.
Describe specific actions that can prevent tower crane accidents.

6. Michigan Safety Conference
April 7, 2009
Tower Cranes: Defined
Luffing Jib
Hammerhead

7. How many tower crane accidents?
Michigan Safety Conference
April 7, 2009
How many tower crane accidents?
Short Answer: Nobody knows exactly.
Web sites inconsistent, not comprehensive.
Industry sources are not comprehensive.
Bureau of Labor Statistics (BLS)
Census of Fatal Occupational Injuries (CFOI)
Commonly used and widely accepted.
Limitations.
Fatalities only.
Data sometimes incomplete, little accuracy checking.
McCann (2008) cites 632 crane related fatalities from 1992 – 2006.
First report from CPWR cited 323 crane related fatalities from 1992 – 2006*.
To determine number of tower crane accidents, I sought data from many sources:
Crane accidents.com seems to be spotty, at best in it’s reporting. Certainly misses many and seems to be losing steam.
Other crane web sites just have no consistent way of reporting.
BLS CFOI data aren’t the best bet. always 100% consistent and accurate – but it paints a broad picture.
Some is obviously wrong (Example: shows 4 fatalities, trade listed: 4 in precision production, 3 in construction (obviously there can’t be 7, so there is an error here). Also, some accidents may not be getting reported – check the 2007 list to be sure they are there.
* As reported in Greene, M.V. (Sept 2008) Many sided problem. Safety and Health Magazine. National Safety Council.

8. Michigan Safety Conference
April 7, 2009
BLS Classifications
Portal Crane
(portalcranes.com)
Two Groups May Apply:
Portal, tower, and pillar (grouping comes from ASME B30.4).
Hammerhead cranes.
Pillar crane (hoists.apluswhs.com)
All listed fatalities are in Portal, Tower, and Pillar. Zero in hammerhead.
Even using the BLS data, we can conclude that most of the fatalities are from tower cranes associated with construction – because most of the BLS data puts the worker in the construction trades. No fatalities were reported with Hammerhead cranes, which are erected permanently and used in shipyards and logging, etc.
Hammerhead Crane (freefoto.com)

9. Michigan Safety Conference
April 7, 2009
Tower Crane-Related Deaths in Construction by Year,
1992 – 2007 Bureau of Labor Statistics Census of Fatal Occupational Injuries
2008 data summarized from news sources

10. Crane-Related Deaths in Construction by Year, 1992-2006
Michigan Safety Conference
April 7, 2009
Crane-Related Deaths in Construction by Year,
McCann shows there is no trend up or down in crane related deaths.
Data summarized by: McCann (2008) Crane Related Deaths and Injuries in Construction. Center for Construction Research and Training.
Original Source: U.S. Bureau of Labor Statistics Census of Fatal Occupational Injuries Research File. 10

11. Michigan Safety Conference
April 7, 2009
Tower Crane Versus All Crane Deaths in Construction by Year,
What can we conclude from this? All crane deaths have stayed pretty constant. Tower crane fatalities have become fairly regular events. But, just not enough data or accurate enough data to really know.
1992 – 2007 Bureau of Labor Statistics Census of Fatal Occupational Injuries.
2008 data summarized from news sources.

12. Expected Frequency of Tower Crane Accidents and Fatalities
Michigan Safety Conference
April 7, 2009
Expected Frequency of Tower Crane Accidents and Fatalities
2.1% of cranes are tower cranes.
2000 tower cranes and cranes total*.
5% of crane accidents are tower cranes
(16 of 306)**.
42 crane related fatalities per year (average)**.
Expect .84 tower crane fatalities per year, if accidents were proportional.
Actual for = 34 fatalities or 2.83 per year.
This slide looks at 2 things: how many tower crane accidents occur and how many fatalities associated with tower cranes occur. It is compared to how many we would predict, based upon the number of tower cranes versus cranes. Results indicate that tower cranes are at least twice as likely to be involved in a fatal accident.
Figure of 2000 tower cranes and cranes supplied in OSHA press release about the new crane standard, no source given. These numbers are verified by industry figures in Cranes Today magazine.
The vast majority of crane accidents that result in fatality are single fatality incidents. Very few multiple fatality incidents.
OSHA press release (2008)
McCann (2008)

13. Is it just recently that tower cranes have started having accidents?
No.
Crane type has changed:
internal vs external to the structure.
Far more tower cranes in use.
There appears to be an increasing incident rate.

14. What Does It All Mean?
Increased rate has been happening for years, but barely noticed.
Still very infrequent compared to:
5 fatal falls in Michigan in 2008.
3 electrocutions in Michigan in 2008.
Crane accidents in general.
Digital cameras, 24 hour news:
Sometimes cause us to over-estimate dangers.
In this case, it made us more aware of an important problem!

15. Recent Tower Crane Accidents
Michigan Safety Conference
April 7, 2009
Recent Tower Crane Accidents
New York, (3/15/2008), 7 dead.
Rigging failed, collar dropped, crane fell.
Miami, FL, (3/25/2008), 2 dead, 5 injured.
Dropped section of crane while “jumping” crane
New York, NY, (5/30/2008), 2 dead.
Weld on turntable fails, jib and cab fall.
New York, NY, (9/4/2008), 1 dead.
Guardrail removed. Erector falls.
Annapolis, MD, (4/30/2008), 1 dead.
Crushed between boom sections while disassembling.
Bellevue, WA, (11/16/2006), 1 dead.
Inadequate base. Collapse onto apartment.
5/30/08 – weld on turntable had been repaired in past. Crane was a Kodiak, which had not been manufactured since 1982, so it was an old crane. Crane had been shut down a couple times when it was first erected due to problems. Calls into question the use of old equipment by some. How old before we refuse to use?

16. Review of accidents: Bellevue, Washington, 11/16/2006
Michigan Safety Conference
April 7, 2009
Review of accidents: Bellevue, Washington, 11/16/2006
Crane severed 15’ from base.
No load on crane.
Landed on 3 buildings.
One bystander killed.
Minor injuries to operator.
Operator drug use?
Excessive leaning? 3 feet.
Proper weathervane prior to incident? 80 mph winds.
Crane was 210 high.
Operator was in the cab, shutting crane down for the night. As he slewed into position to leave it for the night, it just tipped.
Operator had history of drug abuse: multiple conviction for methamphetamine. Passed a post accident drug test. Life turned into a living hell after the accident – reporters at door, constant phone calls, people blaming him in the news.
Crane appeared to be leaning – many photos were reviewed after, showed nearly 3’ of lean. Normally, lean occurs approx. 1” per 40’. Question rises about the base of the crane twisting or bolts being loose prior to the incident. This could account for abnormally amount of lean, result in massive stress to the tower of the crane, and result in the tower simply failing.
Questions about whether the crane was allowed to properly weathervane were asked. They had nearly 80 mph winds
Photo courtesy: Andrea James and John Iwasaki (Nov 17, 2006) Seattle Post Intelligence

17. Bellevue, Washington, 11/16/2006
Michigan Safety Conference
April 7, 2009
Bellevue, Washington, 11/16/2006
Source: Andrea James and John Iwasaki (Nov 17, 2006) Seattle Post Intelligence
Article: Operator in crane wreck has history of drug abuse No other victims found; state orders inspections of similar equipment

18. Bellevue, Washington, 11/16/2006
Michigan Safety Conference
April 7, 2009
Bellevue, Washington, 11/16/2006
Citations:
$5,600 – Magnusson Klemencic Associates – Engineering firm that designed the foundation.
The base did not meet manufacturer requirements.
$9,200 – Lease Crutcher Lewis – The general contractor.
Not ensuring the crane was maintained and used properly.
Not inspecting the tower.
Hanging two large banners on it that could affect the crane's operations.

19. Michigan Safety Conference
April 7, 2009
12/1/2006 Near Miss
Another Bellevue, Washington.
Cracks in the tower.
Cause: Water collected inside. Weepholes were clogged. Water froze and burst the steel.
Source: Scott Eklund (Dec 1, 2006) Seattle Post Intelligence
Notice that these workers are about 15’ off the ground. About the same height as where the other crane failed when it collapsed. Coincidence?
I still don’t believe the water freezing and bursting the welds story. This demonstrates a lack of inspections and a lack of general maintenance.
Photo courtesy: Scott Eklund (Dec 1, 2006) Seattle Post Intelligence

20. Michigan Safety Conference
April 7, 2009
12/1/2006 Near Miss
Duct Tape???
Note: same company erected this one as the crane that fell in Bellevue.
Note – 2 other cranes were found to have 2’ long hairline cracks in the next week in the same city.
The fact that 3 cranes were found to have massive cracks suggests a pervasive problem with use of the cranes, maintenance of the cranes, and inspection of the cranes.
Photo courtesy: Scott Eklund (Dec 1, 2006) Seattle Post Intelligence

21. Review of Accidents New York: March 15, 2008
Michigan Safety Conference
April 7, 2009
Review of Accidents New York: March 15, 2008
Illustration courtesy New York Times.

22. Michigan Safety Conference
April 7, 2009
New York: March 15, 2008
Seven Fatalities.
Rigger offered FOUR new slings by construction manager.
No inspection of slings.
Used FOUR slings. Manufacturer said use EIGHT.
Did not use softeners.
Photo courtesy: New York Times

23. Michigan Safety Conference
April 7, 2009
New York: March 15, 2008
Photo courtesy: New York Times

24. The Red Flag That Got Overlooked New York: December 15, 2007
Michigan Safety Conference
April 7, 2009
The Red Flag That Got Overlooked New York: December 15, 2007
Here is the story that NOBODY is talking about. Sling failure 3 months prior while lifting a load of metal studs. Lifting 14K with a 19K sling should not have caused a failure, so it was either sharp edges or a bad sling. This is the warning sign that got missed.
Load dropped. One worker injured.
Lifting over construction office trailers.
Sling failure – 14K load with a 19K nylon sling.
Photo courtesy: Jin Lee (Dec 14, 2007) New York Times

25. Review of Accidents Miami: March 25, 2008
Michigan Safety Conference
April 7, 2009
Review of Accidents Miami: March 25, 2008
Two Fatalities.
Dropped section of mast while “jumping” crane.
Crashed through house being used for storage.
One deceased was insurance safety inspector.

26. Review of Accidents New York: May 30, 2008
Michigan Safety Conference
April 7, 2009
Review of Accidents New York: May 30, 2008
Two Fatalities.
Failure of a repair weld on turntable.
Jib and cab fall.
Crane was a Kodiak, 1982 or older.
Photo courtesy Associated Press, Dima Gavrysh

27. Canada Tower Crane Accident Review
Michigan Safety Conference
April 7, 2009
Canada Tower Crane Accident Review
Includes: Near Miss, Property Damage, Injury, and Fatality Accidents
Year Number of Incidents
2008** 19
Total 72
These did not all result in fatalities, or even in injuries for that matter. This data gives us a much better picture of the “near misses”, and minor incidents. From this we can surmise what types of things to work on to prevent fatalities and injuries from working with tower cranes.
* WorksafeBC.com
** Through September of 2008

28. Canada Tower Crane Accident Type
Michigan Safety Conference
April 7, 2009
Canada Tower Crane Accident Type
What do we learn? Experts keep telling me that most of the accidents happen during assembly/disassembly. I agree that this is a critical time. Particularly because assembly/disassembly accidents are often of a massive and catastrophic nature. However, these other events are occurring that can also be fatal, if not catastrophic. From this we can come up with solutions that will truly prevent these problems. For example, dropped loads requires better trained and better supervised riggers, more stringent rules about what rigging will be used, more stringent rules about operating over pedestrians, roads, etc.
* WorksafeBC.com

29. What Do We Learn: The 331 Rule Applies
Michigan Safety Conference
April 7, 2009
What Do We Learn: The 331 Rule Applies
Fatal/Catastrophic
Injury/Property Damage
Near Misses
Main Points:
1. There are usually some warnings that a serious accident or fatality may occur. For every fatal tower crane accident, there are many smaller accidents that should act as warnings that something needs to be changed. There are also many more near misses that could be used to identify problems and fix them before any accidents occur.
Example you may use: You drive through a bad intersection every day where you see cars almost crash. A couple times, you’ve seen fender benders. You say to yourself “somebody is going to get killed here some day”. Eventually, a bad accident occurs and somebody is killed. Think about your job sites the same way.
2. The fatal tower crane accidents are just the tip of the ice berg. We are not operating perfectly, except for these few incidents. The Canada data shows many near misses and minor accidents. The US incidents showed that many other problems existed with nearby cranes.
The triangle was developed as 1. “serious accidents and fatals” 2. “minor accidents” and 3. “near misses”.
It has been stated that for every 1 serious accident or fatal that there were 30 minor accidents and 300 near misses.
We might note that these numbers are not definite, but vary from situation to situation.

30. What Do We Learn? Causes of Accidents
Lack of sufficient crane inspections.
Improper repairs.
Failure to follow manfacturers’ procedures.
Operators, riggers, erectors, crane owners, general contractors.
Failure to follow OSHA/MIOSHA rules.
Human error.
Miscalculation.
Forgetting.
Misunderstanding, miscommunication
Failure to act:
If something looks wrong, DO SOMETHING about it!

31. Michigan Safety Conference
April 7, 2009
So is it Over-hyped?
NO!!!!
Accident severity warrants the attention.
Many non-fatal accidents.
Increased use in the future.
Changing nature of use:
self erecting.
World market: use some places is scary!
Photo from Dubai
Picture is from Dubai. They must collide cranes with one another all the time

32. Michigan Safety Conference
April 7, 2009
What Can I Do to Help?
General Contractors
Know the crane inside and out.
Read the manual.
Meet with the owner, erector, operator.
Learn history of the crane.
Age.
Repairs/modifications/replacement/damage.
Strengths/weaknesses with crane model.
Where/how it has been used.
Previous inspection history.
Third party inspections before erecting.
Qualified erectors.
Story told by one General Contractor in Michigan. When setting up crane, he got 3 different specs for torque on bolts holding sections together – one from erector, one from from the crane owner, and one from the crane manual. Manual turned out to be correct. If GC hadn’t checked, it would not have been erected correctly
Story told by a GC. Before erecting crane, they had an independent 3rd party inspection. As the GC reviewed the inspection, he noticed “inspected all 12 sections of crane mast”. The GC went out and counted – there were 13. This called into question the entire inspection. GC ordered another inspection, by a different inspector, who found several serious problems (none were likely critical) that had been missed by the first inspector.

33. Michigan Safety Conference
April 7, 2009
What Can I Do to Help?
General Contractors
Operator certification and more.
Don’t push the schedule.
Process in place to verify correct procedures at every step.
Widen public barriers.
Watch for the near misses.
Operator certification and more:
Give the operator time onsite when the crane arrives – to learn the site, to see the crane on the ground, to work with the third-party inspector, to get to know the subs onsite, to get to know the GC site safety person and project superintendent.
Give the operator absolute authority to stop
Don’t push the schedule: rushing always causes accidents
Verify correct procedures: If somebody makes a mistake, who is going to catch it? GC has to have somebody who is double-checking everything.
Widen public barriers: Both in space and time. Critical lifts, jumping crane may occur on a weekend when little public is around. Widen physical barriers to give the operator more room to lift and lessen likelihood of a lift ending up accidentally over pedestrians. Further, in event of a catastrophe, wider barriers mean fewer public probably around.
Near misses: the 331 rule

34. Subcontractors on site:
What Can I Do to Help?
Subcontractors on site:
Know crane limits.
Stay on schedule – when plans change accidents happen.
Plan ahead – need to give operator and riggers advance information.
Keep job-site orderly – less visual distraction.
Observe “no lifting over” rules.
Report near misses.

35. Michigan Safety Conference
April 7, 2009
What Can I Do to Help?
Everybody:
Stay out from under loads.
No rigging or landing loads unless trained.
Be an inspector: keep an eye on the crane.
Report near misses, even the little things.
Help the operator, rigger, erector:
Remember they are humans who;
WILL make mistakes – forgets, misunderstands.
Get tired, frustrated, distracted.
Do not distract, interrupt their routines.
State things twice, have them repeat it back.
Keep site clean, orderly.
Keep job on schedule.
Story told by a person in the tower crane business in Michigan – Electrician was working near base of the crane – he noticed the base could lift in one corner, that the anchor bolt was not tight. They checked the bolts, and two had come loose. This could have been critical
Things that cause mistakes: changing the plan. Working too many hours. Too much going on at once (many people talking, visual clutter). Rushing. Not following procedure – taking a slight shortcut (must be a routine). Any interruption – stop and remind where you left off. Miscommunication – follow through on things, state things twice, repeat it back what they say.

36. Sources of Additional Info
ANSI Standard B30.3 – 1996 Construction Tower Cranes
Tower Crane Management: Avoiding Problems Through Proper Selection, Erection, Testing, Maintenance, Operation, and Dismantling (1985) D. E. Dickie; Construction Safety Association of Ontario.
- Listing of tower crane accidents world wide.
- Listing of many crane accidents.
- Proposed new OSHA rule: Cranes and Derricks in Construction.
- Lift and Crane Magazine.
- Research articles on safety, including McCann (2008) Crane Related Deaths and Injuries in Construction. Center for Construction Research and Training.

37. Thank You for Attending
Michigan Safety Conference
April 7, 2009
Thank You for Attending
Michigan Occupational Safety & Health Administration
Consultation Education & Training Division
7150 Harris Drive, P.O. Box 30643
Lansing, Michigan
To request consultation, education
and training services, call (517) or