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33. Safety of cranes, etc
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Cranes installed in factories, mobile cranes, etc. used for various cargo handling, and gondolas, are used in many working sites for productivity improvement, etc., and there are dangers involved in handling heavy objects, or in the possibility of falling, etc. In addition, with the upsizing, speed-up, etc. of machines, damage may be greater, and labor accidents may occur more frequently. So, the Industrial Safety and Health Law and the Ordinances concerned stipulate many requirements to be satisfied by employers in order to ensure the safety of the machines themselves and the safety of the working conditions during the stages from manufacture to usage. |
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In recent years, in view of the international situation, etc., some regulations have eased. (The Industrial Safety and Health Law, Safety Ordinance for Cranes, etc., and the Safety Ordinance for Gondolas) |
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1. Permission for manufacture, national inspection, etc.
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| a. |
Permission for manufacture (Law, Article 37; Enforcement Order of Industrial
Safety and Health Law, Article 12; Crane Ordinance, Articles 3, 53, 94,
138 and 172; Gondola Ordinance, Article 2)
| (a) |
Cranes, etc. requiring permission
The manufacture of the following cranes, etc. is subject to advance permission
by the Director General of the Prefectural Labour Bureau concerned.
| • |
Cranes with a maximum lifting load of 3 tons or more (1 ton or more in
the case of a stacker type crane) |
| • |
Mobile cranes with a maximum lifting load of 3 tons or more |
| • |
Derricks with a maximum lifting load of 12 tons or more |
| • |
Elevators with a carrying capacity of 1 ton or more |
| • |
Lifts for construction work with a guide rail height of 18 meters or more
(excluding a lift with a carrying capacity of less than 0.25 ton) |
| • |
Gondolas |
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| (b) |
Units considered for permission
The types of cranes, etc. as units considered for permission are as follows:
(Overhead traveling cranes)
| • |
Overhead traveling cranes: six types, including hoist-type overhead traveling
cranes |
| • |
Jib cranes: ten types, including tower jib cranes and portal jib cranes |
| • |
Portal Bridge cranes: five types, including portal bridge crane with hoist
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| • |
Unloaders: three types, including portal bridge crane-type unloaders |
| • |
Cable cranes: three types, including cable crane with fixed tower
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| • |
Telphers |
| • |
Stacker cranes: stacker-type stacker cranes and cargo-elevator type stacker
cranes |
(Mobile cranes)
| • |
Truck cranes: those with a telescopic jib or a non-telescopic jib |
| • |
Wheel cranes: those with a telescopic jib or a non-telescopic jib |
| • |
Crawler cranes: those with a telescopic jib or a non-telescopic jib |
| • |
Railway cranes: locomotive cranes, wrecking cranes, and beam-erection cranes |
| • |
Floating cranes: fixed floating cranes, boom-hoisting floating cranes,
and rotary floating cranes |
(Derricks)
| • |
Guy derricks |
| • |
Stiff-leg derrick |
| • |
Guard frame derricks |
| • |
Gin pole derricks |
(Elevators)
| • |
Regularly installed elevators: rope-type, hydraulic-type, and rack-type
elevators |
| • |
Construction elevators: five types, including rope-type construction elevators
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(Lifts for construction work)
| • |
Tower lifts
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| • |
Double-pole lifts |
| • |
Single-pole lifts |
| • |
Long-span lifts for construction work |
(Gondolas)
| • |
Arm-fixed types, arm-elevating types, suspension types, deck types, and
chair types |
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| (c) |
Documents necessary for application for permission
When an application is filed for permission to manufacture, the following
documents are necessary:
| • |
Basis of strength calculation
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| • |
Outline of the equipment for inspection of manufacturing processes
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| • |
Names and brief histories of the chief designer and the responsible person
for workmanship
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| (d) |
Outline of permission criteria (1972 Notification No. 76)
The permission criteria for manufacture is as follows:
| • |
The construction should conform to the Construction Code.
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| • |
The inspection equipment, the chief designer, and the responsible person for workmanship should satisfy specific requirements.
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| b. |
Inspection at the time of manufacture, etc.
| (a) |
Manufacturing inspection (Law, Article 38; Crane Ordinance, Articles 53
to 56; Gondola Ordinance, Article 4)
| • |
A mobile crane or gondola that has been manufactured with permission must
undergo a manufacturing inspection by the Director General of the Prefectural
Labour Bureau concerned. |
| • |
A mobile crane or gondola that has passed the manufacturing inspection
will be impressed, and a passing seal will be affixed to the specification.
Furthermore, an inspection certificate will be issued.
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|
| (b) |
Inspection at the time of import, and usage inspection (Law, Article 38; Crane Ordinance, Article 57; Gondola Ordinance, Article 6)
The following persons must undergo the usage inspection by the Director General of the Prefectural Labour Bureau concerned:
| • |
A person who has imported a mobile crane or gondola |
| • |
A person who is going to install and use a mobile crane that has not been
installed for 2 years or more (3 years as a result of deregulation if the
storage conditions are good) after undergoing the manufacturing inspection,
or a person who is going to install and use a mobile crane, the use of
which has been suspended |
| • |
A person who is going to install and use a gondola that has not been installed
for 2 years or more (3 years as a result of deregulation if the storage
conditions are good) after undergoing the manufacturing inspection, or
a person who is going to install and use a gondola, the use of which has
been suspended |
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|
| c. |
Inspection at the time of installation and usage
| (a) |
Installation notification and completion inspection (Law, Articles 38 and
88; Crane Ordinance, Articles 5 to 9, 11, 61, 96 to 98, 111, 140 to 143,
145, and 172 to 177; Gondola Ordinance, Article 10)
| • |
An employer who is going to install a crane, derrick, elevator, or lift
for construction work must submit an installation notification to the Chief
of the competent Labour Standards Inspection Office concerned, and undergo
a completion inspection.
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| • |
An employer who is going to install a mobile crane or gondola must submit
an installation report to the Chief of the competent Labour Standards Inspection
Office concerned, along with the specifications and the inspection certificate.
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| • |
For an apparatus that has passed the completion inspection, an inspection
certificate will be issued.
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| • |
An employer who is going to install any of the following apparatuses must
submit an inspection report to the Chief of the competent Labour Standards
Inspection Office concerned:
| : |
Cranes with a maximum lifting load of 0.5 ton to less than 3 tons (0.5
ton to less than 1 ton in the case of stacker cranes)
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| : |
Derricks with a maximum lifting capacity of 0.5 ton to less than 3 tons
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| : |
Elevators with a carrying capacity of 0.25 ton to less than 1 ton
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| : |
Light-capacity lifts
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| (b) |
Regular inspection (Law, Article 41; Crane Ordinance, Articles 40 to 43,
81 to 84, 125 to 128, and 159 to 162; Gondola Ordinance, Articles 24 to
27)
| • |
In the case where a crane, mobile crane, derrick, elevator, or gondola is used beyond the validity term of the inspection certificate, the apparatus must undergo a regular inspection by the Chief of the competent Labour Standards Inspection Office concerned or by an authorized agency for performance inspections.
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The validity terms and renewal terms of the respective apparatuses are listed below:
| Apparatus |
Validity term of inspection certificate |
Renewal term |
| Crane |
2 years (less than 2 years depending on the situation) |
2 years (less than 2 years, or more than 2 years to within 3 years depending
on the situation) |
| Mobile crane |
2 years (less than 2 years depending on the situation) |
2 years (less than 2 years, or more than 2 years to within 3 years depending
on the situation) |
| .Derrick |
2 years (less than 2 years depending on the situation) |
2 years (less than 2 years, or more than 2 years to within 3 years depending
on the situation) |
| Elevator |
1 year |
1 year (less than 1 year, or more than 1 year to within 2 years depending
on the situation) |
| Lift for construction work |
From installation to disuse |
|
| Gondola |
1 year |
1 year (less than 1 year depending on the situation) |
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| (c) |
Alteration inspection (Law, Articles 38 and 88; Crane Ordinance, Articles 44 to 47, 85 to 88, 129 to 132, 163 to 166, and 197 to 200; Gondola Ordinance, Articles 28 to 31)
| • |
When a structural portion, or similar part of a crane, mobile crane, derrick, elevator, lift for construction work, or gondola is going to be altered, an alteration notification must be submitted to the Chief of the competent Labour Standards Inspection Office concerned, and it must undergo an alteration inspection.
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| • |
For the structural portion, or similar part, that has passed inspection, the inspection certificate will be endorsed in the altered portion.
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| (d) |
Reuse inspection (Law, Article 38; Crane Ordinance, Articles 49 to 52,
90 to 92, 134 to 136, and 168 to 170; Gondola Ordinance, Articles 33 to
35)
| • |
When a crane, mobile crane, derrick, elevator, or gondola, the use of which
has been suspended, is going to be reused, it must undergo a reuse inspection
by the Chief of the competent Labour Standards Inspection Office concerned. |
| • |
For the apparatus that has passed inspection, the inspection certificate
will be endorsed with the inspection date and the inspection results. |
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2. Restriction of use (Law, Articles 37 and 40; Crane Ordinance, Articles
17, 23, 64, 69, 104, 109, 148, 150, 181, 184 and 205; Gondola Ordinance,
Articles 11 and 13)
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• |
Cranes, mobile cranes, derricks, elevators, lifts for construction work,
and gondolas cannot be used unless they conform to the Construction Codes
established by the Minister of Health, Labour and Welfare. |
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• |
Cranes, mobile cranes, and derricks cannot be used with a load in excess
of the rated capacity, and elevators, lifts for construction work, light-capacity
lifts, and gondolas cannot be used with a load in excess of the carrying
capability.
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• |
When a crane, etc. is transferred or lent, the inspection certificate must
be attached. |
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3. Limitation of job placement (Law, Articles 59 and 61; Crane Ordinance,
Articles 21, 22, 67, 68, 107, 108, 151, 183 and 206; Gondola Ordinance,
Article 12)
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Only persons having the following qualifications, etc. are allowed to operate
cranes, etc.:
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| Apparatus |
License |
Completion of skill-training course |
Special education |
|
Crane
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(with a maximum lifting capacity of 5 tons or more) |
 |
- |
- |
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| (with a maximum lifting capacity of less than 5 tons) |
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- |
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| Mobile crane |
(with a maximum lifting capacity of 5 tons or more) |
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- |
- |
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| (with a maximum lifting capacity of 1 ton to less than 5 tons) |
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- |
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| (with a maximum lifting capacity of less than 1 ton) |
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Derrick
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(with a maximum lifting capacity of 5 tons or more) |
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- |
- |
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| (with a maximum lifting capacity of less than 5 tons) |
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- |
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| Lift for construction work |
- |
- |
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| Gondola |
- |
- |
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Note
1: For an elevator, the operation method and actions to be taken when trouble
is encountered, should be made known to the operator.
2: For a light-capacity lift, signals should be established for operating
the lift.
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4. Periodical voluntary inspection (Law, Article 45; Crane Ordinance, Articles
34 to 39, 76 to 80, 119 to 124, 154 to 158, 192 to 196, and 208 to 212;
Gondola Ordinance, Articles 21 to 23)
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For cranes, etc., it is necessary to conduct periodic inspections at the
following cycles, and to inspect the overwinding preventive devices, brakes,
etc. before work is started. Furthermore, after an earthquake, strong winds,
etc., temporary inspection is necessary. The inspection records should
be preserved for three years, and defective portions of the equipment must
be repaired.
| Apparatus |
Every year |
Every month |
Before work is started |
After strong winds, earthquake, etc. |
| Crane |
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| Mobile crane |
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- |
| Derrick |
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| Elevator |
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| Lift for construction work |
- |
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| Light-capacity lift |
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- |
| Gondola |
- |
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| 5. Ensuring safety during work |
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a. |
Prevention for over-winding limit, etc. (Crane Ordinance, Articles 18,
19, 20, 65, 66, 105, 106, 149, 182 and 204)
| • |
It is necessary, for example, to sufficiently adjust the overwinding preventive
devices, alarms, and safety valves of cranes, mobile cranes, derricks,
or lifts for construction work, and the safety devices of elevators or
light-capacity lifts.
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b. |
Signals for operation (Crane Ordinance, Articles 25, 77, 111, 185 and 206;
Gondola Ordinance, Article 16)
| • |
When a crane, mobile crane, derrick, lift for construction work, light-capacity
lift, or gondola is used for operations, it is necessary to establish specific
signals and to appoint a person to give the signals for operations. (This
does not apply to work performed by one operator only.)
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c. |
Restruction on Riding (Crane Ordinance, Articles 26, 72, 73, 112, 186 and
207)
| • |
It is prohibited to carry or lift a worker using a crane, mobile crane
(excluding a case where this is inevitable for operations), derrick, lift
for construction work (excluding a case where this is inevitable for operations),
or light-capacity lift (excluding a case where this is inevitable for operations).
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d. |
Off limits (Crane Ordinance, Articles 28, 29, 74, 74-2, 114 and 187; Gondola
Ordinance, Article 18)
| • |
In the case where a crane, mobile crane, derrick, lift for construction work, or gondola is used for operations, it is prohibited to allow a worker to stand under lifted cargo.
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e. |
Appointment of a work leader for assembling (Crane Ordinance, Articles
33, 75-2, 118, 153 and 191)
| • |
For assembling or disassembling a crane, derrick, or lift for construction
work, for assembling or disassembling the jib of a mobile crane, or for
assembling or disassembling the step, etc. of an elevator, it is necessary
to appoint a work leader for operations.
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f. |
Prohibition of operations, etc. (Crane Ordinance, Articles 30-2, 31, 31-2,
74-3, 74-4, 116, 116-2 and 152; Gondola Ordinance, Article 19)
| • |
For a crane, when a girder, or similar apparatus, is inspected or repaired
and, for example, when strong winds blow, operations are prohibited.
Furthermore, for an outdoor crane, it is necessary during storms to take
preventive measures against the possibility of overturn.
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| • |
For a mobile crane or derrick, for example, when strong winds blow, operations
are prohibited. Furthermore, it is necessary during storms to take preventive
measures against the possibility of overturn.
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| • |
For an elevator installed outdoors, it is necessary during storms to take
preventive measures against the possibility of equipment collapsing. |
| • |
For a lift for construction work, it is necessary during storms to take
preventive measures against the possibility of equipment collapsing. |
| • |
The operation of a gondola during bad weather is prohibited. |
|
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g. |
Use of safety latches (Crane Ordinance, Articles 20-2 and 66-3)
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For a crane or mobile crane, it is necessary to use a safety latch to prevent
the unhooking of a wire rope for slinging work, etc. |
|
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| 6. Safety for slinging work |
|
a. |
Safety factor of wire rope for slinging work, etc. (Crane Ordinance, Articles
213 and 214)
| The safety factor of wire rope for slinging work by a crane, mobile crane,
or derrick must be 6 or greater, and the safety factor of a hook or shackle
must be 5 or greater. Otherwise, its use is prohibited. |
|
|
b. |
Prohibition of the use of inadequate wire rope (Crane Ordinance, Article 215)
| It is prohibited to use the following wire ropes for slinging work by a
crane, etc. |
| • |
Wire rope having 10% or more strands broken per one lay length
|
| • |
Wire rope, the diameter of which has decreased by more than 7% of the nominal
diameter |
| • |
Kinked wire rope |
| • |
Remarkably deformed or corroded wire rope |
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c. |
Limitations of job placement (Crane Ordinance, Articles 221 and 222)
| • |
It is prohibited that any person other than a person who has completed
the skill-training course on slinging work, or any person other than a
person authorized as being equal or superior to said person, engage in
the slinging work by a crane, etc. with a maximum lifting capacity of 1
ton or more.
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| • |
Employers must specially educate, in advance, the workers engaged in the
slinging work by a crane, etc. with a maximum lifting capacity of less
than 1 ton. |
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(The next article in this series covers the examination of machines and
other equipment.) |
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