ONE  VOICE

I have worked in multiple aspects of construction and civil engineering over the last two decades, regardless of the construction method and type of crane hand signalling and radio issues especially at full radius or on the blind continue to cause issues.

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The UK is an extremely diverse country and one of the challenges I face as a crane coordinator/ lift supervisor are the variation of hand signals and radio commands across different nationalities. HandCOMM’s a.i machine learning is the only product that I am aware of that completely mitigates both issues that I face on a day-to-day basis at work.

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The “thinking” is taken out of the equation with regards to translation, HandCOMM’s third eye helmet based camera gives the operator a 4K high-res view of everything the slinger is looking at and the magic glove sends an audible command to the operator’s cab in real time regardless of your nationality, native tongue, visual barriers, concrete walls, there is just no limit to what the Signalman Communication Assist System (SCAS) can do!
 

At time of writing I have 16 years of experience within the heavy lifting  industry, spanning roles from a slinger/ rigger to operator, supervisor, and currently an appointed person.

 

Throughout my career, particularly in crane operations, I've encountered several issues with  crane radios during lifting operations. For instance, while working on a contract during a job in Edinburgh, we experienced cross-talk from another site. This resulted in receiving instructions to hoist up that were not intended for my team. The ground team's location meant they didn't hear these instructions. Due to the associated risks, it took two days of recording all sounds in the cab to identify the erroneous commands. Eventually, we changed all the frequencies. Interestingly, we were picking up transmissions from a local gym, which, while not as severe, still posed a risk of blocking our communications on site.

 

Another significant issue occurred next to the central station in Glasgow, where we experienced loud interference resembling an untuned radio, disrupting our channel for 10 to 20 seconds at a time. This halted all crane activities until the interference ceased. It took six weeks to identify the source of the interference: electric trains pulling into the station. Knowing this, we switched to an older analogue system, which resolved the issue.

 

Moreover, on numerous jobs, miscommunication has been a persistent problem. In London, a repeater system was necessary to facilitate communication between slingers at the front and back of a building. Until the repeater stations were installed, I had to relay messages, highlighting the importance of direct communication.

 

Instances where loads were abruptly landed due to missed stop commands, often caused by signal degradation near building lines, have underscored the challenges of maintaining clear communication.

 

These experiences highlight the critical nature of reliable communication systems in crane operations and the need for continuous adaptation and improvement to ensure safety and efficiency.

In our operational endeavours, we have encountered a multitude of instances where our crane operators encounter a significant communication barrier with our signalmen due to the absence of a direct line of sight.

 

This challenge is particularly pronounced within our underground project, where a substantial number of crane picks become visually obstructed once the load is transferred into the shaft. To effectively address this issue, we have implemented a well-defined hoisting procedure that relies on the utilization of two signalers. The first signaler, known as the top lander, is positioned on the surface, while the second signaler, referred to as the bottom lander, is stationed at the bottom of the shaft.

 

The successful execution of this procedure hinges upon the establishment of efficient radio communication between the landers and the crane operators. It is noteworthy that accessing the bottom of the shaft is strictly confined to the utilization of personnel baskets suspended from the crane.

 

This restriction amplifies the potential consequences of any malfunctions or deficiencies in the radio communication system during these blind operations.

 

While we have been fortunate thus far in avoiding any injuries, it is imperative to acknowledge the substantial risks associated with these events. I am able to provide you with several examples that emphasize the critical nature of this communication challenge. It is essential that we remain vigilant and proactive in mitigating potential risks to ensure the continued safety of our personnel and equipment.

It is well-known that communication barriers between signalmen and crane operators can lead to accidents and operational inefficiencies. Some incidents may include misinterpretation of hand signals, delays in relaying signals, or misunderstandings due to limited visibility or external factors.

 

These may include:

- Limited visibility: When the signalman is not within the line of sight of the crane operator, it becomes difficult to convey hand signals accurately.

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- Environmental factors: Noise interference from machinery, poor weather conditions, or crowded work areas can hinder effective communication between the signalman and the crane operator.

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- Language barriers: In multicultural work environments, language differences can impede clear communication between signalmen and crane operators.

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- Distractions: The presence of multiple signalmen or other activities happening on the worksite can create distractions that affect the communication process.

Addressing these communication issues through AI-based solutions, such as the prototype you mentioned, has the potential to enhance safety and efficiency in crane operations.

I would like to bring your attention to a significant challenge we encounter in the project I am currently involved in. Specifically, during the summer months, we often experience dense fog conditions in the mornings.

 

This poses a considerable hindrance to our operations, as they are either carried out with diminished efficiency and speed or are halted entirely.

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Considering the circumstances described above, I believe that the proposed prototype you recommended would prove instrumental in resolving this issue. By implementing the suggested kit or solution, we would be able to ensure the uninterrupted progress of our lifts even in the presence of heavy fog.

 

This would enable us to maintain optimal functionality and efficiency throughout our operations, thereby avoiding potential delays and disruptions.

In the capacity of lift supervisor, a notable operational challenge associated with radio communication systems lies in the manual activation of the microphone using one's hand.

 

Particularly during rigging setup or fieldwork scenarios, the necessity to interrupt ongoing tasks, activate the microphone to relay commands to the operator, and subsequently return to the initial activities poses a considerable inconvenience.

The envisaged improvement involves establishing a system or methodology that allows seamless communication with the operator while concurrently engaging in other operational tasks. This enhancement would optimize time utilization and contribute to the uninterrupted flow of activities during lift operations.
 

When confronted with the task of executing a lift in circumstances where two different levels or a physical obstruction such as a building hinder direct visual communication, the adoption of a blind lift strategy involving two signalmen becomes a customary practice.

 

This particular approach has been routinely employed in similar scenarios to facilitate successful lifting operations. The implementation of a blind lift involving two signalmen serves as a practical solution to address the absence of direct visibility between the crane operator and the load.

 

By assigning two skilled signalmen to the task, effective communication channels are established, compensating for the lack of visual contact. Consequently, crucial instructions and commands can be relayed to the crane operator accurately, enabling precise crane movements and ensuring the overall safety of the lift.

 

Nonetheless, it is essential to acknowledge that the reliance on indirect signalling methods in a blind lift scenario introduces a notable delay in the transmission of signals. As a result, this delay may present challenges that warrant meticulous coordination between the signalmen and other personnel involved in the operation

Incident Case Study: 

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During operations at the K+S Potash mine (Canada), while collaborating with the site crane, an incident occurred when the crane operator was in the process of lowering the hook inside a building to attach rigging.

 

Unfortunately, the operator did not receive the signal to stop lowering the hook, resulting in the hook making contact with the ground and causing the hoisting rope on the hoist drum to become loose.

 

This incident stemmed from a failure in radio communication, where the necessary signal to halt the lowering process was not effectively conveyed to the operator.

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Importance of Visible Signals for Crane Operations:

It is crucial for crane operations that the operator has a clear line of sight to the signals being provided. In situations where the operator's visibility is hindered, such as when the signal person must position themselves at a distance from the load, potential risks may arise.

 

The distance between the signal person and the load being lifted may impede the operator's ability to accurately interpret the signals, potentially leading to oversights that would have been visible had the signal person been in closer proximity. This highlights the significance of maintaining proper visibility between the signal person and the crane operator during lifting operations.

Over the past two decades, my professional engagement has primarily centred around the lifting industry in central London.

 

Throughout this period, notable advancements have been witnessed, encompassing improved lift plans, evolving legislation, proactive control measures by the Health, Safety & Environment (HSE), the implementation of two-way communication systems, and the integration of block-mounted high-resolution cameras with built-in audio capabilities.

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Despite these advancements, incidents leading to injuries and fatalities persist, primarily attributed to ineffective communication between slingers and crane operators, especially during "blind lift" operations in the U.K. construction sector.

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Pursuing safety in construction demands continual improvement, and HandCOMM's (SCAS) system represents an integral component of this ongoing evolution. Introducing AI learning software to assist lifting operations marks a transformative step within the global industry. I welcome any process or product contributing to narrowing the gap in serious injuries or fatalities in construction.

Effective communication between the signalman and the crane operator holds significant importance, particularly during the erection of a vertical column within a building.

 

The Urea plant, being a multistorey structure housing various vessels, exchangers, and columns, presents unique challenges during lifting operations, especially in the case of precast buildings where the structure is already in place, impeding the ease of lifting activities.

 

To address this issue, a carefully devised strategy was implemented, involving the deployment of two signalmen. One signalman was positioned at a lower level to closely monitor the precise positioning of the column during insertion, providing hand signals to the signalman stationed at the top of the structure.

 

The signalman at the top was strategically placed to maintain visibility for the crane operator. The complexity of this lift, coupled with the necessity for meticulous coordination, resulted in the operation spanning an entire day to ensure utmost caution and accuracy.

 

It is important to note that this particular lifting activity carried a high level of criticality due to the intricacies involved. The aforementioned scenario exemplifies the vital role of effective communication and clear visibility between the signalman, crane operator, and the overall lifting team. Such measures are paramount in executing safe and successful lifting operations within complex environments like the Urea plant

During the lifting operation involving two vessels, namely PK-01 and PK-02, we encountered a challenging scenario where the signalman was unable to maintain direct visual contact with the crane operator.

 

The primary cause for this hindrance was the elevated foundation height, which was situated within an already constructed structure. In order to overcome this situation, we implemented a strategy involving two signalmen to fulfil the duty effectively.

 

One signalman positioned themselves in close proximity to the final set location, while the other stood on the edge of the structure, providing hand signals to guide the crane operator. Typically, a similar lifting operation would require approximately half a day to complete.

 

However, due to the intricacy of the lift and the slow coordination between the signalmen and the crane operator, the operation extended over the course of an entire day. Each crane signal was meticulously executed with caution and precision, ensuring the prevention of any untoward incidents.

 

It is worth noting that the challenge at hand could have been resolved by assigning a single signalman to oversee the entire lifting operation. Regrettably, this was not a feasible option due to the crane operator's restricted visibility.

 

The complexities encountered during this particular lift underscore the significance of optimizing communication and coordination between signalmen and crane operators.

During an underground pipe lifting operation, the employment of four signalmen was necessary. However, the completion of the task was significantly delayed due to communication gaps that arose during the process.

 

The signalmen relied on cell phones as a means of communication amongst themselves. One signalman had to assume a leadership role to provide the necessary signals to the crane operator.

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In another instance, when employing two mobile cranes to transport an oversized load, a hazardous situation arose on the construction site. This occurred when one of the crane operators lost sight of the signalman while the load was in a vertical position.

 

Such a circumstance had the potential to lead to accidents. Fortunately, prompt action was taken to rectify the situation and mitigate the associated risks.

Another challenge encountered during operations involves the comprehension of hand signals by a crane operator when the signalman is positioned at a considerable distance.

 

The remote positioning of the signalman from the crane operator makes it difficult for the latter to accurately interpret the hand signals. Consequently, the crane operator must perceive the signals, comprehend their intended meaning, and then execute the corresponding actions. This process introduces delays in the crane operation.

During the installation process of a reactor weighing over one thousand tons, characterized by a height of 60 meters and a diameter of 12 meters, and secured by 64 anchor rods, meticulous attention to every millimetre was imperative.

 

The signalman assumed a critical role in guiding the crane operator with precision to ensure the successful erection or installation of the reactor. The complexity arose from the time-sensitive nature of communication, as the signalman issued multiple commands within a five-second interval, a duration that exceeded the crane operator's capacity to respond promptly.

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Similar challenges were encountered in installing a flare system, with an overall height of 120 meters, demanding precise positioning of each stack high above the ground. This precision became paramount to guarantee the effective functioning of the entire system.

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The intricacies of lifting and rigging operations extended to wind farms, where the same level of precision was essential for successfully deploying equipment and structures. In these scenarios, factors such as wind conditions and equipment specifications further amplified the need for meticulous planning and execution to ensure the safety and accuracy of the lifting and rigging operations.

I am a professional slinger, crane supervisor, and appointed person based in the UK, accumulating over 15 years of extensive experience in the heavy-lifting industry.

 

In May 2023, I oversaw a lifting operation involving the placement of pre-cast concrete stairs into a high-rise core, collaborating with the lifting team.

 

It was considered the best option despite historical issues with 2-way radio communication. Problems such as garbled messages, signal loss during transmission, and wet microphones in inclement weather were recurring issues.

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During this particular lift, I was positioned on the ground floor, awaiting the crane's guidance to lower the load through a confined space into its landing position. The slinger remained upstairs to assist the operator in navigating the stairs through the core opening. While descending, I instructed the operator to stop, adhering to the standard practice of allowing a 2-3 second pause before resuming operations upon receiving further commands.

 

However, the operator did not follow this safety protocol on this occasion. Despite repeated radio calls for an emergency stop, no action was taken.

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In a desperate attempt to avert a potential disaster, I shouted above the noisy site to get the slinger's attention. Only then could he hand signal the operator, having a clear line of sight from his vantage point.

 

This incident could potentially escalate into a severe safety hazard, and I categorize it as a safety-critical event. After the incident, my report highlighted the urgent need for a safer method to mitigate interference on 2-way radios.

During tower crane removals, we consistently deployed a minimum of three riggers for signaling purposes. Each floor necessitated the presence of a rigger as the crane sections had to pass through them. Our most effective approach was as follows:

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Utilizing the same channel for all floors as the load progressed, the next rigger above would continue signaling until the load cleared that particular floor. Subsequently, only one signaler remained. As an additional safety measure, we equipped each floor with a radio operating on a separate channel.

 

Furthermore, we installed one radio within the crane cabin specifically for emergencies. In the event that a stop signal was not received due to signal interference, only this designated radio would communicate with the operator to halt operations.

 

We assigned a crane assistant outside of the crane, equipped with a radio to hear all signals and facilitate communication with the operator. For our 550-ton crane, we installed a camera on the boom tip to provide the operator with a view of the load. This proved to be highly beneficial. Having familiarized myself with the available information regarding the AI concept you mentioned, I must admit it evokes a sense of unease.

 

While such a camera robot may serve its purpose for routine, repetitive tasks, I would be hesitant to rely on a device with a reported accuracy rate of 93% during complex heavy lifts.

 

However, if it were possible, I would consider implementing a camera attached to the signalman's helmet, with the feed displayed exclusively in the crane cabin for the operator's visual reference.

In general, crane lifts can be facilitated through the use of hand signals, provided there is an unobstructed line of sight between the Signalman and the Crane Operator.

 

However, there are exceptional cases in which hand signals become necessary. One such instance occurred during a project at the life plant (Brownfield), where the use of walkie-talkies was prohibited due to violations of the Plant's rules and regulations.

 

Compliance with military department registration requirements was mandatory for walkie-talkie usage. As an alternative, the Plant Owner offered the use of their operators' radios. Unfortunately, these radios experienced reception issues and signal delays due to the transmissions being routed through the local service provider's network instead of direct communication with the receiver.

 

Consequently, our only viable option was to proceed with the lift utilizing a combination of radios and hand signals. However, it is essential to ensure that there are no visual obstructions impeding the line of sight between the Crane Operator and the signalmen.

 

The challenges faced in this scenario highlight the critical importance of clear communication and unhindered visibility between the Signalman and the Crane Operator during crane lifts. The reliance on effective radio signals and unobstructed visual contact is paramount in ensuring safe and efficient operations.

As a subcontractor in the UK's heavy lifting industry, I have contributed to many Tier 1 multi-crane projects, I have encountered numerous "blind lift" incidents despite robust control measures and the appropriate safety equipment in place.

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Even in Tier 1 projects, where two-way communications are generally mandated, these protocols including block mounted cameras which have also been in use, have failed in one area or another during every blind lift incident that I have witnessed.

Working in diverse locations, from central London to nuclear installations and military bases across the UK, I have experienced disruptions in two-way radio transmissions due to military signal jamming technologies, channel interference from local services and mobile phone cell tower microwave energies in built-up areas all of which can clash with communication equipment during lifting operations.