E&PM SABIC CONSTRUCTION CRANE COMMITTEE SCCC
E&PM SABIC CONSTRUCTION CRANE PROCEDURE
Signature Approved by
General Manager Engineering
Reviewed by
Projects Manager
Developed by
EPM Support Safety Section
Date
This document is issued by SABIC E&PM, Jubail Industrial City, Kingdom of Saudi Arabia. The information contained in this document is the confidential property of SABIC. It cannot be disclosed, copied or used for any purpose without approval from SABIC. If you are not authorized to posses this document, please destroy it immediately.
SABIC Engineering and Project Management
Standard #
SABIC EPM Construction Crane Procedure
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Index Index .................................................................................................. 2 Preface................................................................................................ 4 Summary ............................................................................................ 5 Lifting Principles ................................................................................... 5 Center of Gravity .................................................................................. 5 Leverage ............................................................................................. 6 Stability .............................................................................................. 6 Structural Integrity ............................................................................... 7 2.
Definitions ................................................................................ 8
3.
General Lifting Requirements ..................................................... 12
4.
Crane Operator Certification ...................................................... 18
5.
Rigger Certification ...................................................................19
6.
Cranes Lifting Requirements ...................................................... 20
7.
Planning for Critical Lift ............................................................. 24
8.
Critical Lifting Plan ....................................................................25
9.
Inspection Testing and Operating of Crane/Lifting Equipment. ....... 25
10.
General Inspection and Testing Requirements .............................. 29
11.
Crane Setup ............................................................................30
12.
Starting The Periodic Inspection ................................................. 31
Crane Operator Daily Inspection Checklist .............................................. 53 Standard Hand SignalsCritical Lifting Plan ............................................... 56
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Critical Lifting Plan ...............................................................................57 Critical Lifting Plan Matrix .....................................................................59 Periodic / Initial Inspection Check List for Mobile and Crawler Cranes ......... 60 Periodic / Initial Inspection Check List for Tower Cranes ........................... 67 Crane Suspended Man Basket Permit ..................................................... 73 Sling Inspection Log ............................................................................75 Sample of Equipment Inspection and Test Certification............................. 76
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Preface The purpose of the Sabic Construction Crane Standards is to prevent injury and uniform the cranes criteria’s for the equipment and crane activates at SABIC EPM Projects. This is the first edition of the SABIC Construction Crane Standards. The construction site functions in a dynamically changing work environment in which updating of equipment and standards is a continuous process resulting from changes in operating variables, regulatory requirements, and safety practices.
Although
this
standard
has
been
reflect
the
latest
12
Sabic
Construction Crane requires, as time goes on there may be a need to consider new procedures, standards, or operating conditions. Such new developments, including potential conflicts with existing provisions, should be referred to the SABIC EPM Support Safety for resolution. The SABIC EPM Support Safety will issue interim revisions or updates where appropriate. All SABIC construction contractor involved in the crane activities at SABIC EPM Projects site shall be follow the provisions in this Standards. The Project Management shall be ensuring the contractor is fully complying with this standard. Only with the active commitment of everyone can we ensure that SABIC EPM maintains the safest possible work environment. General Manager Sabic Engineering and Project Management
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Summary Cranes are some of the most useful and widely operated items of plant and equipment on construction sites- however, if misused and abused, they can cause serious harm and damage. There is no other item of construction equipment which has the capacity for causing as much damage or injuring so many people’s as does a crane in an accident. Most serious accidents involving cranes are a result of inadequate planning and unsafe use leading to instability and overturning. All site engineers, managers and supervisors who are involved in the specifications, installation or use of crane on SABIC EPM Projects site, shall be aware of the fundamental criteria, planning issues and the checks that are needed to ensure lifting operations proceed in a logical, safe and stable manner.
Lifting Principles There are four basic lifting principles that govern a crane's mobility and safety during lifting operations:
Center of Gravity The center of gravity of any object is the point in the object where its weight can be assumed to be concentrated or, stated in another way; it is the point in the object around which its weight is evenly distributed. The location of the center of gravity of a mobile crane depends primarily on the weight and location of its heaviest components (boom, carrier, upper-works and counterweight).
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Leverage Cranes use the principle of leverage to lift loads. Rotation of the upper-works (cab, boom, counterweight, load) changes the location of the crane's center of gravity, its leverage point or fulcrum. As the upper-works rotates, the leverage of a mobile crane fluctuates. This rotation causes the crane's center of gravity to change and causes the distance between the crane's center of gravity and its tipping axis to also change. Stability can be affected by the fluctuating leverage the crane exerts on the load as it swings. The crane's rated capacity is therefore altered in the load
chart
to
compensate
for
those
changes
in
leverage.
Provided the ground is capable of supporting the load, a crane can be made more stable by moving the tipping axis further away from its center of gravity. The extra stability gained by moving the tipping axis can then be used to carry larger/heavier loads. INCREASED STABILITY = MORE LOAD
Stability Is the relationship of the load weight, angle of the boom and its radius (distance from the cranes center of rotation to the center of load) to the center of gravity of the load. The stability of a crane could also be affected by the support on which the crane is resting. A crane's load rating is generally developed for operations under ideal conditions, i.e., a level firm surface. Unlevel surfaces or soft ground therefore must be avoided. In areas where soft ground poses a support problem for stability, mats and or blocking shall be used to distribute a crane's load and maintain a level stable condition.
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In addition to overturning (stability failure), cranes can fail structurally if overloaded enough. Structural failure may occur before a stability failure. In other words, a mobile crane's structure may fail long before it tips. As loads are added beyond its rated capacity, a crane may fail structurally before there is any sign of tipping. Structural failure is not limited to total fracture; it includes all permanent damage such as overstressing, bending and twisting of any of the components. When a crane is overstressed, the damage may not be apparent. Nevertheless, a structural failure has occurred and overstressed components are then subject to catastrophic failure at some future time.
Structural Integrity The crane's main frame, crawler track and/or outrigger supports, boom sections, and attachments are all considered part of the structural integrity of lifting. In addition, all wire ropes, including stationary supports or attachment points, help determine lifting capacity and are part of the overall structural integrity of a crane's lifting capacity. The following elements may also affect structural integrity: The load chart capacity in relationship to stability; the boom angle limitations which affect stability and capacity; and the knowledge of the length of boom and radius in determining capacity.
1. Scope This standard applies to all construction projects under the control of the SABIC EPM
Projects.
It encompasses
all transporting,
movement,
positioning or maneuvering and lifting work operations performed by personnel on project including contractor, subcontractor and or Third Party Company and /or employees.
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2. Definitions 2.1.
A-Frames/Gantries: A crane similar to an overhead crane, expect that the bridge for carrying the trolley or trolleys is rigidly supported on two Or more legs running on fixed rails or other runway.
2.2.
Anemometer: An instrument for measuring wind speed.
2.3.
Anti
two
block
collision
warning
device:
A
device
which
automatically indicates to the crane operator when the hook block approaches the jib/boom point. 2.4.
Articulating Boom Crane: A crane, consisting of a rotating mast, main frame or base, boom and one or more operator’s stations, such as ground Controls, top seat controls, or remote controls.
2.5.
Boom (JIB): The main structural part of the crane, in the form of a projecting arm, from which the load is suspended.
2.6.
Certified Inspector:
A person certified to perform inspection and
certification on elevating/ lifting equipment. The certification shall be in accordance with the SABIC EPM Crane Standard regulation requirements. 2.7.
Counterweight: Weight or series of weights might be added or built in the lifting equipment.
2.8.
Crane: A machine for lifting and lowering a load and moving it horizontally, with the hoisting mechanism as an integral part of the machine. Cranes whether fixed or mobile are operated manually or by power.
2.9.
12
Crane Operator: A person certified by Sabic Construction Crane Committee approved third party and operating licensed by the
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Saudi Government as being to operate a specific model and capacity of carne; may also additional certifications for crane attachment. 2.10.
Certified: A person certified by the Sabic Construction Crane Specialist approved Third party and posses a valid certification.
2.11.
Certified Inspector: A Third party person certified by the Sabic Construction
Crane
Specialist
to
perform
inspection
and
certifications on elevating/lifting equipment. 2.12.
Critical Lift: Any crane lift that requires a Critical Lifting Plan.
2.13.
Critical Lifting Plan: A document that identifies a specific load and the operating restrictions. Pertinent information includes all weight on hook blocks and attachments.
2.14.
Daily Pre-operational Inspection: A documented inspection of cranes carried out by the crane operator daily, prior to use, or whenever operators are changed.
2.15.
Emergency Shut off Button: A device that stop electric or air flow into a regular operating controls.
2.16.
EPM: Engineering and Project Management.
2.17.
Extensive
repair:
any
repair,
alteration,
or
modification
to
elevating/ lifting equipment which is a load bearing and/ or load controlling component that could affect the load. 2.18.
Falls / Hook block reeving of hoist rope:
The total number of
vertical part of rope or lines from which the pulley hook block is suspended. 2.19.
Fly Jib: A detachable auxiliary jib fitted at the end of the boom.
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Gantry: An elevated structure in the basic crane frame which carries the boom suspension ropes.
2.21.
Initial Inspection: Inspection carried out on new, repaired, or modified equipment.
2.22.
Outriggers: Extendable or fixed structural members on the crane carrier and rest on support at the outer ends of the crane base to increase the effective base.
2.23.
Periodical Inspection: A documented inspection carried out by a SCCC
approved
certified
inspector
(Usually
quarterly,
semi-
annually, or in the case of crawler lattice boom cranes, after relocation or boom re-configuration). 2.24.
Radius: The horizontal distance between the point at which the centre of rotation of the crane and the vertical centre line through the hook.
2.25.
Rated Capacity (load) Limiter (RCL): A device that automatically monitors radius, load weight, and load rating and prevents movement of the crane, which would result in an overload condition.
2.26.
Rigging Hardware: The items used to rig, lift, secure, and/ or support a load example: slings, shackles, eyebolt, and master links.
2.27.
Rigger: A person certified to prepare a load for lifting. The certification shall be issued from the SCCC Third Party.
2.28.
12
Safe Working Load (SWL): The maximum load which can be applied under general conditions of use to a crane, hoist, rope, chain, sling, or other rigging hardware. The component with the lowest SWL
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limits the system Safe Working Load capacity.SWL is also called Working Load Limit (WLL) or Recommended Working Load (RWL). 2.29.
SAG: Saudi Arab Government.
2.30.
SCCC: Sabic Construction Crane Committee.
2.31.
SCCS: Sabic Construction Crane Specialist.
2.32.
Shall: The “shall” as used in this document is intended to describe mandatory requirements.
2.33.
Suspended Manbasket: A device designed and constructed to be attached to the hook block of a crane to lift personnel in a safe manner.
2.34.
Swing (Slewing):
The rotary motion of crane, jib and/or super-
structure about the centre of rotation. 2.35.
SWL: Safe Working Load.
2.36.
Tackle (Hook Block Assembly): An assembly of ropes and sheaves arranged for hoisting and pulling.
2.37.
Tailing The placement of a load resting on the ground from the horizontal position to the vertical position or the vertical position to the horizontal position.
2.38.
Tandem Lift (Multi-Crane Lift): Any crane lift involving two (2) or more lifting equipment lifting or tailing the same load at the same time.
2.39.
Telescopic Boom: A boom which incorporates extension elements in the basic boom structure.
The boom length can be extended or
shortened by motion.
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2.40.
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Third Party: An organization approved and legally registered as an inspection agency to inspect and verify the condition of all types cranes accordance with the Sabic Construction Crane Procedure used in Sabic Engineering and Project Management Projects.
2.41.
Turning: The placement of a load suspended in the air from the horizontal position to the vertical position or the vertical position to the horizontal position.
2.42.
Visual inspection: A daily walk-around of a piece of elevating/lifting by a competent crane operator for the purpose of inspecting the equipment before use.
If applicable, the visual inspection shall
include operating the equipment.
3. General Lifting Requirements 3.1.
All crane lifts (standards and critical) requires properly SAG licensed and SCCS approved third party certified operators.
3.2.
All electrical or engine powered cranes require a valid SCCS approved third party sticker.
3.3.
The crane operator shall have the final decision on any crane lift that affects the safety of his crane.
3.4.
SCCS approved third party certified riggers/ rigging competent persons shall be used to rig all loads, regardless of weight to be lifted, configuration, or location.
3.5.
SCCS approved third party certified crane operator and a certified rigger or rigging competent person shall not be allowed to perform both functions at the same time, nor shall such a person be permitted to supervise a lift while operating a crane.
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3.6.
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All crane travel on construction areas and roads shall be with the normally mounted boom sections only.
All hydraulic cranes shall
have boom sections fully retracted, jibs removed or stowed, and hook blocks secured. A swing locking device shall be engaged to prevent the boom from swinging during travel. For all cranes fitted with retractable suspension units, the suspension shall be engaged on the travel mode. 3.7.
Before moving the crane, a warning shall be given to all personnel working in that area by means of an alarm or any other suitable device.
3.8.
All cranes working on construction areas shall have barricaded placed to provide clearance for tail swing. Only authorized personnel shall be permitted inside the barricaded area.
3.9.
Cranes working near trenches and excavations shall be kept twice the distance of the depth of trench or excavation. If a safe distance cannot be kept, the trench or excavation shall be filled and compacted prior to the crane being moving on site. The contractor shall be responsible for conducting soil compaction and test.
3.10. Standard and critical crane lifts shall not be performed in wind speed exceeding 32km/h (20mph- 17.4 knots- 9 meters/second), unless otherwise specified by the crane manufacturer. 3.11. If the range of visibility of the crane operator is impaired due to adverse weather conditions, the operation shall be temporarily suspended. 3.12. Suitable knot-free and defect-free tag lines shall be used to control suspended loads.
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3.13. The pinned extension of the hydraulic boom crane shall be extended prior to using a jib to obtain the maximum lifting capacity and radius. 3.14. All cranes shall have their safe working load rating clearly visible in English and Arabic. All information and warning decals shall be in English and with Arabic. 3.15. Each crane operator shall perform a daily pre-operational safety inspection, prior to operating his assigned crane, using Crane Operator
Daily
Inspection
Checklist.
(Attachment
#
1)
any
hazardous safety deficiency shall require corrective maintenance prior to the crane being used.
Records of daily pre-operational
inspections shall be maintained by the contractor or crane owner. 3.16. The Contractor shall ensure that all cranes have a documented program of preventive maintenance that is properly implemented and
maintained.
Crane
maintenance
shall
be
performed
in
accordance with manufacturer’s specification. 3.17. All cranes shall be fitted with the following safety items: 3.17.1.
Fire Extinguisher
3.17.2.
Back-up alarm
3.17.3.
Spark arrestor (for cranes that are without an emission controlled engine system).
3.17.4.
Emergency shut of button.
3.17.5.
Seat belts.
3.17.6.
Revolving warning lights.
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3.18. Cranes extending more than 60 meters (197 feet) above ground level shall have a permanently mounted aircraft warning light operating 24 hours a day. This light shall be a medium intensity, flashing
white
obstruction
light
during
daytime
hours
12
with
automatically selected reduced intensities for twilight and nighttime hours. The warning light shall be placed at the highest point of the crane. 3.19. All mobile cranes shall be equipped with properly working Rated Capacity (load) Limiter / Load Movement Indicator (LMI) and antitwo-block device or two-block damage prevention features for all points of two-blocking. 3.20. Spreader bars / beams and crane suspended personnel platforms man baskets shall be inspected by SCCS approved third party certified inspector and have valid SCCC inspection sticker. 3.21. Removable float-pads on cranes shall be removed and stowed prior to travelling the crane. 3.22. The contractor shall be advice the crane operator and the rigger/ rigging competent person of all underground utilities in the area of the crane prior to any lift. 3.23. Mobile cranes shall not be operated over or adjacent to basements or on a new earth filling without proper compaction. Contractor shall conducted geotechnical studies were a cavity is reported or noticed. 3.24. All cranes shall be leveled in accordance with manufacture’s specification and shall be located on a properly compacted foundation prior to performing any lift.
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3.25. Welding or modification on load hooks and other lifting equipment is strictly forbidden. 3.26. When outriggers are used, they shall be extended or deployed according to the crane load rating chart specifications. The crane’s wheels shall be raised completely off the ground. 3.27. Outrigger mats shall be used all crane outrigger float pads during crane lifts. Outrigger mats shall not be permanently attached to the crane outriggers. 3.28. Cranes shall be secured during high wind or after working hours by laying down the lattice boom, withdrawing the hydraulic boom extensions, and/ or following manufacturer’s specifications. 3.29. The crane operator shall not leave the controls at any time while a load is attached. 3.30. The hoisting, slewing, crossing, or travelling motions of a crane shall not be used to drag any load along the ground with the hoist rope out of the vertical position. Crane operators shall only pick up loads when the boom head and hook are in plumb (centered directly over the load). 3.31. The main boom line and the auxiliary boom line (whip line) shall not be used at the same time on the same load. 3.32. All cranes shall have load chat available in the cabs stating lift capacity
based
on
boom
length,
attachments,
boom
12
angle,
outrigger configuration, radius, and lift quadrant. All load charts shall be in English Language. 3.33. Windows shall be provided in the front and on both sides of the cab or operator’s compartment with clear visibility forward and to either
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side. Visibility forward shall include a vertical range adequate to cover the boom point at all time. 3.34. Personnel shall not ride the hook, auxiliary head-ache ball, or the load during the lift. 3.35. Cranes working in close proximity to operating high heat sources (flare stack, etc.) that may affect the boom, sheaves, boom line, crane components shall take special precaution to protect such equipment from damage. 3.36. When a crane is operating on soft or water- logged ground, suitable mats, steel plates, timber wooden blocks shall be used to distribute the operational loads of the crane. 3.37. A designated signalman shall be used at all times during the lift, moving, and setting of a load. Only one designated signalman shall give signals to the crane operator. Standard hand signals are available at (Attachment # 2). For blind lift signal may be relayed by more than one signalman. 3.38. The type of communication to be used shall be determined prior to the lift by the crane operator. He shall also provide a full explanation of hand signals to be used, whether as primary or back-up communication. The designated signalman and crane operator shall verify that they are familiar with the same set of hand signals. The signalman shall wear a bright fluorescent vest for easy identification. Radio communication is preferred, especially in case where signal relays are required. 3.39. If, at any time, the crane operator does not have direct eye contact with the designated signalman, he shall immediately stop the crane lift operation until such time that he can again see the signalman.
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3.40. All crane lifts shall have a trail lift prior to the actual lift. The trial lift shall consist of the load being hoisted just clear of the support (float/suspend the load) to test mechanical condition of the crane and to ensure that rigging hardware is properly secured. 3.41. When handling irregular shaped loads where the position of their center of gravity is not readily ascertained, care shall be taken to ensure that the load is evenly balanced before lift. 3.42. Rated load capacities, and recommended operating speeds, special hazards warnings, or instruction, shall be conspicuously posted on all equipment. Instruction or warning shall be visible to the operator while he is at his control station.
4. Crane Operator Certification 4.1.
In order to become a certified crane operator shall be meet the following requires: 4.1.1.
SAG Crane operating license. To operate the specific cranes types listed in Table # 1 to which he is assigned.
4.1.2.
SCCS Approved third party certification.
4.1.3.
More than 18 years of age.
4.1.4.
Medically fit.
4.1.5.
Understand English language.
4.1.6.
Demonstrate satisfactory skill in operating crane.
4.1.7.
The operator shall show adequate understanding and proficient use of the load charts as related to the equipment in use and the loads being lifted.
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4.2.
Use
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table
below to
verify
the
crane
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operator SAG
license
requirements for a particular piece of crane equipment. Note: Additional pieces of crane, not currently listed in the below table may also require a special certification. Table # 1
4.3.
Crane Type
Crane SAG License with Stamp
Crane Mobile
YES
Crane Pedestal
Yes
Crane Tower
Yes
Boom Truck
Yes
Craftsmen (mechanics, electricians, inspectors, etc.) operating cranes for maintenance and testing reliability shall be certified by the SCCS approved third party.
4.4.
Any crane operator in EPM Projects involved in a crane accident, shall immediately surrender his third party certification to the SCCS accident investigation committee.
5. Rigger Certification 5.1.
All riggers shall be certified by SCCS approved third party as Rigger-III,
Rigger-II,
or
Rigger-I
certification.
The
rigger
certification identifies the load weight limits and type of lifts can be rigged. 5.1.1.
Rigger- III
12
Can rig loads up to 10 tons.
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5.1.2.
Rigger- II
Page
Can loads up to 40 ton, originate Critical Lift Plans, and rig crane suspended personnel platform (man basket) operations.
5.1.3.
Rigger-I
Can rig all loads and originate the super lift plans and method statements for the super lift.
5.2.
The Rigger- I competent person shall physically examine the job site, the route of the cranes and nearby occupants prior to the lift.
5.3.
Certified riggers/ rigging competent person shall be used to rig all loads, regardless of weight to be lifted, configuration, or location.
6. Cranes Lifting Requirements 6.1. High risk work environment crane lift include, but are not limited to the following examples and restricted/ requirements: 6.1.1.
Any part of a crane whose boom or boom attachments are working around any process plats (out off temporary fencing area of the project).
6.1.2.
Any part of a crane whose boom or boom attachments are working around populated/ traffic area. This includes cranes having to suspend a load over pedestrians, vehicle traffic, occupied construction equipment, and/ or occupied buildings.
6.1.3.
Any crane lift that requires an attachments to the main boom segment.
6.1.4.
Any load weigh 40 tons or greater.
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6.1.5.
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Any load that exceeds 85% of the crane’s rated load capacity or manufacturer’s specifications for that specific lift.
6.1.6.
Any
crane
working
near
energized
power-lines
as
specified in the table # 2. When working less than 1-1/2 fully extended boom lengths
from
energized
power-lines,
a
designated
signalman shall ensure the following minimum distances are maintained: Table # 2
6.2.
Line Voltage
Absolute Limit of Approach
Up to 50,000 volts
3.0 meters/ 10 feet
50,000 to 250,000 volts
6.1 meters/ 20 feet
Over 250,000 volts
7.6 meters/ 25 feet
Special critical crane lifts, hazardous by their nature and requiring special training, rigging, and/or boom attachments, include, but are not
limited
to,
the
following
examples
and
restrictions/
requirements. 6.2.1. Tailing, tandem (multiple), or turning lifts: 6.2.1.1. De-rate all cranes involved in the lift by 25% of the load chart.
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6.2.1.2. Utilize cranes of same size, manufacturer, and model, if possible, (except tailing lift) for tandem (multiple), and turning lifts. 6.2.1.3. Have
a
separate,
approved
Critical
Lift
Plan
from
contractor SCCS approved Rigging Superintendent on site prior to the lift, each time one of these types of lift is performed. 6.2.1.4. Have a Rigger-I in charge of actual lift coordination. 6.2.2. Man Basket Lift (Personnel Man Basket) 6.2.2.1. Only allow work from, or transported by a crane suspended
personnel
platform
(Man
Basket)
when
conventional means of performing the work or reaching the worksite would be more hazardous, or is not practical, because of structural design or worksite conditions. 6.2.2.2. Have an approved Critical Lifting Plan on site prior to the lift. 6.2.2.3. Have
a
Crane
Suspended
Personnel
Platform
12
(Man
Basket) permit properly completed, signed, and onsite prior to the lift. 6.2.2.4. De-rate the crane by 50% of the load chart. 6.2.2.5. Not perform crane suspended personnel platform (man Basket) lift in wind speeds exceeding 25 km/h (15 mph13 knots-7 meters/second).
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6.2.3. Night Time crane lifts. 6.2.3.1. Obtained approval from the contractor SCCS approved third party certified rigging superintendent. 6.2.3.2. Method of statements and lighting positions shall be submitted to SCCS approved third party certified rigging superintended. 6.2.3.3. Have proper lighting, sufficient to perform the lift safely. 6.2.4. On Rubber or Pick and Carry Lift 6.2.4.1. Have the on rubber and pick and carry lift duties stated on the manufacturer’s crane load chart for this duty to be an acceptable option. 6.2.4.2. Have an approved Critical Lifting Plan on site prior to the Pick and Carry Lift. 6.2.4.3. Have
the
crane
recommended
operator
tires
are
confirm
fitted
that
(Sand
the
tires
proper are
not
acceptable). 6.2.4.4. Have
the
crane
operator
confirm
the
proper
recommended tire pressure and that the tires have no obvious defects. 6.2.4.5. Have the travel surface level, free of chuckholes, and with acceptable ground conditions. Travel speed shall not exceed 4km/h (2.5 mph). 6.2.4.6. Have the load secured to prevent any swing into the crane structure. Snubbing or tag lines shall be used.
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6.2.4.7. Have travel procedures, as specified by the manufacturer, followed (e.g., the turntable swing-lock pin should engage during travel). Note: Travelling with a load is an inherently hazardous procedure that requires extra precautions to ensure operations are conducted safely.
7. Planning for Critical Lift 7.1.
In selecting a mobile crane for a particular job, the type of crane mounting, the type of job and the relevant conditions of operation shall be considered, including the maximum load to be carried and the corresponding load radius.
7.2.
All critical lifts require a Critical Lifting Plan (Attachment # 3) approved from Contractor certified rigging superintendent.
7.3.
Loads noted in approved Critical Lifting Plan shall be rigged by a rigger certified for that load category (For Rigger categories refer section 5.1.1).
7.4.
The Critical Lift Plan form shall be properly completed, signed, and approved prior to the lift. It shall be approved by SCCS approved Third Party Certified Contractor Rigging Superintendent.
7.5.
An additional endorsement required from the Project Electrical department for any work near energized power-lines on project.
7.6.
The certified Rigging Superintendent shall physically examine the jobsite and the equipment to be used prior to giving signature approval to the Critical Lift Plan. He shall be physically present to supervise all lifts that require a Rigging Superintendent.
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7.7.
The
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stability
of
the
crane
shall
be
checked
Page
by
frequently
examination of the supporting surface during the operation.
8. Critical Lifting Plan 8.1.
All Critical Lifting Plans shall be developed by Rigger-II up to 40 tons above 40 tons Rigger-I.
8.2.
All critical lifting plans shall be approved by the Contractor certified rigging superintendent prior to the lift.
8.3.
For special lift lifting plans and the methods of statement shall be develop by the certified rigging superintendant and Rigger-I.
8.4.
Approval of the special lift shall be conducted by the SCCC Approved Third Party. Note: Find the Critical Lifting Plan Matrix on (Attachment # 4).
9. Inspection Testing and Operating of Crane/Lifting Equipment. Daily Pre-Operational Inspections 9.1.1.
Pre-operation inspections shall be performed by the crane operator daily, prior to use. The checklist could include, but not limited to the following examples at (Attachment #1).
9.1.1.1.
Control functions;
9.1.1.2. Safety devices; 9.1.1.3. Hydraulic systems;
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9.1.1.4. Hook and lifting tackle; 9.1.1.5. Wire rope and reeving; 9.1.1.6. Electrical system for proper operation; 9.1.1.7. Tires, wheels, tracks; 9.1.1.8. Air system; 9.1.1.9. Coolant system; 9.1.1.10. Inspection sticker; 9.1.1.11. Monthly inspection for the safety items; 9.1.1.12. Hour meter and or odometer; 9.1.1.13. All min boom sections, including power pinned section, shall be extended and inspected for corrosion, proper operation and damage prior to use; 9.1.1.14. Any
other
items
recommended
by
the
crane
manufacturer. 9.1.2.
Deficiencies
for
cranes
shall
be
reported
immediately to the crane operator’s supervisor on the daily pre-operational inspection checklist. 9.1.3.
Deficiencies, reported in the daily pre-operational inspection shall be corrected prior to use, without correct the deficiencies operator shall not be operate the crane.
9.1.4.
12
Daily pre-operational inspection checklist shall be daily verified and endorsed by the direct supervision of the operator.
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9.1.5.
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Weekly contractor certified rigging superintendent shall
be
verified
the
Daily
pre-operation
inspection
checklist to ensure the preventive maintenance program is functioning. 9.1.6.
The Contractor shall apply preventive maintenance and repair program.
Periodic Inspections. 9.1.7.
The
Contractor
shall
maintain
the
periodic
inspection
in
accordance with this procedure describe. 9.1.8.
The contractor shall request to SCCC approved Third Party to perform periodic inspection on crane every three month (90 days).
9.1.9.
Cranes that has been involved in an accident, causing damage to the
crane
itself,
shall
have
its
safety
inspection
sticker
immediately removed by accident investigation committee. The SCCC
inspection
sticker
shall
be
given
to
the
accident
investigation committee. Crane shall not be used until it has passed a re-inspection from the SCCC approved Third Party. A proof-load test may also be required if the damage affects a load bearing members. All slings, wire ropes, and other rigging equipments directly involved in the accident shall be removed from the project. 9.1.10.
All crane periodic inspection shall be performed by a Third Party certified inspector using checklist (Attachment #5).
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Contractor shall be verifying the inspection items noted on periodic inspection check list (Attachment #5) shall be functioning prior to third party inspection.
9.1.12.
Crane failing the Periodic inspection shall be removed from service until all deficiencies have been corrected, and re-certified. Repairs shall conform to the manufacturer’s instructions.
Initial Inspection 9.1.13.
Any cranes are mobilizing on the Engineering and Project Management Projects required an initial inspection and proof load test certification and sticker on equipment from the Sabic Construction Crane Committee approved Third Party.
9.1.14.
Any repaired, modified, or altered shall have an initial inspection and a proof load test prior to returning to service.
9.1.15.
The initial proof load test and inspection shall be conducted by the Approved Third Party (Find the list of approved third parties(Attachment #5).
9.1.16.
All new
cranes
required
a
manufacturer’s
proof
load
test
certification to be furnished by the contractor to the Third Party prior to the initial inspection. 9.1.17.
Any
repaired
on
RCL/
LMI
is
required
re-calibration.
All
calibrations on RCL/LMI shall in accordance with manufacturer recommendations.
Record Keeping of Inspection Document 9.1.18. Record of daily pre-operational inspections for cranes shall be maintained by the contractor for a minimum of three (3)
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months. Failure to maintain these records may result in immediate sticker or certification invalidation. 9.1.19.
Records of periodic inspection and initial inspection
performed by the Third Party shall be maintained by the contractor. The original copy shall be available at the site and copy of the certification and the inspection sticker shall be available with the crane. Failure to maintain these records immediately removal of cranes from the project. 9.1.20.
A copy of the manufacturer’s manual shall be made
available by the crane. The contractor shall responsible for to arrange the manufacture’s manual. 9.1.21.
A copy of safe operation manual shall be made available
by the crane. The contractor shall responsible to arrange the manual. 9.1.22.
All manuals shall be available in English language the
contractor shall arrange responsible for to arrange the manuals on crane cabins.
10.
General Inspection and Testing Requirements
10.1. The Contractor shall ensure all the cranes have a valid SCCC inspection sticker prior to mobilize on EPM projects. 10.2. The Contractor shall be ensuring that the periodic inspections are conducted prior to SCCC sticker expiration. 10.3. Any extensive repair, modification, or alteration to any crane requires a manufacturer test certification to be furnished by the Contractor to the SCCS approved Third Party inspector upon request. This
certification shall state
that the
repairs
12
were
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completed in compliance with the manufacturer specifications and recommendations. 10.4. A crane jib is considered to be an extension of the main boom and repairs to a jib shall be treated in the same way. 10.5. Where the re-rating of crane is necessary, the crane shall be proofload tested by the SCCS approved Third Party.
11.
Crane Setup
11.1. The initial survey of crane operations, look for crane stability, physical obstructions to movement or operation, and proximity of electrical power lines. 11.2. The crane operator shall ensure the crane up level and in a position for safe rotation and operation. 11.3. The crane operator shall ensure the outrigger is extended in accordance with manufacturer’s recommendations. 11.4. The crane operator shall ensure the crane stability. The relationship of the load weight, angle of boom, and its radius (the distance from the cranes center of rotation to the center of load) to the center of gravity of the load. Also, the condition of crane loading where the load moment acting to overturn the crane is less than the moment of the crane available to resist overturning. 11.5. The crane operator shall ensure the equipment structural integrity prior to daily initial lift. The crane’s main frame, crawler, track and outrigger supports, boom sections, and attachments are all considered part of structural components of lifting. In addition, all wire ropes, including stationary supports, help determine lifting
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capacity and are
part of the
Page
structural elements
of crane
operations.
12.
Starting The Periodic Inspection The crane inspections being with a general walk-around and observation of the overall crane set up and operation, followed by a specific inspection of item or components, the following guidelines are presented in that order.
12.1. Contractor shall submit to SCCC Approved Third Party the crane manufacturer’s inspection record and at least three months maintenance record for all types of crane. 12.2. For periodic and daily preoperational inspection the inspectors shall be conduct a walk-around inspection, paying particular attention to mechanical systems leaks or damage (oil, hydraulic, air) and structural deficiencies. 12.3. Crane cab for properly marked controls, damaged instruments and for properly displayed and legible load charts. All signs and load charts shall be in English Language. 12.4. The operator shall questions on load charts, rigging and load weight determinations and capacities. 12.5. Request the operator to raise and lower the boom/load line, and inspect, from the cab position, the running line or rope of the main hoist drum and secondary line or jib line. Check brake action and its ability to stop.
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12.6. Lower the boom to look at the condition of booms sections, lacing, lifting components, anti-two-block devices, jib back stops, and the condition of the hook. 12.7. Crane set up and stability of outriggers on hydraulic and/ or the effectiveness of cribbing on crawlers. 12.8. Manufacturer’s
operating
and
maintenance
manuals
12
shall
accompany all mobile hoisting equipment. These manuals state forth specific inspection, operation and maintenance for each mobile crane and lifting capacity. 12.9. All exposed moving parts such as gears, chains, reciprocating or rotating parts shall be guarded. 12.10.High voltage warning signs displaying restrictions and requirements shall be installed at the operator’s station and at strategic locations on the crane. 12.11.Shock absorbing or hydraulic type boom stops are installed in a manner resist boom overturning. 12.12.Jib Boom Stops are functioning properly clear cut off systems are functioning. The Jib Boom Stops are restraints to resist overturning. 12.13.A boom angle indicator readable for the operator station is installed accurately to indicate boom angle. 12.14. A Boom Hoist Disconnect, Automatic Boom Hoist Shutoff is functioning accordance with the manufacturer recommendation. A Boom Hoist disconnects safety shutoff or hydraulic relief to automatically stop the boom hoist when the boom reaches a predetermined high angle.
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12.15.Anti-two-blocking / Two- blocking damage preventions features shall be tested in accordance with the manufacturer requirements. All cranes hydraulic and fixed boom shall be equipped with twoblocking devices on all hoist lines intended to be used in the operation. The anti-two-blocking device has automatic capabilities for controlling functions that may cause a two-blocking condition. 12.16.Power
Controlled
Lowering
systems
shall
be
inspected
in
accordance with the manufacturer recommendations. Cranes using for hoist personnel shall be equipped for power controlled lowering operation on all hoist lines. Check clutch, chains, and sprockets for wear. 12.17.A device for checking the leveling of the crane shall be provided inside the operator cabin and the outside the cabin. The leveling device shall be inspected. 12.18.All sheaves grooves shall be inspected for smooth and free from surface defects, crakes, or worn place that could cause rope damage. Flanges shall not be broken, cracked, or chipped. The bottom of the sheave groove shall from a close fitting saddle for the being used. Lower load blocks shall be equipped with close fitting guards. Almost every wire rope installation has one or more sheaves – ranging from traveling blocks with complicated reeving patterns
to
equalizing
sheaves
where
only
minimum
rope
movement is noticed. 12.19.Main Hoist and Auxiliary Drum System shall be inspected for drum crushing. Drum crushing is a rope condition sometimes observed which
indicates
deterioration
of
the
rope.
Spooling
is
that
characteristic of a rope which affects how it wraps onto and off a drum. Spoiling is affected by the care and skill with which the first
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larger of wraps is applied on the drum. Manufacturer’s criteria during inspection usually specify: Minimum number of wraps to remain on the drum. Condition of drum grooves. Condition of flanges at the end of drum. Rope end attachment. Spooling characteristics of rope. Rope condition. 12.20.Main Boom, jib Boom, Boom Extension shall be inspected for free from cracked or corroded. Bolts
and rivets shall be
tight.
Certification that repaired boom members meet manufacturers original
design
standard
shall
be
documented.
Non-certified
repaired members shall not be used. 12.21.Hooks and blocks shall be permanently labeled with rated capacity. Hooks and blocks are counterweighted to the weight of the overhaul line from highest hook position. All the hooks shall be equipped with effective positive safety catches. Hooks shall not have cracks or throat openings. 12.22.Hydraulic Hoses Fittings and Tubing shall be sound and show no sings of leaking at the surface or its junction with the metal and couplings. Hoses shall not show blistering or abnormal deformation to the outer covering and no leaks at threaded or clamped joints that cannot be eliminated by normal tightening or manufacturer recommended. There shall be no evidence of excessive abrasion or sc rubbing on the outer surface of hoses, rigid tubing, or hydraulic fittings. 12.23.Outrigger number, locations, types and type of control are in accordance
with
manufacturer's
specifications.
Outriggers
are
designed and operated to relieve all weight from wheels or tracks within the boundaries of the outriggers. Outriggers shall be visible to the operator or a signal person during extension or setting.
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hoist
and
auxiliary
wire
rope
inspection
Page
shall
include
examining for: Broken Wires; Excess wear; External damage from crushing, kinking, cutting or corrosion. 12.25.Operator cabs shall be inspected for function controls in additional boom angle indicator, electric wipers, RCL/ LMI functioning cut off system, warning lights and buzzers, fire extinguishers, seat belts, horn and clear unbroken glass. 12.26. The braking systems shall be inspected and tested in accordance with the manufacturer recommendation. The swing brakes, hoist line braking and braking system for the truck cranes and selfpropelled cranes mounted on rubber-tired chases. 12.27.The turntable/Crane body shall be inspected for the rotation point of a crane gear and roller are free of damage, wear and properly adjusted and the components are securely locked and free of cracks or damage. 12.28.The counterweight shall be installed according to manufacturer’s specifications with attachment points secured. 12.29.An anemometer shall be provided, when recommended by the manufacturer, to enable the operator to read the wind speed. The anemometer shall be inspected and calibrated accordance with the manufacturer recommendation.
13.
Typical Crane Safety Features The safety features in mobile cranes will vary somewhat in design and application with the various crane manufacturers and the individual crane model.
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The points listed in this section are general required on the cranes using in SABIC Engineering Project Management Projects: 13.1. A fire extinguisher in a readily accessible position. Operator and rigger shall be familiar with the use and care of the fire extinguisher provided. 13.2. Self closing fuel filler caps and flame arrestor on fuel tanks and the exhaust line. 13.3. Rear view mirrors on both sides of mobile equipment those are large enough to give the operator a satisfactory rear view. 13.4. Boom angle indicator. The indicator shall be clearly visible to the operator from his seat. It shall also be readable to within one degree. 13.5. Boom length indicators shall be on all cranes. 13.6. Boom stop and boom hoist safety shutoffs. 13.7. Rated capacity limiter/ load movement indicator shall be fixed and calibrated from the manufacturer any cranes maximum rated capacity of 3 (three) tons or more. 13.8. Devices to automatically stop boom drum motion when the maximum boom angle is reached. 13.9. Drum rotation indicators clearly visible to the operator. 13.10.Outriggers shall be marked or painted to clearly indicate the outrigger beam is fully extended. 13.11.A clear audible outside warning signals, backup alarms and the flash lights on the operator cabins.
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13.12.A spirit level at the outrigger and the operator cabin for leveling the crane. 13.13.Crane drums shall have sufficient clutching or power engaging devices that immediately start and stop the drum motion. 13.14.Crane drums shall have self-setting fail-safe brakes that are capable of supporting the rated loads with recommended reeving and which operates automatically should the power fail. 13.15.Crane drums brake and clutch assemblies shall have adjustments to compensate for wear and maintain adequate spring force, when used. 13.16.Crane drum boom hoisting mechanisms shall have an auxiliary ratchet and pawl or an equivalent position locking device. 13.17.Crane hoist drum shall be provided with a method to ensure spooling of the wire rope on the drum. 13.18.Crane drums shall have rims and flange guards large enough to prevent a slack wire rope from jumping off the drum. 13.19.Crane drums shall have at least three full wraps of rope remaining on the drum in all service conditions. 13.20.Grooved crane drums shall have the correct minimum groove pitch and grove depth for the diameter of the rope. 13.21.Pneumatic, hydraulic and electrical brakes shall be designed so the brakes will apply automatically if there is a loss of power or pressure. The brakes shall not release until power has been restored to the machine and the brake is deliberately released. 13.22.Hoist brakes shall be capable of holding the capacity rated load.
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13.23.Swing brakes shall have a fail-safe method stopping the swing with full load, and hold the boom in 50 km/hr (30 mph) winds. They shall hold without operator attention. 13.24.Cranes hall have a positive swing lock or house lock to prevent accidental engagement of disengagement. 13.25.Hydraulic cranes shall be equipped with integrally mounted devices to prevent boom lowering or retracting in the event of hydraulic failure. 13.26.The identification shall be attached to all removable components including the boom from the manufacture. The identification shall be clearly visible on the cabin, the Model number, serial number and the weight shall be identified by the manufacture.
14.
Loading Cranes on Trucks for Transportation
14.1. When loading crawler cranes and wheel-mounted mobile cranes by trucks, sufficient care shall be taken to ensure that the crane does not tip over backwards. 14.2. The maximum gradient for stability of the crane shall not be exceeded. 14.3. The loading capacity and loading surface dimensions of the transporting vehicle shall be adequate for the crane. 14.4. The crane operational brakes shall be engaged. 14.5. The crane shall be fully chocked against all movements. 14.6. The crane shall be securely lashed to the vehicle to prevent the crane bouncing, tipping or sliding off the loading surface.
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14.7. Swing brake and/or slewing lock shall be applied and upper portion cross-chained against possible rotation. Loose items such as the hook block shall be lashed to prevent its motion.
15.
Crane Man basket Operations Lifting of personnel through Man basket shall be avoided as far as practicably possible. Use of all alternative means shall be carefully considered before.
15.1. The man basket and the rigging equipment utilizing for man basket rig up shall be inspected and certified by a SCCC approved Third Party inspection and have valid SCCC sticker. 15.2. When dedicated rigging has changed, or as determined by the operator or riggers entire man basket and rigging equipments shall be re-inspected and certified. 15.3. The approved third party inspector shall inspected for proof-load test of 200% of the rated capacity at each periodical inspection and inspect the physical condition of the man basket. This shall be done by floating the crane suspended man basket and test weight approximately 31cm (12inches) from the ground for five minutes. After completion of a successful proof-load test and inspection, a certified inspector shall attach a safety inspection sticker to the man basket. 15.4. The
crane
manufacturer
operator
shall
become
recommendations,
familiar
operating
with
the
instruction,
crane and
restrictions, and restrictions related to man basket operations. 15.5. The man basket permit (Attachment # 6) shall be prepared by a rigger I and Contractor rigging superintendent with the assistance of the crane operator.
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to
the
actual
lift,
the
rigger-I,
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contractor
rigging
superintendent of the lift shall make a trial lift by floating the load from the ground for five minutes.
16.
General Man basket Requirements
16.1. Man basket shall have a safe working capacity based on a minimum design safety factor of 5:1. 16.2. An identification plate shall be attached to the man basket and display the following minimum information: 16.2.1.
Identification Number for the Man basket.
16.2.2.
Empty
Weight
of
man
basket
(include
the
rigging
equipment). 16.2.3.
Rated Capacity of Man basket.
16.2.4.
Maximum Number of Personnel Allowed.
12
16.3. Contractor shall provide a proof-load test certificate from the Man Basket manufactured factory to Third Party at the time of initial inspection conducted by the SCCC approved Third Party. The manufacturer proof –load test certificate shall be available on site. 16.4. A head roof shall be provided for man basket. Roofing shall be constructed of expanded metal to allow visibility for the workers. 16.5. An approved Critical Lift Plan shall be available on site, prior to any man basket lift. 16.6. A Pre-Lift Safety Meeting is mandatory, as required by the Critical Lift Plan form and the Man basket Permit.
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16.7. The crane capacity load chart shall be de-rated fifty percent (50%) when lifting a man basket. 16.8. Each site setup for man basket operations shall have an approved Man basket Permit. 16.9. Man basket lifts shall not be performed if: 16.9.1.
The crane operator, and/or rigger does not consider the crane operator to be physically or emotionally fit to perform the operation;
16.9.2.
The crane operator has been working for more than (10) continuous hours;
16.9.3.
Whenever the crane operator considers that the lift cannot be performed safely, or that the requirements to undertake the lift is not performed;
16.9.4.
The man basket inspection sticker and / or crane inspection stickers is expired;
16.9.5.
Any crane Rated Capacity[load] Limiter (RCL)/ Load Movement Indicator (LMI) and anti-two-block device or two-block damage prevention feature for all points of two-blocking (i.e., jibs, extensions, etc.) is not working properly;
16.9.6.
The Crane Man basket Permit attachment # 6 has not been properly completed.
16.10.All man basket dedicated rigging hardware, for attachment to the crane hook, shall:
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Have four (4) swaged (mechanically spliced Flemish eyes) wire rope slings of equal length attached to a shackle or approved steel master link, which shall be attached to the crane hook on one end;
16.10.2.
Have each of the other ends of the four (4) slings attached to the top of man basket eyelets with individual shackles and designed with thimbles in each eye;
16.10.3.
Have the length of the four (4) slings long enough to permit
adequate
head
room
for
workmen,
while
maintaining a minimum sling angle of 45 degrees from the crane hook; and 16.10.4.
12
The crane hooks shall have the self locking safety caches and the crane shall have valid SCCC sticker.
16.11.Slings designated for man basket use shall not be used for any other lifting purpose. 16.12.Man baskets shall not be used for any purpose other than lifting personnel and their work tools. Any violation will cause the SCCC sticker removal of man basket and the crane. 16.13.Hoisting of the man basket shall be performed in a slow, controlled, cautious manner with no sudden movements of the crane or derrick, or the man basket. 16.14.Cranes shall not travel with a suspended man basket occupied. Any violation will cause the termination of the operator certification from all Sabic Engineering and Project Management (E&PM) projects site.
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16.15.Free fall devices shall not be used on a friction or hydraulic type crane hoist during suspended man basket operations. Free fall system operational cranes shall not be utilize for the Man Basket operation. 16.16.The crane operator shall not leave the controls at any time while a man basket is attached to the hook. 16.17.Workers shall not be leave from the man basket when its suspended and workers shall not be permitted to work outside a suspended man basket. 16.18.A rescue plan has been developed by Contractor and approved by the rigging superintendent and the Sabic Project Management Safety Managers or his deputy and is in effect prior to beginning the work. 16.19.A rigger in charge of the lift shall observe the man basket operation all the time during lifting personnel .Only one designated signalman shall give signals to the crane operator. 16.20.Fall arrest procedures and equipment are approved by the assigned rigger-I and the Rigging Superintendent and properly utilized . 16.21.All workers shall wear full body safety harness with double shock absorbing lanyard and secured at all times to the man basket and in-depended lines provided from the crane structures. 16.22.Fall protection shall allow a maximum free fall of 1.8 meters (6 feet) in the event a man basket support fails. 16.23.Load and boom hoist drum brakes, swing brakes, and locking devices shall be engaged when the occupied man basket is in a stationary working position.
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16.24.The type of communication to be used shall be determined prior to the lift by the Rigger.
He shall also provide a full explanation of
hand
used,
signals
to
communication.
be
whether
as
primary
or
back-up
The designated signalman and crane operator
shall verify that they are familiar with the same set of hand signals. The signalman shall wear a bright fluorescent vest for easy identification.
Radio communication is preferred, especially in
cases where signal relays are required. 16.25.Workers shall keep all parts of the body inside the man basket during hoisting and lowering operations. 16.26.Suitable knot-free and defect-free tag line(s) shall be attached to the man basket and controlled at all times. 16.27.Man basket crane lifts shall not be performed in wind speeds exceeding 25 km/h (15 mph – 13 knots – 7 meters/second) or manufacturer’s specifications, whichever is less. 16.28.Crane hook suspended air tugger operations shall not be permitted onshore. 16.29.The crane shall not be used for other purposes while handling a suspended man basket. 16.30.When welding occurs from the man basket, suitable electrode holders shall be used to protect workers from contact with any conducting component of the man basket. The electrode shall be removed from the electrode holder when welding operations are discontinued for any period of time. 16.31.At night time Man basket operations is not permitted on the construction activity.
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17.
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Rigging Hardware
17.1. Lifting/Spreader Beams 17.1.1.
Lifting/spreader beams shall receive a periodic inspection every 6 (six) month.
17.1.2.
Lifting/spreader beams require an initial proof-load test of 125% of the rated safe working load. This test shall be conducted by the SCCC approved third party and the inspection shall be witnessed by the SCCS approved superintendent.
17.1.3.
A visual inspection shall be performed by certified rigger/rigging
competent
person
designated
by
the
contractor prior to each lift. 17.1.4.
If the headroom does not permit the use of long slings, a suitable spreader beam shall be used. The angle between the legs of the sling shall be taken into consideration in determining the size of sling to be used.
17.2. A-Frames/Gantries 17.2.1.
A-frames/gantries
shall
be
periodic
6
(six)
month
inspection by a SCCC approved third party. 17.2.2.
A visual inspection shall be performed by a rigger/ competent person prior to each use.
17.3. Slings Requirements 17.3.1.
Slings – General Specification The contractor shall verify that:
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17.3.1.1. All slings meet the minimum design safety factor of 5:1, chain and chain components shall meet safety factor of 4:1. 17.3.1.2. All slings have been proof-tested by the manufacturer at 200% of the rated capacity. The contractor shall provide, the rigging hardware proof-load test certificate upon request. One copy of the manufacturer proof-load test certificate shall be available on site. 17.3.1.3. Unique slings required for heavy lift rigging or other special applications meet the ASME B30.9 standard as a minimum. In cases where the load charts of ASME B30.9 do not cover the material, type, or size of the sling to be used, the manufacturer's recommendations shall apply. 17.3.2.
Slings – Usage
17.3.2.1. All
sling
types
shall
have
identification
information
permanently affixed with durable identification tags or wire rope swages and shall be maintained by the rigging hardware owner so as to be legible during the life of the sling. 17.3.2.2. Sling proof-load test certificates shall be properly filed by the contractor. 17.3.2.3. Slings shall be shortened, or otherwise adjusted, only by methods approved by the sling manufacturer. 17.3.2.4. Slings shall not be shortened or lengthened by knotting, by re-splicing, or by wire rope clips. 17.3.2.5. Use of slings that have been repaired shall be prohibited.
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17.3.2.6. Slings shall be hitched in a manner that provides the best control of the load. 17.3.2.7. Slings or other rigging hardware in contact with sharp corners shall be padded with material of sufficient strength to minimize damage to the sling, other rigging hardware, and/or the load being lifted. 17.3.2.8. Working conditions that may affect slings and other rigging
hardware
shall
be
considered,
with
special
attention to temperatures, chemicals, abrasions. 17.3.2.9. The rigging hardware manufacturer's rated SWL capacity shall not be exceeded. 17.3.2.10. When not in immediate use, slings and other rigging hardware shall be stored in an area where they will not be subjected to mechanical damage, corrosive action, direct sunlight,
abrasives,
moisture,
extreme
heat,
12
and/or
kinking. 17.3.2.11. All attaching devices (i.e., rings, links, coupling pins, etc.) shall be selected to provide capacities equal to, or greater than, the slings used. 17.3.2.12. Fasteners manufactured in-house from bolts, rods, pins, hooks, etc. shall not be used. 17.3.2.13. Approved, self-closing safety latches shall be used on all hooks designed for safety latches. 17.3.2.14. Horizontal sling angles less than thirty degrees (30º) shall not be used.
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17.3.2.15. Defective or damaged rigging hardware, or rigging hardware that does not comply with standard, shall be immediately removed from service and shall be destroyed to prevent further use. Slings removed from service shall be recorded in the sling inspection log maintained by the rigging hardware owner see (Attachment # 7). 17.3.2.16. Alloy
steel
chain
slings
shall
not
be
used
in
temperatures greater than 316 degrees C (600 degrees F) or less than -40 degrees C (-40 degrees F). 17.3.2.17. Alloy steel chain sling links shall be measured by the rigging hardware owner prior to use to verify that they have not stretched beyond the manufacturer’s acceptable limits. 17.3.2.18. Eyes in wire rope slings shall not be formed using knots. 17.3.2.19. When the D/d ratio for using wire rope slings is less than 25, the rated load (or SWL) of the sling shall be decreased accordingly.
Consult the sling manufacturer
for specific data or refer to the Wire Rope Sling Users Manual. 17.3.2.20. All wire rope slings shall be the Flemish eye type with swaged endings.
Fold back eyes for wire rope slings is
prohibited. 17.3.2.21. Aluminum is prohibited as a material for use as wire rope sling ferrules. 17.3.3.
Alloy Steel Chain Slings
17.3.3.1. Alloy steel chain sling identification tags shall state:
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a) Manufacturer, b) Grade of steel, c) Reach, d) Number of legs, e) SWL and angle upon which the rating is based, and f) Identification number (ID #) which links to the certificate of proof-load test. 17.3.4.
Metal Mesh Slings
17.3.4.1. Metal mesh sling identification tags shall state: a) Manufacturer, b) SWL rating for a basket hitch, c) SWL rating for a choker hitch, and d) Identification number (ID #) which links to the certificate of proof-load test. 17.3.5.
Natural and Synthetic Fiber Rope Slings.
17.3.5.1. Natural and synthetic fiber rope sling identification tags shall state: a) Manufacturer, b) Date of manufacture, c) Type of material used, d) Manufacturer's code or stock number,
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e) SWL ratings for approved hitches used, and f) Identification number (ID #)
which links
to
the
certificate of proof-load test. 17.3.5.2. Coated slings shall be proof-load tested before coating. 17.3.6.
Synthetic Webbed Slings.
17.3.6.1. Stitching shall be the only method used to fabricate synthetic webbed slings. 17.3.6.2. Synthetic webbed slings identification tags shall state: a) Manufacturer, b) Date of manufacture, c) Type of material used, d) Manufacturer's code or stock number, e) SWL ratings for approved hitches used, and f) Identification number (ID #) which links to the certificate of proof-load test. 17.3.7.
Wire Rope Slings.
17.3.7.1. Wire rope sling identification tags shall state: a) Manufacturer, b) SWL rating, and c) Identification number (ID #) which links to certificate of proof-load test.
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17.4. Rigging Hardware Inspection 17.4.1.
Inspection of slings and rigging hardware shall be of two (2) types:
17.4.1.1. Frequent inspection - Visual examination by certified rigger/rigging competent person prior to use. 17.4.1.2. Periodic inspection - Detailed visual inspection by certified rigger/rigging competent person performed within a maximum of 1 (one) month intervals. The inspection is recorded in the Sling Inspection Log as per attachment # 7 listing any deficiencies found.
Records shall be
maintained by the contractor on site. 17.4.2.
Periodic inspection records shall be kept for the life of the sling.
17.4.3.
All frequent and periodic sling inspections shall be performed by certified rigger/rigging competent person.
17.4.4.
All slings, upon arrival from the manufacturer, shall be inspected by the contractor competent person and the following information, as a minimum, entered into the Sling Inspection Log sample in (Attachment # 7). Additional information shall also be logged in prior to initial use and during all periodic inspections. Each sling shall have its own Sling Inspection Log page. a) Serial number (ID #),
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b) Sling type, c) Sling
description
(including
length
and
width
or
diameter), d) Safe working load (SWL), e) In-service date, f) Out-of-service date, g) Rigger/rigging competent person name, h) Inspection date, and i) Remarks (results of inspection). 17.4.5.
Rigging hardware that does not comply with this standard shall be immediately removed from service and shall be destroyed to prevent further use.
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Supervisor Name
Date
Telephone #
Manufacturer
Equipment #
Model
Capacity
Carrier
Hour Meter Finish
Crane
Hour Meter Start
Location
Hour Meter Finish
Item Item name
No.
1.0 PRE-START WALK-AROUND CHECKS
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Attachment # 1
Crane Operator Name
Phase
0
Page
Crane Operator Daily Inspection Checklist
Hour Meter Start
12
1.1
Inspection Sticker
1.2
Carrier Doors/Panels/Mirrors
1.3
Spark Arrestor
1.4
Under-Chassis Leak Check
1.5
Air Reservoir
1.6
Tire Condition – Pressure/Tread/Sidewalls
1.7
Tracks/Drive Chains
1.8
Deck - Housekeeping/Leaks
1.9
Coolant Level (Radiator)
1.10
Engine Oil Level
1.11
Engine Oil Leak Check
1.12
Wire Rope - Condition/Drum Lay
1.13
Sheaves/Hook Block/Headache Ball
1.14
Swing-Away Jib
1.15
Cab – Doors/Glass/Mirrors/Housekeeping
1.16
Seat Belts
1.17
Load Chart(s) - Accessible/Readable
1.18
Fire Extinguisher(s) – Mounted/Inspected
1.19
Hydraulic Oil Level
Ok
No
N/a
Deficiency
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& HYDRAULIC SYSTEM CHECKS
2.0 ENGINE START-UP CHECKS 3.0 CRANE SAFETY DEVICE(S)
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1.20
Battery – Terminals/Cables/Electrolyte
1.21
Fan Belts
2.1
Engine Start
2.2
Voltmeter/Ammeter/Tachometer (RPM Gauge)
2.3
Turn Signals/4-Way Flasher Switch/Beacon Light(s)
2.4
Horn/Lights/Wipers
2.5
Engine Oil Pressure Gauge
2.6
Transmission/Converter Temperature Gauges
2.7
Engine Coolant Temperature Gauge
2.8
Fuel Gauge Level
2.9
Braking System(s)
2.10
Transmission Oil Level
2.11
Air Filter/Restriction Condition
2.12
Hydraulic Filter Condition
2.13
Suspension System
3.1
Anti-Two Block/Two Block Damage Prevention
3.2
Rated Capacity (Load) Limiter (RCL)
3.3
Outriggers/Stabilizers/Float Pads
3.4
Bubble Check
3.5
Steering System
3.6
Rear Axle/Oscillation/Lockout System
3.7
Boom Extension/Lift Controls/Lift Operations
3.8
Page
Hoist Controls/Hoist Operations
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Positive Swing Lock/Swing Controls/Operation Back-Up Alarm
Crane Operator Name
Supervisor Name
(Please Print) Signature
(Please Print) Signature
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Attachment # 2
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Attachment # 3
Critical Lifting Plan Critical Lift Plan
(*Each Piece Of Participating Lifting Equipment Shall Have A Separate Critical Lift Plan)
Contractor Name: ______________________ Project Title:___________________________
Date of Lift:________________________ Specific Work Location:________________________
Area:_________________________________
Work Permit Required: Yes
NO
A) Load Description & Weight (from Contractor): ____________________ _________lbs/kgs
B) Load Handling Devices (See “Notes” Below): Load Handling/Boom Stowed Erected N/A Weight lbs/kgs Attachments
C) Crane Information (See “Notes” Below):
Swing-Away Jib:
1. SCC Inspection Sticker
Yes
No
Other Jibs:
2. Inspection Sticker Expiry Date: __________
Hook Block (Main):
3. Equipment Serial #: ____________________
Auxiliary Boom Head:
4. Crane Model: ______________________
Headache Ball:
5. Crane Type: _______________________
Lifting/Spreader Beam Needed?
6. Crane Rated Capacity: ___________ lbs/kgs
Does Beam Have Current Inspection Sticker? YES NO
7. Crane Operating Code # (if applicable): ____ 8. Single Line Pull Capacity: ________ lbs/kgs 9. # of Parts of Line: ______________
YES
NO
Slings, Shackles, etc.: Other: ________________________________ Weight of Load Handling Devices (Section B above)
10. Total Gross Capacity Hook Block as Reeved: _____________________ lbs/kgs
+
Weight of Load to be Lifted (Section A)
=
Total Gross Weight (Sections A + B)
D) Crane Configuration (See “Notes” Below):
E) Rigging (See “Notes” Below):
1. Required Boom Length: __________ ft/m
1. Hitch Arrangement:_______________________
2. Boom Angle: ________________ degrees
2. Sling Type(s): ___________________________
3. Required Counterweight: _________ lbs/kgs
3. Sling Size(s): ___________________________in/cm
4. Operating Radius: _______________ ft/m
4. Sling Length(s): _________________________ft/m
5. Lift Quadrant (Front, Rear, 360°): ________
5. Shackle Size: ______ in/cm & Capacity: ________ lbs/kgs 6. Capacity of Above Configuration: _______________ lbs/kgs
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F) Crane Capacity in This Configuration (De-rated, if applicable):
lbs/kgs
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Total Gross Weight ÷ Capacity =___ %
G) Surface Requirements Needed (Other Than Mandatory Outrigger Pads): Mats? YES Is the Ground Level? YES NO Proper Ground Compaction? YES Excavation Hazards Controlled? YES NO Other _____________? YES
NO NO NO
H) Wind Speed Shall Not Exceed 32 km/hr Limits for Man baskets 25Km/hr Limits/Crane Manufacturer’s Specifications. I) Energized Power-Lines Within Boom Radius? Explosion/Fire/High Heat Hazards Within Boom Radius?
YES YES
***Attention: A Pre-Lift Safety Meeting is Mandatory Positions:
Name (Signature)
NO NO CAN CRANE MAKE LIFT?
Badge #
Certificate #
YES
Approved by: Rigging Superintendent
Originator:
Name (Print):
Rigger I/II:
Badge #:
Crane Operator: Contractor Supervisor:
NO
Certificate #: Signature:
Note: 1. Attach sketch (es) of lift site, noting obstacles to movement of load, boom, or tail swing. 2. All units of weight shall be listed in the same units of measure as Crane Load Chart. 3. All units of measure shall be listed in the same units of measure as Crane Range Diagram. 4. Attach copy of Crane Load Chart, Range Diagram, and Safety Notes. 5. Certain weight may be deducted from Crane Load Chart capacity based on manufacturer’s specifications.
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Attachment # 4
Critical Lifting Plan Matrix Title
Developing
Review
Approval
On Spot Review
Less than
