020-t001-100_crane_lifting_operations_rev5.pdf
This document was uploaded by user and they confirmed that they have the permission to share it. If you are author or own the copyright of this book, please report to us by using this DMCA report form. Report DMCA
Overview
Download & View 020-t001-100_crane_lifting_operations_rev5.pdf as PDF for free.
More details
- Words: 17,070
- Pages: 50
McConnell Dowell Corporation MCD Management System
CRANE AND LIFTING OPERATIONS MMS No: 020-T001-100
Revision History Rev
Date
Details
Author
Reviewer
Approver
1
14Jun2012
Added Section 6.11.18 Crane Free fall
R Brown
J Phillips
2
22Jul2013
Full Review
D Woods
J. Phillips
3
20Oct2014
Updated Section 6.7.1, Definitions of High Risk Work licence responsibilities for licensed Basic, Intermediate and Advanced Rigger classes.
T Knight
K. Rolls
M. Collins
4
11 Aug 2015
Revision of 6.4.1 to include requirements of pick and carry operations with side slopes >2.50
M Collins
M Collins
M Collins
5
6 Oct 2015
Updated section 6.1.8b Inclination Factors.
N. Kidd
M Collins
M Collins
This document remains the property of McConnell Dowell Corporation. Its contents are confidential and shall not be reproduced, destroyed or given away without the express, written permission of McConnell Dowell Corporation. The electronic version of this document in MMS Database on designated server(s) is the Master Copy and is a controlled document. Unless specifically noted thereon, other copies of this document are uncontrolled. Based on MMS Template# 010-J011-000 Rev3 2Oct2014
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
TABLE OF CONTENTS 1
PROCESS SUMMARY .................................................................................................................... 6
2
OBJECTIVES .................................................................................................................................. 6
3
DEFINITIONS .................................................................................................................................. 6
4
RESPONSIBILITIES ........................................................................................................................ 6
5
4.1
Project Manager (PM) ............................................................................................................... 6
4.2
Senior Project OHS representative (SPOHSR) .......................................................................... 6
4.3
Superintendents and Supervisors (S) ........................................................................................ 7
4.4
McConnell Dowell and subcontractor personnel ........................................................................ 7
4.5
Contracts and Procurement Personnel ...................................................................................... 7
4.6
Crane Lift Supervisor ................................................................................................................ 7
PROCESS DESCRIPTION .............................................................................................................. 7 5.1
Plan the Job .............................................................................................................................. 7
5.1.1
Review legislation, standards, other related MCD SOPs and Project Risk Register ............. 7
5.1.2
Select lifting equipment that is fit for purpose ...................................................................... 8
5.1.3
Identify licence or competency requirements for crane and lifting personnel ....................... 8
5.1.4
Select Plant operators ........................................................................................................ 9
5.1.5
Initial inspection and approval to bring plant on site ...........................................................10
5.1.6
Report defects...................................................................................................................10
5.1.7
Statutory plant inspections ................................................................................................10
5.1.8
Develop a plant maintenance schedule .............................................................................11
5.1.9
Arrange maintenance and refuelling ..................................................................................11
5.2
Do the Job ...............................................................................................................................12
5.2.1
Plan the lift ........................................................................................................................12
5.2.2
Daily plant inspections.......................................................................................................12
5.2.3
Report defects...................................................................................................................12
5.2.4
Prepare work area and evaluate weather ..........................................................................13
5.2.5
Conduct the lift ..................................................................................................................13
5.3
Supervise and Monitor Lifting Operations .................................................................................13
5.3.1 5.4
Take action when safety risks are identified..............................................................................13
5.4.1 6
Supervise the lifting operation ...........................................................................................13
Report and Take Action.....................................................................................................13
TECHNICAL STANDARDS .............................................................................................................14
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 2 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
6.1
Crane Selection and Planning ..................................................................................................14
6.1.1
Pre-Mobilisation ................................................................................................................15
6.1.2
Crane location planning – vicinity, visibility ........................................................................15
6.1.3
Ground Support ................................................................................................................16
6.1.4
Cranes on Suspended Surfaces ........................................................................................16
6.1.5
Weather Conditions...........................................................................................................17
6.1.6
Marine Conditions .............................................................................................................17
6.1.7
General Operation of Cranes on Floating Barge ................................................................17
6.1.8
Guidelines for Crane De-rating and Tie Down/securing......................................................18
6.1.9
Crane Tie Down ................................................................................................................18
6.2
Crane Operation ......................................................................................................................19
6.2.1
General Safe Use requirements ........................................................................................19
6.2.2
Competency......................................................................................................................19
6.3
Communication ........................................................................................................................20
6.3.1
Hand Signals ....................................................................................................................20
6.3.2
Radio Communication .......................................................................................................20
6.4
Lift Categories..........................................................................................................................22
6.4.1
Travelling Loads (Pick and Carry)......................................................................................22
6.4.2
Multiple hoist or crane operation ........................................................................................22
Requirements for multiple crane hoisting .........................................................................................22 Planning for multiple crane hoisting .................................................................................................23 Synchronisation of the crane and crab motions ...............................................................................23 Pick and Carry (Multiple Cranes) .....................................................................................................23 6.4.3
Controls ............................................................................................................................23
6.4.4
Crane Lift Plans ................................................................................................................24
6.5
Maintenance, Inspection and Repair - Cranes ..........................................................................24
6.5.1
Maintenance .....................................................................................................................24
6.5.2
Inspections........................................................................................................................25
6.5.3
Periodic inspections ..........................................................................................................25
6.5.4
Major inspection to assess a crane for continued safe operation. .......................................26
6.6
Repairs ....................................................................................................................................26
6.6.1
Assessment for repair procedure .......................................................................................26
6.6.2
Management of repairs. ....................................................................................................26
6.6.3
Repair work.......................................................................................................................27
6.6.4
Welding repair examination ...............................................................................................27
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 3 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
6.7
Rigging and lifting ....................................................................................................................27
6.7.1
Competency......................................................................................................................27
6.7.2
Equipment Selection & Planning........................................................................................28
6.7.3
General requirements- Lifting Equipment...........................................................................28
6.7.4
Chains ..............................................................................................................................29
Care................................................................................................................................................29 Use .................................................................................................................................................29 6.7.5
Steel Wire Rope ................................................................................................................30
6.7.6
Synthetic Slings ................................................................................................................30
6.7.7
Lifting Hardware ................................................................................................................31
Shackles .........................................................................................................................................31 Eye Bolts ........................................................................................................................................32 Lifting Beams ..................................................................................................................................32 Sundry Equipment ..........................................................................................................................33 6.8
6.8.1
Slinging the Load ..............................................................................................................33
6.8.2
Executing the Lift ..............................................................................................................33
6.8.3
Management of change during a lift ...................................................................................34
6.9
7
Lifting the Load ........................................................................................................................33
Inspection, Repair and Modification ..........................................................................................34
6.9.1
Inspection .........................................................................................................................34
6.9.2
Repair and Modification.....................................................................................................35
OTHER EQUIPMENT USED FOR LIFTING ....................................................................................36 7.1
Earthmoving Equipment Used For Lifting..................................................................................36
7.1.1
General requirements for lifting with earth moving equipment ............................................36
7.1.2
Requirements for rated capacity at maximum reach/radius ................................................37
7.1.3
Controlled lowering devices ...............................................................................................37
7.1.4
Stability .............................................................................................................................37
7.1.5
Rated hydraulic capacity ...................................................................................................38
7.1.6
Quick-hitches ....................................................................................................................38
7.1.7
Marking and Labelling .......................................................................................................38
8
RECORDS......................................................................................................................................38
9
REFERENCES ...............................................................................................................................39
10
APPENDICES .............................................................................................................................40
Appendix A – Licences To Perform High Risk Work ............................................................................40 Appendix C – Communication Signals and alarms ..............................................................................42 COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 4 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Appendix D – Working near overhead power lines - No go zone .........................................................43 APPENDIX E – Free Fall Features on Cranes ....................................................................................44 APPENDIX F – Typical Adverse Weather Guidelines ..........................................................................45 APPENDIX G - Commonly used Terms and Alternative Names ..........................................................47
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 5 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
1 PROCESS SUMMARY To manage crane and lifting operations in order to minimise or eliminate the risk of injuries, fatalities and incidents This Safe Operating Procedure addresses the following MCD Golden Rules:
“Never be under a suspended load.”
2 OBJECTIVES This procedure applies to all crane and lifting activities conducted on land within McConnell Dowell controlled sites and activities, and to all McConnell Dowell employees, contractors and visitors when involved in crane and lifting operations.
3 DEFINITIONS Competent Person – A person, who has through training, qualification, experience, or a combination of these, has the knowledge and skill enabling them to correctly perform the required tasks. Lifting equipment – Any equipment or device used or designed to be used directly or indirectly to connect a load to a crane and which does not form part of the load e.g. Wire rope slings, chain slings, synthetic fibre slings, hooks, fittings, swivels, shackles, eye bolts, rigging screws, wedge sockets, plate clamps and lifting beams. SWL – Safe Working Load WLL – Working Load Limit
4 RESPONSIBILITIES 4.1 • •
4.2
PROJECT MANAGER (PM) Ensure that this procedure is communicated to relevant Project personnel. Ensure that all relevant aspects of this procedure are implemented by McConnell Dowell and contractor personnel.
SENIOR PROJECT OHS REPRESENTATIVE (SPOHSR)
•
Assist the Project Manager, Superintendents, Supervisors and Contractor Representatives to implement this procedure
•
Modify this procedure to meet any project specific contractual and legislative requirements
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 6 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
Monitor compliance with the procedure and report noncompliance to the Project Manager
4.3 • •
SUPERINTENDENTS AND SUPERVISORS (S) Prepare and supervise crane and lifting operations in accordance with this procedure Ensure that sufficient resources are available to conduct a safe lift
4.4 •
MCCONNELL DOWELL AND SUBCONTRACTOR PERSONNEL Comply with all relevant aspects of this procedure
4.5
CONTRACTS AND PROCUREMENT PERSONNEL
•
Make sure that all purchased or hired-in lifting equipment to be used on MCD projects, complies with the relevant standards of the country, and is fit for purpose.
•
All contracts awarded comply fully with the requirements and intent of this procedure.
4.6 •
CRANE LIFT SUPERVISOR Review all technical details and plans for lifts
5 PROCESS DESCRIPTION 5.1 5.1.1
PLAN THE JOB Review legislation, standards, other related MCD SOPs and Project Risk Register
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Review the Project OH&S Legal & Other Requirements to identify any legislation that is relevant to this procedure
Start of project
SPOHSR
Project OH&S Legal & Other Requirements Refer to Compliance with Legal & Other Requirements (MMS # 000-D004-000), and Project Compliance with Legal & Other Requirements (MMS # 300-E012-100).
Identify any Standards, Codes of Practice etc relevant to this operation
Start of project
SPOHSR
Review MCD SOPs to identify any that are relevant to this operation
Start of project
SPOHSR
SOP MMS# 020-T005-100 Height SOP MMS# 020-T009-100 Overhead Power Lines
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 7 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
SOP MMS# 020-T003-100 Workbox Use Plan works using the HSE Risk Register. (Create Construction Execution Procedures, JSEA/SWMS and ITPs, or refer to existing risk assessments and documents).
Start of project and ongoing
SPOHSR Project Manager Construction Manager
Project Risk Register will identify phases in the project where this SOP is applicable. Refer to procedure HSE Risk Management (MMS # 020-D012-100)
5.1.2
Select lifting equipment that is fit for purpose
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Select crane
Commencement of project and ongoing
Project Manager
See section 6.1 cranes (below) for selection criteria
Project Engineer
Where possible employees undertaking lifting operations should be consulted.
Supervisor Select rigging and lifting equipment
Commencement of project and ongoing
Project Manager Project Engineer
See section 6.7.1 rigging and lifting equipment (below) for selection criteria
Lifting Supervisor Supervisor
5.1.3
Identify licence or competency requirements for crane and lifting personnel
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Once the types of cranes to be used on the project are known, the specific licence requirements to operate these vehicles are identified.
Commencement of project and ongoing throughout project
SPOHSR
Crane operators must hold appropriate certification or license for the country state or region relevant to the project
Record the licence and competency requirements
See Appendix A – Certificates of Competency (below) for Australian competency tickets Record any licence requirements in Project Training Plan – Legislation Compliance Identify the specific licence requirements for the range of persons assisting crane operations Record the licence and competency requirements Identify whether any additional training is required to operate the plant
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
Commencement of project and ongoing throughout project
SPOHSR
See Appendix A – Certificates of Competency (below) for Australian competency tickets.
Commencement of project and ongoing throughout project
SPOHSR
Difficult site conditions may mean that operators need additional training even though they have the requisite licenses.
PAGE 8 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Record any additional training requirements in Project Training Plan (use MMS # 030-J008-100).
5.1.4
Select Plant operators
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Employ crane operators and other personnel and check their licence and training.
Commencement of project and ongoing throughout project
SPOHSR
See 6.2.2 Training and Competency below for selection criteria. HR to arrange a fitness for work medical examination as part of the employment process. Photo copy operator licences and competency tickets and record in the appropriate project Operator Competency Registers: File the photo copies of licenses etc in the employee personal file.
Arrange training and/or test competency
Record competencies of each plant operator.
Commencement of project and ongoing throughout project
SPOHSR
Commencement of project and ongoing throughout project
SPOHSR
Plant Operator Assessment (MMS # 030F047-100) or Assessment by external training organisation Competency Register (MMS # 030-F044-100, and Competency Register – By Person MMS # 030-F045-100).
Notification of loss of license or onset or medical condition that could make it unsafe to operate mobile plant
Immediately the employee becomes aware.
Or mobile plant operators
It is the responsibility of a plant operator to notify their Supervisor if they have a medical condition that may affect their ability to operate plant safely, or if any medication has been prescribed that may affect their ability to operate plant safely.
12 monthly fitness for work medical examination.
Rescind the authority to operate plant
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
As soon as management becomes aware
Supervisor to be immediately notified of the expiry or loss of license by any person.
Supervisor SPOHSR
Where there is a medical condition the issue is to be discussed with the employee before any decision is made.
PAGE 9 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
5.1.5
Initial inspection and approval to bring plant on site
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
When plant arrives on site
Lifting Supervisor
Incoming Plant Inspection Checklists (MMS # in the number sequence 045Fnnn-100).
Initial inspection and approval to bring plant on site Carry out an inspection of all lifting equipment before commencement of work. For external hires, service records, inspection records, log books etc. must be checked
SPOHSR
For items supplied internally by [McConnell Dowell entity], obtain and review inspection & service records. Once lifting equipment has been inspected
Supervisor SPOHSR
Plant & Equipment Register (MMS # 045F136-100 or equivalent).
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Write-down all defects and damage in the inspection report.
As required
Plant operator
Mobile Equipment Daily Inspection Report
Record approval of cranes.
5.1.6
Report defects
If the defect requires immediate attention or endangers the safety of employees, phone the supervisor immediately.
(MMS # 045-F030-100).
If plant is unsafe to operate tag with an ‘Out of Service’ tag.
Immediately
Supervisor
Arrange for repairs.
As required
Supervisor
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Identify any statutory requirements for Plant inspection or any requirements listed in relevant Standards
At project commencement
SPOHSR Lifting Supervisor
See 6.5 Maintenance, Inspection and repairs – Crane (below) for MCD requirements
5.1.7
Refer to procedure Tagging and Locking (MMS # 020E015-100)
Statutory plant inspections
See 6.9 Maintenance, Inspection and repairs -Rigging and lifting Equipment (below) for MCD requirements. Record any statutory inspection requirements in Project Legal & Other Requirements (MMS # 020-J004-YYYY and MMS # 025-J001-YYYY) Schedule inspections on the project plant maintenance and inspection schedule
At project commencement
SPOHSR
Project plant maintenance and inspection schedule
Arrange inspections
See schedule
SPOHSR
Record completed inspections in the project plant register
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 10 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
5.1.8
Develop a plant maintenance schedule
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Develop a project plant maintenance and inspection schedule that complies with legal requirements MCD requirements and manufacturers’ recommendations for all cranes and lifting equipment
Commencement of project and ongoing throughout project
Plant Manager
See 6.5 Maintenance, Inspection and repairs – Crane (below) for MCD maintenance and repair requirements See 6.9 Maintenance, Inspection and repair Rigging and lifting Equipment (below) for MCD maintenance and repair requirements Project plant maintenance and inspection schedule
5.1.9
Arrange maintenance and refuelling
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Project commencement and ongoing
Project Manager
Refer to Storage Maintenance & Refuelling of Machinery
Arrange maintenance and refuelling Source Plant maintenance and refuelling suppliers.
Plant Manager
(MMS # 025-L007-100). Potential suppliers are to provide information on safe operating procedures for tasks such as refuelling, plant isolation systems, elevated work, qualifications of maintenance personnel etc. Potential suppliers must provide evidence of being able to meet the environmental conditions of the project Maintenance companies are to provide a written assurance that all work is performed by appropriately trained and competent persons and that all work is done in accordance with any relevant legislation or standards. Modification to lifting Equipment Ensure that all modifications to lifting equipment if required are designed and carried out by a competent Engineer and in accordance with the relevant legislation and standard.
As required
Project Manager
Obtain the engineers certification before returning any modified lifting equipment to service
As required
Supervisor
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
See 6.9 (below) for MCD requirements on modification of lifting equipment
PAGE 11 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
5.2
DO THE JOB
5.2.1
Plan the lift
WHAT HAS TO BE DONE
WHEN
WHO
Review the work pack
When planning the lift
Lift Supervisor
Inspect the work site
When planning the lift
Supervisor
INFORMATION
Check for issues such as overhead services existing structures. proximity to excavations Underground services other cranes and mobile plant etc in the vicinity.
Develop the lift plan.
When planning the lift
Supervisor
See section 5.11(below) for MCD lift plan requirements
Obtain the Ground Load Bearing Capacity Calculations for Outrigger placement
When planning the lift
Supervisor
See section 6.13 (below) for MCD requirements
Identify additional equipment required
When planning the lift
Lift Supervisor
Develop Safe Work Method statement (SWMS)
Prior to the lift
Supervisor
Communicate SWMS to workgroup
Prior to the lift
Supervisor
Set up crane and inspect crane and all lifting equipment
Prior to the lift
Lift Supervisor
See section 6.1 (below) for inspection requirements after crane has been mobilised.
Supervisor Rigger
See sections 6.8 (below) for MCD requirements on executing the lift.
Lift and place the load
5.2.2
Daily plant inspections
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Carry out and record daily pre-start checks of all lifting equipment. Submit check sheets to the project office weekly.
Daily or at start of each shift.
Plant operator
Mobile Equipment Daily Inspection Report (MMS # 045-F030-100).
Pre-start checks are to be performed when taking over from another operator..
5.2.3
Report defects
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Write-down all defects and damage in the inspection report.
As required
Plant operator
Mobile Equipment Daily Inspection Report
If the defect requires immediate attention or endangers the safety of employees, phone the supervisor immediately.
(MMS # 045-F030-100).
If plant is unsafe to operate tag with an ‘Out of Service’ tag.
Immediately
Supervisor
Arrange for repairs.
As required
Supervisor
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 12 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
5.2.4
Prepare work area and evaluate weather
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Identify and barricade ‘no-go’ zones.
Prior to the lift
Supervisor
Traffic controllers may be required where loads are lifted over access roads
Check weather forecast and current wind speeds
4 hours prior to the lift
Supervisor
Check manufacturers manual for safe wind speeds.
Notify other workgroups in the immediate area
Prior to the lift
Supervisor
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Check that slings, ropes chains etc are correctly attached to the load.
Immediately before the lift
Lift Supervisor
See section 6.8 (below) for MCD requirements on safe lifting.
5.2.5
Conduct the lift
Rigger
General Safe Use requirements Executing the Lift
5.3 5.3.1
SUPERVISE AND MONITOR LIFTING OPERATIONS Supervise the lifting operation
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Observe the lifting operations of both MCD employees and contractors
Ongoing
Supervisor
Monitor compliance with this standard.
Conduct regular inspections of lifting operation
Weekly
Rigger Lift Supervisor Supervisor Rigger SPOHSR
5.4 5.4.1
Check that a JSEA/SWMS has been completed for the job. Stop the job if no JSEA/SWMS is available. Refer to HSE Inspections and monitoring (MMS # 020-D010-100).
TAKE ACTION WHEN SAFETY RISKS ARE IDENTIFIED Report and Take Action
WHAT HAS TO BE DONE
WHEN
WHO
Report any defective equipment to the supervisor.
Immediately
All employees
Turn off the equipment
Immediately
Supervisor
Fix an “Out of Service” tag to the suspect equipment.
Immediately
Supervisor
Send the equipment for repair.
Immediately
Supervisor
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
INFORMATION
Refer to procedure Tagging and Locking (MMS # 020E015-100)
PAGE 13 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Report inappropriate or unsafe operations involving crane use and lifting operations
As required
All site management and employees
Stop the job if unsafe
Immediately on the identification of unsafe activity
Supervisor
As required
Project Manager
Initiate disciplinary action were required.
Complete hazard report form
HSR SPOHSR Disciplinary action may include suspension of authority to operate plant for a period of time, retraining, termination of employment etc
6 TECHNICAL STANDARDS 6.1
CRANE SELECTION AND PLANNING
Before selecting a crane for service, the following criteria are to be taken into account:
• • • • •
The result of an appraisal of an existing crane, if applicable. The maximum permitted forces on the supporting structure. Power supply. Rated capacity of the crane. Classification of the crane taking into account the application, including; -
type of loads to be lifted; mass of loads to be lifted; speed of lifts; and frequency of lifts.
• • • • • • • • •
The maximum load that will be imposed on the crane.
• •
Projected upgrades of plant.
The maximum load moment that will be imposed on the crane. The nature of the rigging or slinging to be used. The position from which the load is to be lifted. The position in which the load is to be placed. The movement limitations of the crane and the load. Other limitations of the crane. Multiple crane lifting. Working environment including hazardous gases, corrosive atmospheres and high ambient temperatures including full speed operation against in-service wind load. The provision of additional crane capacity to cater, where necessary, for changes in the site environment, for example, increases in lifted load mass due to manufacturing tolerances, rapid changes in weather conditions.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 14 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
6.1.1
Pre-Mobilisation
The following planning activities are to be carried out by a competent person(s):
• • • • • • • • • • • • • • • • • • • • • • • • •
Selection of cranes
•
Suitable equipment is available for the installation, maintenance, operation and dismantling of the crane.
• • •
Condition monitoring of the crane and associated equipment.
6.1.2
Crane location planning – vicinity, visibility
Lightning protection Earthing for the conditions – e.g. static build up due to EMR, wind etc Site access and crane siting Safety of personnel and public entering into the site and the lift area Procedures for setting up of the crane Procedures for lifting operations Procedures for dismantling of the crane Selection of the personnel Communication systems(s) Weather conditions Ground conditions Proximity of excavations Selection of lifting gear to the appropriate standards PPE requirements Emergency procedures Procedures for non-routine lifts – Multiple Lifting Operations For multiple crane lift MCD Insurance underwriters require notification Night Operations Parking & Storage facilities for crane components Marking of crane and ancillary equipment e.g. rated capacity, safety signs Access for servicing Interface with existing plant and traffic Obtaining of approvals from statutory authorities or other relevant parties Appraising an existing crane for suitability for use, and ensuring that the appraisal is carried out by a competent person.
The maintenance, inspection and safe operation of the crane and associated equipment. The preparation, availability and maintenance of instructions for the assembly, operation, maintenance and inspection of the crane.
Assess the risks of the following:
• • •
Overhead Power Lines Underground services Wind loading is to be taken into account, including increased funnelling effects between adjacent buildings or structures.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 15 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
• • • • • • • •
Nearby structures or other cranes
• •
The crane should be sited so that the crane operator has optimum visibility
6.1.3
Ground Support
•
For Heavy Lifts, e.g. Bridge Beams; Tilt-up Panels and other lifts where the load is 50 tonnes or more, certification of the ground bearing capacity must be obtained from a geo-technical engineer before performing a lift.
•
A competent person must make sure that loads imposed by the crane can be sustained by the ground or any other means of support and that the crane can operate within the levels and other parameters specified by the manufacturer.
•
Where the crane is required to work in the vicinity of an excavation or an embankment, the possibility of slip or collapse of the supporting surface is to be evaluated by a competent person – and where applicable the embankment or excavation is to be reinforced.
•
Loads are not to be imposed on any new concrete supporting structure until the structure has reached sufficient strength.
6.1.4
Cranes on Suspended Surfaces
•
An assessment should be carried out by a structural engineer when planning to position a crane on a suspended surface. A suspended surface could include but not limited to the following; suspended concrete slabs, wharfs, jetties, barges or any other instance where the surface integrity or rating is unknown.
•
The assessment should ensure that the supporting surface is capable of supporting loads imposed by the crane, and the loadings it would apply to the supporting surface during its proposed operation.
•
The structure needs to be assessed during various stages of the job, including driving to the set up location on the structure, set up, use and, if different or the structure is changed during the job, dismantling and removal of the crane.
•
Where there is a requirement to use a propping system for the supporting structure, a structural engineer must advise of the correct location and ensure the design considers all loading factors that will be imposed upon it. A competent site representative is to ensure the propping system is functioning and maintained in line with the engineer’s advice.
• •
If the crane cannot be set up in the planned location than full assessment is to reoccur.
Excavations Fixed hazards – (Trees, poles, protruding objects) Personnel movement within the crane working area/s Mobile equipment movement within the crane working area/s Public access areas including roadways, railways, rivers and aircraft flight paths Effects of EMR (e.g. busbars, strobe lights, welding) on radio, infra-red or electronic controls The vicinity of airfields (High operating Cranes) maybe required warning lights and jibs painted high visibility colours. Precautions should be taken against the effects of noise, exhaust gases, hydraulic fluids, lubricants, fuel, dust and other environmental pollutants emitted by the crane.
Assessment items to address, but are not limited to the following include; - Crane model
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 16 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
- Crane configuration - Any crane de-ratings - Maximum outrigger loadings - Type of dunnage to be placed under outriggers - Principal Contractor details and representative - Structural Engineer completing assessment
•
The crane operator has the right to refuse to operate, where the above assessment cannot be validated and provided on site.
6.1.5
Weather Conditions
Prior to commencing crane and lifting operations the Crane Operator is to review the prevailing weather conditions (wind speed and direction, visibility, etc.). Crane and lifting operations shall not commence if the weather or environmental conditions are likely to jeopardise the safety of the activity – refer to Appendix F Adverse Weather Guidelines, for a comprehensive guide to the effects of varying wind speeds on land and water. 6.1.6
Marine Conditions
Crane and lifting operations occurring in a marine environment may be subject varying conditions (such as swell or unexpected wave action) which have potential to shock or dynamic load lifting plant and equipment, particularly when loading or unloading equipment to and from barges or vessels. If a load suddenly comes onto the lifting equipment, or if a load being lowered is suddenly stopped, the weight of the load borne by the equipment is effectively increased. The movement of the vessel and the hoist motion of the crane can combine to produce severe dynamic loading of up to three times the static weight of the load. Shock loading is not only experienced by the crane: the lifting accessories between the load and crane will also be subject to increased loading and, in the case of chains, shackles, etc. this may result in deformation known as permanent set. Twist may be induced in lifting equipment leading to the whole lifting assembly becoming tangled and shackles becoming jammed in their attachment points. Such deformation prevents the shackles being pulled into line with the sling and they become loaded in the wrong direction. In addition, the length of the slings can become uneven, causing unequal load distribution. The inherent risks associated with lifting operations in a marine environment, including the dynamic loading described above, mean that agreed requirements in the risk assessment are adhered to. 6.1.7
General Operation of Cranes on Floating Barge
Crane lifting operations on floating barges and vessels are inherently dangerous activities and McConnell Dowell requires the highest standards of planning and operation when these activities are being performed. The requirements of all relevant local legislation and regulations are to be complied with in all circumstances The crane manufacturers’ requirements for operating their specific cranes on floating barges and vessels must always be followed.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 17 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Cranes will be tied down in all conditions except within smooth water limits, and only where site specific conditions permit. In such situations a documented risk assessment must be undertaken. The risk assessment is to fully describe the particular activity or lift to be performed and when and how the crane can be used without the tie downs. Cranes on barges shall be appropriately de-rated for all conditions. Where a project specific assessment shows that an amendment to the guidelines below is warranted, such an amendment is to be considered for that project only. 6.1.8
Guidelines for Crane De-rating and Tie Down/securing
Cranes on floating barges shall be de-rated as follows: a) Dynamic Factors All loads to be lifted shall be factored as indicated and the factored load shall be used when checking against the crane’s current applicable load chart, including any de-rating as derived below. 1. 2. 3. 4.
All lifts in Smooth Waters – 1.1; All lifts in Partially Smooth Waters with wave heights ≤1m – 1.35; All other cases, but wave height ≤3m – 2.4; Where wave heights exceed 3m, no lifts shall be performed.
b) Inclination Factors Manufacturers Crane Maximum Load Charts shall be derated as applicable to the heel and trim inclinations derived in the vessel’s stability booklet that applies to the barge/crane combination intended to be used and for the lift/no lift condition being contemplated. Manufacturers Crane Maximum Load Charts shall be derated as applicable to the heel and trim inclinations derived in the vessel’s stability booklet that applies to the barge/crane combination intended to be used and for the lift/no lift condition being contemplated. Unless a rigorous crane/barge combination stability analysis has been performed and using specific inclination crane capacity data provided by the crane manufacturer, the following factors shall be adopted: 1. 2. 3. 4.
For inclinations < 1% - no change; For inclinations >1% and <1° - 20% de-rating applies; For inclinations >1° and <2° - 35% de-rating applies; For inclinations >2°- do not lift or operate the crane.
Note: the manufacturer’s recommendations may vary from these requirements and, if more stringent, they must be followed. 6.1.9
Crane Tie Down
The tie down system for a crane shall be designed for the following loads:1. 2. 3.
Smooth Waters – 0.1g lateral force in any direction; Partially Smooth Waters - 5° heel, 2.5° trim, 0.1g heave, 0.1g lateral force in down heel/trim direction; Other areas – special analysis is required by independent certified naval architect.
Friction between the crane and the barge is not to be taken into account to mitigate these forces.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 18 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
These provisions do not apply to any coastal or ocean tow, any tow longer than 4 hours in duration, any extreme environmental event (e.g. cyclones) or any operations outside of Inshore Operational Areas. Tie downs/sea fastenings are to be specifically designed for such tows. Refer to USL Code of Australia for definitions.
6.2
CRANE OPERATION
6.2.1
General Safe Use requirements
• • •
The crane will only be operated within the rated capacity and design classification
• • •
All cranes are to be kept clean
•
The crane is to be inspected daily by the crane operator to identify maintenance or repair items that may affect the efficient or safe operation of the crane.
• • • •
The SWL is to be stencilled on the crane.
•
Persons entering a crane operating area must make contact and be acknowledged by the person in charge of the area prior to entering the area. Crane operators should never be approached directly.
• • •
Barricades or guarding may be required where necessary.
•
Clearances are to be maintained and procedures developed to prevent unplanned contact between any parts of cranes working in the same site (refer to AS 1418 or AS 2550)
• •
The crane driver is not to use a mobile telephone whilst operating the crane.
6.2.2
Competency
•
The crane operator is to hold a valid license and/or certification, specific to the type and size of the crane and/or lifting equipment that is been used.
•
All operators who operate any crane are to be familiar with the following:
Power supply is compatible with the crane requirements (Gantry Cranes) Clear safe and defined pathways for cranes operated by pendant or wireless control is to be provided and maintained (Gantry Cranes) Tools and loose objects are to be stowed and secured The crane is to be inspected in accordance with the Operations and Maintenance Manual and/or local regulatory requirements
All cranes be fitted with “Christmas Tree Lights” No repair work or maintenance or refuelling is to be carried whilst the crane is operating. Only one competent person (certified dogman/ rigger or local equivalent) is to give signals to the crane operator.
The crane is not to be left unattended in the operating mode. The crane driver is to be familiar with any electrical power cables or conductors in the lift area and any other potential hazard.
When travelling a crane without a load, all chains and slings must be removed from the hook unless it is either tied to the crane to ensure it cannot bounce or twist: or independently tied back to the hook in such a way that any possible dislodgement caused by the movement of the jib is prevented.
-
Safe operation of the particular crane Locations and operation of all safety backup systems
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 19 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
-
Reading and understanding of load charts Capabilities of the machine Any peculiarities pertaining to that particular crane Safe operation near overhead power lines.
Appendix A Licensing Persons Performing High Risk Work lists the Certificates of competency relevant to the crane industry - Australia Only. Project management is to identify the specific local licensing/certification requirements for persons undertaking crane operations.
6.3
COMMUNICATION
At all times, there is to be adequate communication between all personnel involved in the lifting operation. Either hand signals or radio equipment appropriate for the relevant lifting operation is to be used. 6.3.1
Hand Signals
Crane Operators and dogman/ riggers or local equivalent must be familiar with the system of signalling being used for the operation. The signals presented in Appendix C are recommended for adoption in Australia. The local equivalent should be consulted when operating outside of Australia. The Crane Operator must:
•
Ensure that the signalling system to be used is clearly agreed between the crane crew prior to commencing any crane and lifting activities.
•
Only respond to signals given by the dogman/ rigger or local equivalent or ‘STOP’ when given a signal by other persons in an emergency situation.
• •
Maintain visual contact with the dogman/ rigger or local equivalent at all times.
•
Cease crane operations if inclement weather or darkness impairs the ability to see the dogman/ rigger or and operations cannot continue safely.
6.3.2
Radio Communication
Cease lifting operations if contact is lost and only recommence when a clear line of communication is re established.
The Crane Operator is to reach a clear understanding with the dogman/ rigger or local equivalent before lifting operations begin on the protocols to be used. If there is any interruption to the communication (e.g. third-party transmission) the Crane Operator must STOP the lifting operation immediately, only resuming when communication with the dogman/ rigger or local equivalent is re-established. Radio checks shall be carried out prior to the start of the lifting operation. When directing the load, instructions shall be clear and precise. Where appropriate, a communication method can be used whereby the signaller gives a continuous signal to continue the movement. The equipment operator shall stop immediately if he does not receive the signal. During periods of no radio communication, all lifting operations should be reviewed with suitable controls identified and agreed by personnel involved to enable safe execution of the operation. The following protocol is recommended for radio communication during lifting operations:
•
Call signs should be set up and adhered to.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 20 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
• •
Call signs must be used at all times to establish the authenticity of commands or directions.
• •
The receiving operator should indicate understanding of any dialogue through the response ‘roger’.
•
If the receiving operator is unsure regarding a message, the operator must not acknowledge but should repeat the message as he understands it and ask for confirmation or simply request the transmitting operator to repeat.
•
At the close of communication the transmitting operator should indicate the end of the transmission with the command ‘over and out’.
•
For single function operations the dogman/ rigger or local equivalent should relay to the Crane Operator using terminology such as: ‘up on the hoist’, ‘Boom up’, ‘Slew right’, etc. Where it is necessary to carry out an operation slowly the dogman/ rigger or local equivalent should instruct the Crane Operator accordingly. To stop a function the dogman/ rigger or local equivalent should instruct the Crane Operator to ‘Stop’. To stop all operations the dogman/ rigger or local equivalent should instruct the Crane Operator with ‘All stop’.
•
For simultaneous function operations the dogman/ rigger or local equivalent should relay to the Crane Operator using terminology such as: ‘Come up on the load and boom down’, etc. To stop a function the dogman/ rigger or local equivalent should instruct the Crane Operator to ‘Stop on the boom, slew right only’, etc. To stop all operations the dogman/ rigger or local equivalent should instruct the Crane Operator with ‘All stop’.
• •
Under no circumstances should profane language be used while transmitting.
•
Radio messages should reflect work requirements only; general conversation should not be carried out over the air waves.
•
Always ensure that you fully depress the transmission button before speaking into the microphone. Speak clearly at all times and do not release the button until a few seconds after completing your message.
•
When directing the crane, ensure that any accompanying colleagues’ radios are switched off – if more than one radio is switched on in close proximity interference and distortion of the signal will take place when an instruction is transmitted.
•
During blind lifts when the load is being hoisted or lowered for a long time do not maintain the transmission button in the depressed position for the duration of the lift – the dogman/ rigger or local equivalent should give the initial instruction and then talk to the Crane Operator as required to reassure the Operator that the line of communication is still active and that the lift remains under control.
•
During high winds, ensure that the area of the microphone you speak into is not exposed to the wind as background noise created may distort the transmission.
•
Ensure that the radio microphone is not exposed to rain. If a plastic carrying case offering full protection of the radio is not available, a simple precautionary measure such as a small plastic bag or a piece of cling film around the microphone will ensure that it remains dry.
At the end of an instruction or enquiry the transmitting operator should indicate the end of the message by the command ‘over’. Under no circumstances should the transmitting operator assume understanding without acknowledgement (‘roger’) from the receiving operator.
Should the radio antenna become damaged exposing the central core, the antenna must immediately be replaced in order to maintain not only optimum performance but to ensure user safety.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 21 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
6.4
Do not carry the radio in a pocket always ensure that they are carried on the body by either a belt clip or protective holster. Consider using the protective holster when working at height or climbing ladders to ensure that the radio does not become a dropped object if dislodged.
LIFT CATEGORIES
6.4.1
Travelling Loads (Pick and Carry)
•
No person is to walk between the load and the crane whilst the load is being carried on site roads or within any work area.
•
Dogman/ Riggers are to escort the cranes when travelling with loads on site, and must not travel in the crane cab under any circumstances.
• •
Use of tag lines to tie load to crane at >2.5o side slope gradients is prohibited.
•
Loads are to be kept as close to the ground as possible when travelling.
•
If unstable ground conditions or obstructions in travel path are present, the control methods for these hazards are to be included in a specific JSEA.
When travelling without a load, the hook block is to be secured to prevent swinging and damage to boom sections. Where this is impractical the hook block should be held fast against the boom head.
Pick and Carry cranes shall be de-rated as follows:
• • •
0.0 – 0.6 o manufacturer approved load charts and specifications apply.
•
>5.0 o the activity is to cease and be reassessed to identify another means of load lifting or transportation.
>0.6 – 2.5 o de rate in line with manufacturer approved load charts and specifications. >2.5 - <5.0 o de rate by a full 60% of normal SWL capacity, regardless of boom position and length*.
* Additional MCD safety factor exceeding manufacturer’s instructions 6.4.2
Multiple hoist or crane operation
Requirements for multiple crane hoisting
• •
All multiple crane lifts are to comply with the relevant Australian Standard as a minimum
•
The following minimum capacity requirements for each crane is to apply (where hoisting operation is not designed):
• • • •
For 2 cranes -
20% greater than the calculated share of the load.
For 3 cranes -
33% greater than the calculated share of the load.
Other than for designed lifts, lifting operations using two or more cranes will use cranes of the same type.
For 4 or more cranes-
50% greater than the calculated share of the load.
Where load is suspended from more than one hoist line the load must be handled in such a way that: -
The rated load for each line is not exceeded
-
The load being handled does not exceed the rated capacity of the crane.
-
Supervision is to be provided by a competent person, who is not one of the crane operators.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 22 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Planning for multiple crane hoisting When planning, determine: the accurate proportion of the load to be carried by each crane how the proportioning is to be maintained whether each crane has appropriate additional capacity over the portion of the load to be lifted the operating characteristics of the cranes e.g. speed of hoisting. The allowance that should be made for manufacturer’s tolerances (if the load information is taken from technical drawings) The mass and distribution of the lifting gear on cranes and crabs Manitowoc and Grove cranes require the weight of any wire below the head sheave to include in the total load weight. Weather conditions, and access the prevailing conditions (such as wind) before commencement of and during the multiple hoisting operations. Synchronisation of the crane and crab motions
• •
Crane and crab motions are to be synchronised or one crane placed in free slew mode
•
NOTES:
To allow for the probability of the motions of the cranes or crabs not being accurately synchronized, particularly if the cranes or crabs have dissimilar operating characteristics, the operation must be performed at slow speeds with extreme care being exercised to maintain the hoist ropes as close to vertical as possible. -
-
1. The rated capacity of a crane is calculated on the assumption that the load will be raised and lowered in a vertical plane. The crane structure will have been designed to withstand any lateral loads imposed by accelerations in the various crane and crab motions, but it is unsafe to rely on this lateral strength to withstand horizontal components of non-vertical lifts. 2. In practice, there will always be some variation due to differences in response to the activation of the motion controller and the setting and efficiency of the braking system
Pick and Carry (Multiple Cranes)
•
In pick and carry operations, the axis of both or all cranes or crabs is to be kept aligned in the same direction where possible. The possibility is that once out of alignment especially during cornering; the movement of one crane or crab may push or pull either the other crane(s) or crab(s) and cause loss of stability. Load chart limitation during articulation is to adhered to
•
NOTE: Instruments are available to monitor constantly the angle of the load, and the verticality and force in each hoist rope throughout the lifting operation. Their use is recommended.
•
Tag lines must be used on loads when in pick and carry operations with the exception of dual crane operations
• •
Cranes will not pick and carry loads on a fly or with a fly in the un-stowed position
6.4.3
Controls
•
All lifts require JSEA/SWMS to be completed and reviewed by the Crane Crew and responsible Supervisor prior to commencing the activity.
Dual crane pick and carry is a critical lift requiring a lift study
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 23 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
Lifting of persons in workboxes (Refer MMS Safe Operating Procedure # 020-T003-100 Workbox Use).
•
Working near overhead power lines (Refer MMS Safe Operating Procedure # 020-T009-100 – Overhead Power Lines)
•
Documentation specific to the operation being carried out should accompany the Crane Lift Plan. This includes items such as erection sequences, relevant drawings, fixings etc.
6.4.4
Crane Lift Plans
Crane Lift Plans are to show weight, radius, crane capacity and % of SWL and a drawing showing the plan view of the crane and load. Crane Lift Plans (MMS # 600-F003-100) are required to be completed when any of the following conditions apply:
• •
The client requires one or the crane operator requests one;
• • • • • • • •
The load is 50 tonnes or more;
•
The suspended load passes over any operating facility, or passes over or within 6 meters of any electrical installation such as transformers and substations. In addition, lifting activities near overhead aerial conductors are to comply with SOP MMS # 020-T009-100;
•
Drawings of existing facilities at the site show that the movement of the crane or any operation of the crane may damage underground services.
•
Singapore - All lifts (Refer to WSH Operation of Cranes Regulations 2011)
6.5
The total suspended load including rigging equipment exceeds 85% of available crane capacity (refer to crane load chart); A Bridge Beam is to be lifted during bridge installation work; A Tilt-up Panel is to be lifted; Pre-cast Concrete Panels are to be erected; A Tower Crane is to be erected; A Mobile Crane is to used on a Barge; Lifting large pressure vessels or tanks More than one crane is to be used - either in shared lift configuration or when one of the cranes is to be used as a `tailing' crane;
MAINTENANCE, INSPECTION AND REPAIR - CRANES
Maintenance, inspection and repairs are to be carried out by a competent person in accordance with the requirements listed below and as identified in AS.2550.1 or its local equivalent. 6.5.1
Maintenance
•
A preventative maintenance program will be established giving consideration to the manufacturer’s recommendations. It will be based on the working environment and the frequency and severity of use of the crane.
• •
Ensure all subcontractor contracts include maintenance schedules When parts and components are replaced, replacements will be identical or equivalent to the original equipment parts and components.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 24 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
Where past experience has shown particular problems with a crane, a specific rectification program will be instigated and documented.
• • • •
All malfunctions and problems will be corrected before the crane is returned to service.
6.5.2
Inspections
Maintenance is to be carried out in accordance with the Manufacturer’s recommendations. A documented record is to be maintained for any maintenance completed. Routine inspections should take place at intervals not exceeding those shown in the operator’s handbook.
The following items should be checked for compliance with manufacturers’ specifications and safe operation as part of a pre-operational inspection of a crane:
• •
Check the oil levels, fuel level and lubrication of all moving parts.
• •
Check that all water is drained from air reservoirs.
•
Visually inspect structural members and other critical components such as brakes, gears, fasteners, pins, shafts, wire ropes, sheaves, locking devices and electrical contacts.
•
Check the security of the counterweight. Where this is in the form of removable weights, check that the weights correspond to those shown on the counterweight chart for the operating condition in use.
•
Check that the load moment system where fitted is correctly set or fitted (or both) with the program appropriate to the boom or jib length, and fly-jib lengths and falls or parts of rope.
• •
Check that the indicator appropriate to the boom, jib or fly-jib length is fitted.
• • • • •
Check the pneumatic systems and hydraulic systems including their safety devices.
• • •
Check signage, including warning signs and control markings.
6.5.3
Periodic inspections
•
Inspection is to include all items specified by the manufacturer for annual inspection along with all routine inspection and maintenance items.
•
As the result of a periodic inspection, a competent person may recommend a major inspection.
Check the ropes, rope terminal fittings and anchorages, rope drums and sheaves for any damage and wear. Check the crane for any loose or damaged structural component including supports and outriggers where fitted. Loose joints may be readily noticed by flaking or marking on the paint surface or by rust marks. Similarly, cracks may often be detected by rust runs.
Check that the crane cabin is in a tidy condition and free from grease and oil, rags, tools and materials other than those for which storage provision is made. Check the operation of the crane through all motions with particular attention to brakes. Check the operation of all limit switches or cut-outs, emergency and safety devices. Exercise caution in making the checks in the event of non-operation. Check that, where radio communications are being used, the calling signal is functioning and any messages may be clearly heard. Check that fire extinguishers are in place and satisfactory for use. Additional items nominated in the manufacturer’s instructions or operator’s handbook.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 25 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
• •
For details of inspections for particular types of cranes, refer to relevant Part of the AS 2550 series.
•
Vacuum and magnetic devices are to be fitted with failsafe devices where available
6.5.4
Major inspection to assess a crane for continued safe operation.
• •
All cranes are to be inspected and repaired as per AS2550.1
Where the crane has a non-positive lifting attachment, (vacuum, magnetic etc) suitably qualified personnel are to carry out maintenance according to the manufacturer’s recommendations. If such recommendations are not available, then twice-yearly maintenance is to be carried out. Permanent and electro-permanent lifting magnets are to undergo a yearly residual magnetism check of the magnet core. Where vacuum lifting attachments are used, the frequency of inspection is to be twice daily to ensure no seal damage the machines continue to function as designed.
Where third-party inspections are conducted, the following requirements apply: -
-
6.6
As part of this inspection, the maintenance records of the crane must be reviewed prior to the inspection. After the inspection, a report on the condition of the crane is to be compiled on the current condition of the crane. The usage of the crane must be verified for compliance with the design classification. The inspection is to include checking electrical, mechanical and structural components for safe condition and function. Opening of cover plates and removal of guards is to be as considered necessary by the inspector due to the existing condition. Particular attention must be paid to any component with a recent or existing history of repeated failures.
REPAIRS
Any part of a crane that becomes worn beyond manufacturer’s tolerances, damaged as to constitute a hazard, impairs the operation of the crane, or constitutes a hazard before the next routine inspection, must be repaired or replaced. The repairs and parts must comply with the manufacturer’s recommendations and specifications, or the recommendations of a competent person, taking due cognizance of the Standard to which it was designed and must be carried out by competent persons under competent direction and supervision. The repairs are to be appropriately tested. All repairs are to be adequately documented and recorded. 6.6.1
Assessment for repair procedure
•
• •
A competent person is to make an assessment of the defects and damage requiring repair based on the manufacturer’s tolerances and in accordance with AS 2550.1. The assessment is to be recorded and form a report. The report should contain the following: Details of how the incident happened or circumstances leading to the discovery of the defective parts. Nature and extent of the damage and defects. Proposed action based on the manufacturer’s recommendations.
6.6.2
Management of repairs.
•
Following the review of the competent person’s report, the equipment may only be repaired or scrapped. Where any component is scrapped, arrangements should be made to dispose of the damaged component in a manner that ensures it remains unusable as a load-carrying component.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 26 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Where it is decided to implement the manufacturer’s recommendations, instructions incorporating such recommendations will be prepared. Such instructions must be followed. Following repairs, the crane will undergo the load and operational tests specified in the appropriate part of AS 1418 to an extent commensurate with the type of alteration or repair. 6.6.3
Repair work
•
The repairer selected to carry out the work must be acceptable to the competent person. Repair work is to be carried out according to the following: Personnel with the necessary qualifications and experience will be engaged on the work. Work instructions will be provided. All work is to be in accordance with manufactures recommendations Sign off line manufacturers prior to work commencing All work to be managed by ITP, SMP, QMP, QC checklists. All work will be conducted in accordance with relevant Australian Standards or other applicable national or international Standards. All final non-destructive testing will be conducted by a competent person. A records management system is to be established for the documentation produced by repairers and received from other bodies for transfer to the owner.
• • • • • • • •
6.6.4
Welding repair examination
•
The examination of welding repairs must be carried out in accordance with the manufacturer’s repair procedure, or the appropriate weld inspection Standard. Preapproval for the welding procedures and qualifications of welders is required.
• 6.7 6.7.1
RIGGING AND LIFTING Competency
The slinging method is to be determined by a person who is competent in load slinging in accordance with local Safety Regulations. Project management is to identify the specific local licensing requirements for persons undertaking lifting operations. Within Australia the Riggers licence capabilities are defined as;: Dogging – consists of the application of slinging techniques to move a load (including the selection and inspection of lifting gear) and/or the directing of a crane/hoist operator in the movement of a load when the load is out of the view of the crane/hoist operator. Basic rigging – consists of dogging and rigging work involving: •
Movement of plant and equipment
•
Steel erection
•
Hoists (including mast climbing hoists)
•
Placement of pre-cast concrete
•
Safety nets and static lines
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 27 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
Perimeter safety screens and shutters, and Cantilevered crane-loading platforms.
Intermediate rigging – consists of all basic rigging work including rigging work involving: •
Cranes, conveyors, dredges and excavators
•
Tilt slabs
•
Hoists with jibs and self-climbing hoists
•
Demolition
•
Dual lifts
Advanced rigging – consists of all intermediate rigging work including rigging work involving: •
Gin poles and shear legs
•
Flying foxes and cableways
•
Guyed derricks and structures
•
Suspended and fabricated hung scaffolds
Australia Only Appendix A Licensing Persons Performing High Risk Work lists the Certificates of competency relevant to the crane industry -.(Refer to National Standard for Licensing Persons Performing High Risk Work.) 6.7.2
Equipment Selection & Planning
Before selecting any rigging and lifting equipment, the following should be taken into account;
• • • • • • • • • •
Load Headroom Frequency of use- life of sling Type of load – Steel, Machinery, timber, crates, shipping container etc Current inspection certificate Cost versus efficiency Length of sling Method of slinging Environment – corrosion, heat etc Storage requirements
6.7.3
General requirements- Lifting Equipment
•
A visual inspection will be conducted prior to use of rigging and slinging equipment.
• • • • • •
Never combine different types of slings.
• •
Inspections must be conducted by a competent person and be recorded by that person.
Shackles are to be used where slings are attached to eyebolts or lugs. Shackle diameter must not be less than sling diameter. Multiple individual slings are to be shackled together on the hook. All hooks are to be supplied with devices to prevent load movement. Lifting clutches are to be proof load tested at least at twelve (12) monthly intervals, with a record kept on site to verify such testing. All rigging and lifting equipment either purchased or hired on a project, must have all certifications relevant to the item in accordance with the relevant local standard.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 28 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
Items to be kept include but not limited to records from the manufacturer or supplier, identifying that the equipment has passed all relevant testing and has been supplied in accordance with the relevant local standard. Items include equipment such as; slings, shackles, eyebolts, lifting clutches, chain blocks etc.
•
All rigging and lifting equipment certification and inspection/test records are to be maintained and readily available.
•
Suitable storage arrangement available for the particular types of equipment – typically hung up off the ground in a covered, dry, clean, well ventilated place, away from direct sunlight.
•
If one or more of the defects, listed in Error! Reference source not found. is identified, the item is to be removed from service immediately, tagged out and condition fully assessed prior to being discarded.
6.7.4
Chains
Care
• • • •
Compliance certificate for chains should be available in project files. Store chain slings in a clean dry place, preferably on A-frames or wall racks. Lightly oil chains before prolonged storage. Never heat treat alloy chain or fittings.
Use
• • • • • • •
Minimum size chain for lifting purposes is to be 6mm.
•
The user should seek advice from the manufacturer regarding a reduction in WLL, where chain is to be used at temperature hotter than 200°C or colder than -10°C.
• •
Commence the lift slowly, taking up the slack gradually. Avoid shock loads.
Alloy steel chain Grade (T) 80 or higher is to be used for lifting. Always visually inspect that a chain sling is free from damage or wear before use. Ensure the weight of the load is known and is evenly distributed on the sling legs. Ensure that the chain is free of twists and is protected from any sharp corners on the load. Avoid crushing the chain. Do not use a chain in a manner that will exceed the WLL of the chain for the particular conditions of use.
When lowering, avoid the possibility of crushing the chain by ensuring the load does not land on it. Use packing, timber or similar.
Inspection
• • •
Clean the chain thoroughly.
•
Master links and hooks should be inspected for any sign of wear at their load bearing points and for any signs of distortion, such as widening of hook throat opening.
Lay the chain out on a clean surface or hang it up in a well lit area. Every chain link should be individually inspected for any signs of wear, twisting, stretching, nicks, or gouging and any worn link measured to determine degree of wear using vernier callipers.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 29 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
Coupling links should be inspected for any signs of wear at their load bearing points, for excessive play of the load pin within the body halves and for impaired rotation of the body halves around the load pin.
•
Chain links or fittings having any defects should be clearly marked to indicate rejection and the chain sling should be withdrawn from service until properly repaired and retested prior to returning to service.
Remember - Every link must be examined 6.7.5
Steel Wire Rope
Care and Use
• •
Minimum size wire rope for lifting purposes is to be 8mm
• •
All slings must be visually inspected prior to each lift.
Continuous wire rope slings with large diameter soft eyes must not be used. Wire rope slings with a ferrule secured thimble eye are acceptable A thorough inspection of all slings in use must be made at regular intervals.
Inspection Inspections must be conducted by a competent person who will inspect for the following:
• • • • • •
Broken Wires (refer to Australian Standards for quantity breaks).
• • • • •
Stretching or extended lay.
Corrosion (rust). Kinks Crushed or flattered sections. Bird-caging and high stranding. Damage to Wire Rope Terminations such as; sockets, wire rope grips, thimbles, ferrules, swage buttons, cable stockings etc. >33% wear on individual wires. Adjacent broken wires. Heat damage. Other obvious damage.
If in your opinion a sling has sufficient damage of any type, don’t use it report it! 6.7.6
Synthetic Slings
Round Sling – an endless sling comprising a load-bearing core of high-tenacity continuous-multifilament yarn that is completely enclosed in a woven cover, with or without fittings or coupling components. Flat Webbing Sling – a sling made of flat woven synthetic-fibre webbing, which may incorporate end fittings complying with AS 3585 or AS 3776 or local equivalent for the lifting and handling of loads. Care and Use
• • • •
Never overload equipment Do not use if WLL tag is removed or illegible. Inspect sling for damage prior to use. Do not use if there is any sign of cut webbing, snagging, heat or chemical damage, excessive wear, damaged seams, any other defects or presence of grit, abrasive materials or other harmful matter.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 30 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
• • • • • •
Do not tie knots in sling webbing. Protect sling webbing from sharp edges. Use protective sleeves. Do not expose sling to temperatures above 90°C. Do not allow abrasive or other damaging grit to penetrate fibres. Consult with manufacturer’s recommendations before immersing a sling in a chemical solution. Keep away from strong alkalis and phenolic compounds.
Note: A nylon sling loses 15-18% of its strength on wetting with water, but regains that loss of strength after drying out. Inspection Synthetic slings should be inspected for the following prior to use:
•
One major disadvantage of woven webbing slings is that when used to lift loads such as concrete slabs, grit can penetrate the sling causing internal fibre damage, which is not always obvious.
•
Internal wear, caused by repeated flexing, particularly where particles of grit have penetrated into the fibres.
•
Damage to a fixed protective coating or sleeve can allow abrasive grit easy access to the sling fibres.
•
Melting or shrinkage of fibres due to exposure to high temperatures. Remember that high temperatures can result from friction as well as from a hot environment.
•
Prolonged exposure to ultra violet light, generally from sunlight, will weaken synthetic fibres - this may be indicated by powdering of the outer layer.
•
Chemical attack may also cause fibres to break down and soften. Surface fibres may be plucked or rubbed off and there may be local stiffening of the sling.
6.7.7
Lifting Hardware
Shackles Shackles are used for interconnecting components in lifting, tensioning and staying systems. A shackle consists of a body, a removable pin and any applicable locking device.
• • • • • • • • •
All shackles are to be Alloy steel shackles of grade S or better
•
The pin is screwed tightly with the collar and the pin is bedded evenly on the surface of the shackle eye.
•
The correct type of pin is used for the application.
Commercial grade shackles are not to be used for lifting purposes. Stainless steel shackles are not to be used for lifting purposes. All shackles are to have the SWL cast or stamped into the shackle body Compliance certificate for the batch supplied is to be available in the Project plant files Ensure that all markings are clearly legible. Ensure pin is the correct type. Never replace the pin of a shackle with a bolt. The threads of the pin and body are undamaged and the pin screws freely into position. The body and pin is not unduly worn and free from distortion, nicks, gouges, cracks and excessive wear and corrosion.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 31 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
• • •
A bolt type shackle has a split cotter (safety pin) attached correctly. Shackles should not be heat treated as this may affect their working load limit. Never modify, repair or reshape a shackle by welding, heating or bending as this will affect the working load limit.
Eye Bolts
• • • • • • • • • •
Eyebolts of 12mm or smaller should not be used in general lifting, staying or tensioning purposes. Commercial grade eyebolts are not to be used for lifting purposes or to support loads. Stainless steel eyebolts are not to be used for lifting purposes. Eyebolts should be screwed down fully to the face of the load to be lifted. WLL markings are clear and suit the application. Conduct a visual inspection for deformation and cracking. Conduct a visual inspection of the inside eye for wear. Conduct a visual inspection and check for damaged threads. Ensure the thread centre is aligned with centre of eye. Ensure the eyebolt’s thread form and the thread form in the corresponding hole or nut is the same.
• • •
Avoid excessive tightening of eyebolts.
•
A continuous sling should not be used with pairs of eyebolts. When lifting with pairs of eyebolts supported by slings, always use slings with individual lengths.
Metric and imperial eyebolts that conform to the Australian Standard have a safety factor of 6:1. When using eyebolts in pairs, it is essential that care be taken to properly align them. Eyebolts must not be forced into alignment as overstress will cause a reduction in the WLL.
Eyebolts should be inspected periodically by a competent person as per AS2317 or local equivalent.
Lifting Beams There are three (3) types of lifting beams: Lifting Beam - a lifting beam that is placed in bending by the applied load(s). Spreader Beam or Bar - a spreader beam or bar that is placed in axial compression by the applied load. Combination Beam - a beam that combines both bending and axial compression loads in the one beam.
•
All spreader and lift beams are to comply with AS.4991 or the local equivalent.
When using lifting beams, the following shall be observed:
• • • •
The method by which the load is attached to the beam. The method by which the lifting beam is attached to the crane. Checking the security of the attachment of the load to the lifting beam. Alignment of the centre of gravity of the load to the lifting means.
NOTE: Open sections (UB, UC, PFC) are relatively flexible in torsion and care should be taken to avoid twisting these components by eccentric loading.
•
Checking the security of the attachment of the lifting beam to the lifting means, e.g. crane hook.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 32 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Sundry Equipment
•
6.8
All sundry rigging equipment is to fully comply with the relevant Australian standard or local equivalent as a minimum.
LIFTING THE LOAD
6.8.1
Slinging the Load
• • • • •
The slinging method is to be determined by the shape, size and weight of each load.
• • • • • • •
For large or long loads (12m+) attach 2 taglines and controllers or more if required
6.8.2
Executing the Lift
Slings are to be positioned over flat surfaces not over sharp edges or corners. Use protective padding when using any sling around sharp corners. Secure the lifting area from unauthorised entry. Tag lines of 16mm natural fibre rope or equivalent are to be used as necessary to control load sway. Dual crane lifts do not require tag lines Loads are to be balanced. Ensure no part of the load can slide or fall out during lifting. Don’t stand between the load and other obstructions. Keep hands and feet well clear of pinch points. Loads are not to be lifted over personnel.
While undertaking the lift, the operator and the dogman/ rigger must:
• • •
Coordinate the lift with other operations in the area
• • • • •
If the weight of the load is unknown, do not guess, but seek further advice
• • • • • •
Before lifting any load, ensure all loads are secured to prevent any items falling
Confirm wind speeds immediately prior to the lift Refer to the cranes load chart for load-reach relationship, working within the crane’s lifting capacity at all times No loads in excess of the safe working load shown on the load chart are to be lifted The load chart is to be kept in the cab of the machine at all times Never switch off or override the lift computer during a lift The crane driver is responsible for the overall safety of the lift and must discuss the lift with the dogman/ rigger prior to commencing the lift. The crane driver is to obey the dogman/ riggers directions during the lift Avoid any sudden starts and stops to prevent shock loading of the crane and lifting equipment Tag lines must be attached directly to the load – not the rigging gear Tag lines are to be clean and dry and checked safe before use Tag lines are to be at least 16mm in diameter and made of non-conductive material. Lifting gear is not to be used as a tag line.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 33 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
• • • • • • •
Before giving direction to hoist up, ensure the boom is positioned directly over the load
6.8.3
Management of change during a lift
•
If the operation cannot continue in accordance with the agreed procedure, the operation shall stop and the procedure reassessed to take into consideration the reason for the stoppage.
•
If the reassessment is considered a relatively minor deviation from the agreed procedure the documentation (SWMS) shall be clearly marked with the actions considered appropriate and agreed prior to operations recommencing.
•
If the reassessment is considered a major deviation from the agreed procedure then the appropriate actions shall be taken, as a minimum will require the documentation to be marked and amended in accordance with the revised proposals agreed. If the deviation is significant it may require production of a drawing revision, calculations or other information as applicable.
Loads are to be lifted slowly to prevent swing Loads are to be lifted just high enough to clear obstacles Operators must not leave the load suspended in the air when leaving the cab No person is allowed to climb on or off a moving crane or load Do not allow anyone to stand under a suspended load or near lines under stress No person is to enter the fall zone until the load is as close as practicable to the landing point
6.9 6.9.1
INSPECTION, REPAIR AND MODIFICATION Inspection
All chains and slings purchased new are to be accompanied by manufacturers testing certificates and tagged appropriately as per the equipment’s required standard. Used equipment coming to site, must have records that it has satisfactorily passed inspections by a competent person in the previous twelve (12) months. The person performing annual inspections is to be a person employed by an accredited third party specialist testing and inspection organization (such as Bullivants, Nobles or a local equivalent) that has completed appropriate training and has the skills and knowledge to carry out such inspections. Quarterly inspections (3 monthly) are to be carried out on lifting equipment by a competent person. Records of outcomes from these inspections are to be kept and maintained with the equipment’s records. A person deemed competent to carry out these inspections is someone who has the practical and theoretical knowledge and relevant experience, sufficient to enable the person to detect and evaluate any defects or weakness that may affect the intended performance of the equipment. The visual inspection checklist is located in Error! Reference source not found.. If any of the items fail to meet any of the required checks, the equipment should be tagged out of service and not to be used and upon assessment either discarded or repaired.
Rigging and Lifting Equipment - Testing/ Inspection Frequency Requirements Equipment Type
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
Test/ Inspection
Frequency
Who
PAGE 34 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
All Rigging and Lifting Equipment
Chain Slings –Grade T
Steel Wire Rope
Round Slings – Synthetic Fibre
Flat Synthetic – Webbing Slings
Lifting Devices
Certificates of equipment certification and test results to be provided with new or used within last twelve (12) months Re-inspect equipment annually or as per manufacturer’s recommendations or relevant Australian Standard or local equivalent.
Manufacturer/Supplier Before initial introduction to service
Certified lifting testing/inspecting authority
Manufacturer/Supplier If not specified – twelve (12) monthly as minimum interval.
Certified lifting testing/inspecting authority
Inspect condition of equipment
Prior to each use
Competent Person
Inspect equipment and record results
Quarterly Intervals
Competent Person
Inspect condition of equipment
Prior to each use
Competent Person
Inspect equipment and record results
Quarterly Intervals
Competent Person
Inspect condition of equipment
Prior to each use
Competent Person
Inspect equipment and record results
Quarterly Intervals
Competent Person
Inspect condition of equipment
Prior to each use
Competent Person
Inspect equipment and record results
Quarterly Intervals
Competent Person
Inspect condition of equipment
Prior to each use
Competent Person
Inspect equipment and record results
Quarterly Intervals
Competent Person
6.9.2
Repair and Modification
•
All repair and modification to lifting equipment is to be designed and fabricated in accordance with applicable standards and the modified design registered by the design authority.
•
After repair or modification, lifting equipment must be tested by application of a proof load, specified by a competent person, and then thoroughly examined. A test certificate stating the Working Load Limit and the proof load is to be obtained and retained on site.
•
The design and specifications of purpose made lifting equipment must be approved by the design authority.
• •
A report of the examination is to be produced. Modification and repair of lifting equipment is to be in accordance to the applicable standards.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 35 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
7 OTHER EQUIPMENT USED FOR LIFTING 7.1
EARTHMOVING EQUIPMENT USED FOR LIFTING
The requirements from AS 1418.8 or its local equivalent are to apply when earthmoving equipment including backhoes, front-end loaders, excavators, tool carriers and similar units are used for lifting freely suspended loads as a secondary function associated with the normal application of the equipment. Where it is intended to use the earthmoving equipment for cranage operations other than those indicated above, or where variable rated capacities are specified, all requirements of AS 1418.5 or its local equivalent are to apply. Lift point - A lifting lug located on the boom, arm, linkage, front end loader bucket or quick-hitch as specified by the manufacturer, to which a load may be attached for lifting freely suspended loads. Lift point radius/reach - The lift point radius/reach is the horizontal distance from either the centre-line of the front wheel or equivalent position on track, or the axis of rotation or the centre-line of the load supporting axle as appropriate, to the vertical load line. Where a non-slewing machine is fitted with stabilizers, the reach shall be measured from the centre-line of the stabilizers nearest to the load. Rated lift bucket position - The bucket attitude with the bucket fully rolled forward and the load suspended from the bucket as recommended by the manufacturer. 7.1.1
General requirements for lifting with earth moving equipment
•
The earthmoving equipment shall be travelled only with arm and boom retracted to minimum practicable radius.
• •
No person is permitted under the boom or suspended load.
•
The person slinging the load or directing the operator is to have a certificate of competency for dogging or rigging.
• • • •
No persons are to be lifted by earth moving equipment.
• • •
Loads are not to be suspended from bucket teeth or adaptors.
All persons operating the earth moving equipment are to have the appropriate certificate of competency and/or training
Lift points are to be arranged such that accidental unhooking of the load cannot occur. Operational speed is to be reduced from high-speed mode. Where the sling or tackle is wrapped over the back of the bucket, it is not to come into contact with any sharp projection or sharp edge. Reference is to be made to the manufacturer’s manual for correct operation. A service record (logbook) is to be used to record servicing, maintenance and repair work, and details of any malfunction that may occur with the machine.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 36 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
7.1.2
Requirements for rated capacity at maximum reach/radius
The rated capacity is the maximum mass (expressed in kilograms) that may be handled at the maximum lift point radius, or reach, expressed in metres in the most adverse configuration for each lift point without the strength, hydraulic, and stability requirements being exceeded. The rated capacity comprises of the mass of the lifted load and the lifting attachments. Where a bucket is fitted, the rated capacity is to be established at the rated lift bucket position that results in the maximum radius. A rated capacity chart, identifying the lift point location(s) and the corresponding rated capacity at that position, is to be mounted inside the operator’s cab and is to show the following:
• • • • •
Manufacturer’s name and model.
• •
Tyre track and size (in millimetres) and inflation pressure (in kilopascal), where applicable.
• •
NOTE: Buckets and quick hitches should have their mass marked on them.
• • •
The maximum permitted slope for lifting and pick and carry operations.
7.1.3
Controlled lowering devices
Boom identification (length in metres), where applicable. Arm identification (length in metres), where applicable. Shoe width (in millimetres) and track gauge and length (in metres), where applicable. Deductions for attachments such as a bucket, lifting devices or quick hitch device to allow determination of the net load that can be lifted. Bucket mass (in kilograms) and width (in millimetres), or quick hitch mass (in kilograms), as applicable. Ground speed limit for pick-and-carry rated load for rubber-tyred equipment (in kilometres per hour). Where controlled lowering devices are fitted, a notice of the effect to be displayed. Any other equipment conditions that may impact on rated capacity.
Earthmoving equipment that is used to lift freely suspended loads that have a rated lift capacity at maximum radius/reach greater than 1 t is to be fitted with a controlled lowering device on the raising boom cylinder(s). The control-lowering device is to meet the requirement of ISO 8643, to protect against hydraulic hose failure. Where control lowering devices are not provided, the following is to apply:
• •
A load greater than 1 t shall not be lifted.
•
Suspended loads shall not be lifted over personnel, in any circumstances.
7.1.4
Stability
Controls shall be in place to ensure that uncontrolled lowering shall not result in injury or death to persons in the area.
Stability of earthmoving equipment is to be such that the rated capacity is not greater than the appropriate percentage of the tipping load that has to be applied to tip the earthmoving equipment within AS 1418.8 Section 5 or it is local equivalent. Where the earthmoving equipment requires the use of stabilizers in order to achieve stability, the equipment is to be supported by such stabilizers.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 37 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
7.1.5
Rated hydraulic capacity
The rated hydraulic lift capacity of earthmoving equipment is to be such that the rated capacity is not greater than 87% of the hydraulic capacity at maximum reach/radius. The rated capacity at each lifting point is to be prominently marked at the lifting point. This is not to be exceeded under any circumstance, that is, the lifted load plus any attachments (bucket, etc.) shall not exceed the rated capacity. Deductions from the rated capacity for larger than standard buckets or quick hitch devices are to be considered to determine the maximum allowable mass of the item that may be lifted. Reference is to be made to the manufacturer’s manual for correct operation. 7.1.6
Quick-hitches
Quick-hitches that are fitted to earthmoving equipment used to lift freely suspended loads are to comply with the requirements in AS 4772 or its local equivalent. (Safe use of earth moving machinery fitted with a quick-hitch) Where equipment is used and is fitted with a quick hitch, the following requirements apply:
•
Loads only to be suspended from the manufacturer’s designated lift point on the quick-hitch unless a designated lifting attachment is fitted.
• •
All non-lifting attachments to be removed before any lifting operation is undertaken.
• •
Host machine load rating charts to allow for the additional mass of the quick-hitch.
7.1.7
Marking and Labelling
Quick-hitches to be used only to support attachments specifically designed to fit and specifically designed for the duty to be undertaken. Quick-hitches to be maintained in proper working order at all times.
The earthmoving equipment configured to lift freely suspended loads is to display at a readily accessible and prominent location and on permanent and legible notices the following information, where appropriate:
• • • •
Name or mark of the supplier. Model designation. Serial number. Where earthmoving plant is to be used for lifting a freely suspended load, all controls shall be labelled in accordance with ISO 7000.
8 RECORDS Daily inspection records Lift Plans Maintenance records Plant incoming inspections – internal and external inspections
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 38 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
9 REFERENCES Competency Register Competency Register – By person Compliance with Legal & Other Requirements Crane Lift Plan Height HSE Risk Management Mobile Equipment Daily Inspection Report Overhead Power Lines Project Training Plan Plant & Equipment Register Plant Operator Assessment Project Compliance with Legal & Other Requirements Storage Maintenance & Refuelling of Machinery Workbox Use
030-F044-100 030-F045-100 000-D004-000 600-F003-100 020-T005-100 020-D012-100 045-F030-100 020-T009-100 030-J008-100 045-F136-100 030-F047-100 300-E012-100 025-L007-100 020-T003-100
Cranes and Lifting Equipment Elevated Work Platforms ES&H Aspects of Plant and Machinery ES&H Training and Competency Forklift Trucks Procurement
ESH-047 ESH-111 ESH-057 ESH-003 ESH-048 ESH-021
Singapore - Code of Practise for Safe Lifting Operations at Workplaces Singapore - WSH Operation of Cranes Regulations 2011 Management Systems Australia. Environment, Safety and Health Management System ES&H Compliance Guidelines. See Section 8 ‘External References’ in the guidelines listed below for relevant legislation, standards and guidance material.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 39 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
10
APPENDICES
APPENDIX A – LICENCES TO PERFORM HIGH RISK WORK The following is a list of the licenses for high risk work, as given in the National Standard for Licensing Persons Performing High Risk Work (April 2006), that are relevant to the crane industry in Australia: (DG) (RB) (RI) (RA) (CT) (CS) (CP) (CB) (CV) (CN) (C2) (C6) (C1) (CO) (WP) (HM) (HP) (BP)
Dogging Basic rigging Intermediate rigging Advanced rigging Tower crane operation Self-erecting tower crane operation Portal boom crane operation Bridge and gantry crane operation Vehicle loading crane operation Non-slewing mobile crane operation Slewing mobile crane operation (up to 20 t) Slewing mobile crane operation (up to 60 t) Slewing mobile crane operation (up to 100 t) Slewing mobile crane operation (open/over 100 t) Boom-type elevating work platform operation Materials hoist (cantilever platform) operation Hoist (personnel and materials) operation Concrete placing boom operation
NOTES: 1. The above list was correct at time of publishing. 2. The National (Australian) Standard for Licensing Persons Performing High Risk Work can be downloaded from the Safe Work Australia website at: www.safeworkaustralia.gov.au 3. For crane operations conducted outside of Australia, local regulations should be consulted to determine any specific local requirements.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 40 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
The is no excessive gouging or wear - no more than 8%
✓
Winches
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Clamps
✓
Hoists
Clean before use and inspection
Eye Bolts
Rigging screws and turnbuckles Sockets
Shackles
✓ ✓ ✓ ✓ ✓
Broken wires are no more than one broken at an end connection, two at areas beyond end connection There is no deformation of deformation such as bending twisting, knotting, stretching, kinking, nick and cracking
Sheave blocks
✓
Hooks
Synthetic Slings
SWL or WLL is clearly legible
and Lifting equipment
Chains
Wire Rope
Pre-Use Inspection/Check for rigging
✓ ✓ ✓ ✓ ✓ ✓ ✓
✓
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
✓ ✓
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
No Corrosion or chemical attack
✓
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
End fittings, terminal attachments or links are not deformed/damaged
✓
✓
✓
✓
✓
No wear to external or internal cover No Heat Damage (Discolouration) No holes in cover
✓
No Local Abrasion
✓
No Sunlight degradation
✓
No Deterioration to stitching
✓
Safety catch fully functioning
Increase in throat opening is less than 15% Moving parts have free movement Any threads to be in good working order
✓
✓
✓
✓
✓
✓ ✓ ✓
✓ ✓
✓
✓ ✓ ✓ ✓
✓
All pins and attachments are the correct type and size and free of damage
✓ ✓ ✓
✓ ✓ ✓ ✓ ✓ ✓
There is an end stop fitted
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
✓
✓
PAGE 41 OF 50
✓
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
APPENDIX C – COMMUNICATION SIGNALS AND ALARMS
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 42 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
APPENDIX D – WORKING NEAR OVERHEAD POWER LINES - NO GO ZONE
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 43 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
APPENDIX E – FREE FALL FEATURES ON CRANES
Definition A feature fitted on some mobile cranes that allow the hook and load to fall under gravity in an uncontrolled manner. Background There have been a number of serious accidents caused by loads dropping in a free fall manner. The free fall feature has been traditionally fitted on cranes for activities such as clam shell dredging and dynamic pile compaction. However, the risk associated with an inadvertent activation of the free fall feature can be high and the provision is rarely needed. Most mobile crane manufacturers dot not provide this feature on new cranes. The risk to workers from falling loads and potential damage to the crane and crane operator is considerable. McConnell Dowell Policy McConnell Dowell policy is that no crane is to operate with an active free fall feature. This policy can only be relaxed with written approval of the relevant Executive/General Manager. The policy applies to both McConnell Dowell and hired in cranes. Requirements for McConnell Dowell Cranes The free fall capabilities on McConnell Dowell cranes are to be permanently deactivated. This deactivation of the free fall should include removal of free fall switches on the crane and a certificate from the crane manufacturer or a competent person (preferably a professional engineer) to state that the free fall function has been permanently removed. Requirements for Hired-in Cranes Owners of cranes with free fall features that do not have a physical lockout arrangement to prevent inadvertent activation are to engage a competent person to install a lockout and test the arrangement. Owners are also to engage a competent person to inspect and test to ensure that the lockout has been correctly installed and free fall cannot be inadvertently activated. Guidelines for Relaxation of Policy The use of the free fall function on a mobile crane should be extremely rare and only be permitted where a documented safe work method statement has shown there is no other reasonable alternative. A documented risk assessment is to be prepared for this situation and submitted to the relevant Executive /General Manager with a request for a waiver of the policy.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 44 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
APPENDIX F – TYPICAL ADVERSE WEATHER GUIDELINES
Beaufort Scale
Ave. Wind Speed (knots)
Ave. Wind Speed (km/h)
Ave. Wind Speed (m/s)
Effects of wind speed over land
0
Calm
Less than 1
Less than 1
0 - 0.2
Calm, smoke rises vertically.
Sea like mirror
1
Light Air
1-3
1-5
0.3 – 1.5
Direction of wind shown by smoke drift, but not by wind vanes.
Ripples with the appearance of scales are formed, but without foam crests
2
Light Breeze
4-6
6-11
1.6 – 3.3
Wind felt on face; leaves rustle; ordinary wind vane moved by wind.
Small wavelets, still short, but more pronounced; crests have a glassy appearance and do not break
3
Gentle Breeze
7-10
12-19
3.4 5.4
Leaves and small twigs in constant motion; wind extends light flag.
Large wavelets; crests begin to break; foam of glassy appearance; perhaps scattered white horses
4
Moderate Breeze
11-16
20-28
5.5 – 7.9
Raises dust and loose paper; small branches moved.
Small waves, becoming longer; fairly frequent white horses
5
Fresh Breeze
17-21
29-38
8.0 – 10.7
Small trees in leaf begin to sway; crested wavelets form on inland waters.
Moderate waves, taking a more pronounced long form; many white horses are formed (chance of some spray)
6
Strong Breeze
22-27
39-49
10.8 – 13.8
Large branches in motion; whistling heard in telegraph wires; umbrellas used with difficulty.
Large waves begin to form; the white foam crests are more extensive everywhere (probably some spray)
13.9 – 17.1
Whole trees in motion; inconvenience felt when walking against the wind.
Sea heaps up and white foam from breaking waves begins to be blown in streaks along the direction of the wind
17.2 – 20.7
Breaks twigs off trees; generally impedes progress.
Moderately high waves of greater length; edges of crests begin to break into the spindrift; the foam is blown in well-
7
8
Near Gale
Gale
28-33
34-40
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
50-61
62-74
Effects of wind speed over water
Operating Information
Normal Lifting Zone for most cranes: Confirmation of operating parameters should be sought from the crane operations manual and reviewed by the crane operator.
Review and Assess Zone: Review crane operation limits and effects on loads lifted. Agreement to continue with entire crane crew and person in charge of lifting operations. No Lifting Zone:
PAGE 45 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Beaufort Scale
Ave. Wind Speed (knots)
Ave. Wind Speed (km/h)
Ave. Wind Speed (m/s)
Effects of wind speed over land
Effects of wind speed over water
Operating Information
marked streaks along the direction of the wind 9
Strong Gale
41-47
75-88
20.8 – 24.4
Slight structural damage occurs (chimney pots and slates removed).
High waves; dense streaks of foam along the direction of the wind; crests of waves begin to topple, tumble and roll over; spray may affect visibility
10
Storm
48-55
89-102
24.5 – 28.4
Seldom experienced inland; trees uprooted; considerable structural damage occurs.
Very high waves with long overhanging crests; the resulting foam, in great patches, is blown in dense white streaks along the direction of the wind; on the whole, the surface of the sea takes a white appearance; the tumbling of the sea becomes heavy and shock-like; visibility affected
11
Violent Storm
56-63
103117
28.5 – 32.6
Very rarely experienced; accompanied by widespread damage.
Exceptionally high waves (small and medium sized ships might be for a time lost to view behind the waves); the sea is completely covered with long white patches of foam lying along the direction of the wind; everywhere the edges of the wave crests are blown into froth; visibility affected
12
Hurricane
64 and over
118 and over
32.7 – 36.9
Severe and extensive damage.
The air is filled with foam and spray; sea completely white with driving spray; visibility very seriously affected
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 46 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
APPENDIX G - COMMONLY USED TERMS AND ALTERNATIVE NAMES Cranes TERM
COMMONLY USED TERMS
Crawler
Crane with tracks.
Spragg / spragging
To turn left or right on tracks
Jib Boom / Mast
The main section of the crane used for lifting. It has 3 or 4 chords and lattice sections.
Headache Ball
Used above the hook to weight down and steady the hoist line. (Auxiliary Hook)
Main Block
A sheave block above the main hook used to take multiple parts of the hoist rope.
Rooster
Usually the part at the top or tip of the boom that holds the auxiliary line or whip hoist rope.
Whip / Auxiliary Line
The secondary line for doing smaller or lighter lifts.
Tip
The working end of the boom holds the rooster and the main hoist rope sheaves.
Bridle
Holds the pendant ropes and is connected to the luffing ropes allowing the boom to move up and down.
Pendant/ Pendant Ropes
The main supports holding the boom or jib in place.
Rams Horn
Usually on the main block. This is a double hook used partly to balance the load but it is made to put multiple slings on it for big or awkward lifts and spread weight out more evenly.
Traming / Tracking / Travelling
The forward or backward motion of a crawler crane.
Butt
The bottom section of the boom. This is the part that is connected to the crane that has pins to pivot up or down the crane.
Carbody
This is the part that holds the engine winches and boom of the crane as well as the cab and counterweights
Base / Chassis
This frame supports the car body through the slew ring and the tracks are also fixed to the base
Counter Weights
These provide the balance that the crane requires to lift objects.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 47 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
TERM
COMMONLY USED TERMS
Belly Weights
This provides extra weight to the crane to perform larger lifting capacity.
Mobile-hydraulic / Oilcan
As the name implies it can be setup quickly to move around a site(s). Not for pick and carry these cares usually have some of the attributes of a crawler crane however the boom is telescopic and retracts; it has outriggers for stability and usually has rubber tyres.
Rough Terrain / Roughie
These usually are similar to mobile cranes however they usually have a pick and carry capability. They are sometimes very quick to set up.
Franna
This is proprietary name however they usually have a pick and carry capability.
Tom Thumb
A small hydraulic crane used to set up in very tight or small areas however they cannot pick up large amounts of weight or sizes.
Tower Cranes
These are fixed on top of a frame or tower and are self climbing using extra pieces on the tower. There are usually two types. Luffing Boom Meaning the luffing boom can either move up or down on a pivot point on the main boom Saddle Jib or Hammer Head Meaning the jib is in a horizontal position and a trolley or saddle moves in and out along the boom carrying the hoisting rope with hook below.
Fibre Rope Slings TERM
COMMONLY USED TERMS
Rope
Polypropylene, polyethylene, hemp, sizal, cotton, dyneema. These are some of the types mentioned above. There are numerous others, too may to mention. They should be used as per specifications, recommendations or regulations. They can be used for all of the below.
Taglines
To tie to a load to control load (16mm minimum)
Shark Hook
A hook sometimes connected to the tagline. They alleviate the need to tie the rope to the item being lifted.
Sheep Shank
A rope hitch used to shorten the rope and can be also used to give you purchase when tying a load down.
Clove Hitch
A rope hitch to secure a load.
Bowline
A rope hitch in conjunction with a tagline.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 48 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
TERM
COMMONLY USED TERMS
Figure of 8
A rope hitch to join two ropes together.
And many more knots and stitches. Wire ropes TERM
COMMONLY USED TERMS
Snotter
Is a sling with an eye either hand or machine spliced at each end.
Sheave
This is a grooved wheel used to run a wire over. Usually used on cranes, however can be used for rigging applications.
Stinger
1. Beam between crane and super lift tray or trailer 2. A sling or oblong ring used on the hook for ease of attaching rigging
Grommet
Is formed into a circle and is either hand spliced or machine spliced. These types of wire rope slings can be used for stingers. However they are generally used to increase capacity without increasing the size of the wire rope.
FSWR
Flexible steel wire rope.
IWRC
Independent wire rope core.
FC
Fibre core.
Bulldog Grip
For temporarily joining two ropes together or making an eye.
Thimble
A piece of formed or cast metal formed into an eye to help support the way rope sits and stops deformation of the rope.
Ferrule
Is a piece of metal to clamp two pieces of rope (called a swage) together to form an eye grommet.
Superflex
Is a woven wire rope generally used where a tight bend cannot be overcome or on painted items reducing paint damage.
Flemish Eye
Is a type of splice to form an eye. It is used when steel ferrules are used in making FSWR slings. These should never be used for lifting without being swaged and tested first.
Swage
Is the term used for a ferrule compressed to form an eye in a wire rope.
Hambone / Wedge Socket
Is a fitting generally used on the hook of a crane by wrapping the rope around a wedge and welding the rope into a socket.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 49 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
TERM
COMMONLY USED TERMS
Spelter Socket
Is a socket that a rope terminates in. It is usually used in conjunction with either hot metal or two pack epoxy type compound these have an efficiency rating of 100%, based on the catalogue strength of wire ropes.
Chains TERM
COMMONLY USED TERMS
Latch Lock Hook
Is a hook attached usually to chains. It is a hook with a positive latch closing mechanism.
Sling Hook
Has a spring latch.
Shortening Hook
Small hook to shorten chain assembly.
Grab Hook
Same as above (safer).
Oblong Ring
Usually a fitting incorporated into chain sets.
Hammer Lock / Connecting Link
An important link to make up a chain set or join to equipment.
Multi
Large oblong with two smaller ones permanently fitted to it.
Shackles TERM
COMMONLY USED TERMS
Safety Bow
Bow type, has a pin and nut.
Bow
Same as above however has a screw type pin.
Dee
As the name implies is good for thickened pad eyes.
Other lifting gear TERM
COMMONLY USED TERMS
Cumalong / Lever Hoist
Hoist for short lift jobs.
Chain Block / Chain Hoist
Hoist for short to long lift jobs.
Tirfor / Creeper Winch
Used in communication with wire rope for guy wires or temporary stays.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 50 OF 50
CRANE AND LIFTING OPERATIONS MMS No: 020-T001-100
Revision History Rev
Date
Details
Author
Reviewer
Approver
1
14Jun2012
Added Section 6.11.18 Crane Free fall
R Brown
J Phillips
2
22Jul2013
Full Review
D Woods
J. Phillips
3
20Oct2014
Updated Section 6.7.1, Definitions of High Risk Work licence responsibilities for licensed Basic, Intermediate and Advanced Rigger classes.
T Knight
K. Rolls
M. Collins
4
11 Aug 2015
Revision of 6.4.1 to include requirements of pick and carry operations with side slopes >2.50
M Collins
M Collins
M Collins
5
6 Oct 2015
Updated section 6.1.8b Inclination Factors.
N. Kidd
M Collins
M Collins
This document remains the property of McConnell Dowell Corporation. Its contents are confidential and shall not be reproduced, destroyed or given away without the express, written permission of McConnell Dowell Corporation. The electronic version of this document in MMS Database on designated server(s) is the Master Copy and is a controlled document. Unless specifically noted thereon, other copies of this document are uncontrolled. Based on MMS Template# 010-J011-000 Rev3 2Oct2014
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
TABLE OF CONTENTS 1
PROCESS SUMMARY .................................................................................................................... 6
2
OBJECTIVES .................................................................................................................................. 6
3
DEFINITIONS .................................................................................................................................. 6
4
RESPONSIBILITIES ........................................................................................................................ 6
5
4.1
Project Manager (PM) ............................................................................................................... 6
4.2
Senior Project OHS representative (SPOHSR) .......................................................................... 6
4.3
Superintendents and Supervisors (S) ........................................................................................ 7
4.4
McConnell Dowell and subcontractor personnel ........................................................................ 7
4.5
Contracts and Procurement Personnel ...................................................................................... 7
4.6
Crane Lift Supervisor ................................................................................................................ 7
PROCESS DESCRIPTION .............................................................................................................. 7 5.1
Plan the Job .............................................................................................................................. 7
5.1.1
Review legislation, standards, other related MCD SOPs and Project Risk Register ............. 7
5.1.2
Select lifting equipment that is fit for purpose ...................................................................... 8
5.1.3
Identify licence or competency requirements for crane and lifting personnel ....................... 8
5.1.4
Select Plant operators ........................................................................................................ 9
5.1.5
Initial inspection and approval to bring plant on site ...........................................................10
5.1.6
Report defects...................................................................................................................10
5.1.7
Statutory plant inspections ................................................................................................10
5.1.8
Develop a plant maintenance schedule .............................................................................11
5.1.9
Arrange maintenance and refuelling ..................................................................................11
5.2
Do the Job ...............................................................................................................................12
5.2.1
Plan the lift ........................................................................................................................12
5.2.2
Daily plant inspections.......................................................................................................12
5.2.3
Report defects...................................................................................................................12
5.2.4
Prepare work area and evaluate weather ..........................................................................13
5.2.5
Conduct the lift ..................................................................................................................13
5.3
Supervise and Monitor Lifting Operations .................................................................................13
5.3.1 5.4
Take action when safety risks are identified..............................................................................13
5.4.1 6
Supervise the lifting operation ...........................................................................................13
Report and Take Action.....................................................................................................13
TECHNICAL STANDARDS .............................................................................................................14
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 2 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
6.1
Crane Selection and Planning ..................................................................................................14
6.1.1
Pre-Mobilisation ................................................................................................................15
6.1.2
Crane location planning – vicinity, visibility ........................................................................15
6.1.3
Ground Support ................................................................................................................16
6.1.4
Cranes on Suspended Surfaces ........................................................................................16
6.1.5
Weather Conditions...........................................................................................................17
6.1.6
Marine Conditions .............................................................................................................17
6.1.7
General Operation of Cranes on Floating Barge ................................................................17
6.1.8
Guidelines for Crane De-rating and Tie Down/securing......................................................18
6.1.9
Crane Tie Down ................................................................................................................18
6.2
Crane Operation ......................................................................................................................19
6.2.1
General Safe Use requirements ........................................................................................19
6.2.2
Competency......................................................................................................................19
6.3
Communication ........................................................................................................................20
6.3.1
Hand Signals ....................................................................................................................20
6.3.2
Radio Communication .......................................................................................................20
6.4
Lift Categories..........................................................................................................................22
6.4.1
Travelling Loads (Pick and Carry)......................................................................................22
6.4.2
Multiple hoist or crane operation ........................................................................................22
Requirements for multiple crane hoisting .........................................................................................22 Planning for multiple crane hoisting .................................................................................................23 Synchronisation of the crane and crab motions ...............................................................................23 Pick and Carry (Multiple Cranes) .....................................................................................................23 6.4.3
Controls ............................................................................................................................23
6.4.4
Crane Lift Plans ................................................................................................................24
6.5
Maintenance, Inspection and Repair - Cranes ..........................................................................24
6.5.1
Maintenance .....................................................................................................................24
6.5.2
Inspections........................................................................................................................25
6.5.3
Periodic inspections ..........................................................................................................25
6.5.4
Major inspection to assess a crane for continued safe operation. .......................................26
6.6
Repairs ....................................................................................................................................26
6.6.1
Assessment for repair procedure .......................................................................................26
6.6.2
Management of repairs. ....................................................................................................26
6.6.3
Repair work.......................................................................................................................27
6.6.4
Welding repair examination ...............................................................................................27
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 3 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
6.7
Rigging and lifting ....................................................................................................................27
6.7.1
Competency......................................................................................................................27
6.7.2
Equipment Selection & Planning........................................................................................28
6.7.3
General requirements- Lifting Equipment...........................................................................28
6.7.4
Chains ..............................................................................................................................29
Care................................................................................................................................................29 Use .................................................................................................................................................29 6.7.5
Steel Wire Rope ................................................................................................................30
6.7.6
Synthetic Slings ................................................................................................................30
6.7.7
Lifting Hardware ................................................................................................................31
Shackles .........................................................................................................................................31 Eye Bolts ........................................................................................................................................32 Lifting Beams ..................................................................................................................................32 Sundry Equipment ..........................................................................................................................33 6.8
6.8.1
Slinging the Load ..............................................................................................................33
6.8.2
Executing the Lift ..............................................................................................................33
6.8.3
Management of change during a lift ...................................................................................34
6.9
7
Lifting the Load ........................................................................................................................33
Inspection, Repair and Modification ..........................................................................................34
6.9.1
Inspection .........................................................................................................................34
6.9.2
Repair and Modification.....................................................................................................35
OTHER EQUIPMENT USED FOR LIFTING ....................................................................................36 7.1
Earthmoving Equipment Used For Lifting..................................................................................36
7.1.1
General requirements for lifting with earth moving equipment ............................................36
7.1.2
Requirements for rated capacity at maximum reach/radius ................................................37
7.1.3
Controlled lowering devices ...............................................................................................37
7.1.4
Stability .............................................................................................................................37
7.1.5
Rated hydraulic capacity ...................................................................................................38
7.1.6
Quick-hitches ....................................................................................................................38
7.1.7
Marking and Labelling .......................................................................................................38
8
RECORDS......................................................................................................................................38
9
REFERENCES ...............................................................................................................................39
10
APPENDICES .............................................................................................................................40
Appendix A – Licences To Perform High Risk Work ............................................................................40 Appendix C – Communication Signals and alarms ..............................................................................42 COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 4 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Appendix D – Working near overhead power lines - No go zone .........................................................43 APPENDIX E – Free Fall Features on Cranes ....................................................................................44 APPENDIX F – Typical Adverse Weather Guidelines ..........................................................................45 APPENDIX G - Commonly used Terms and Alternative Names ..........................................................47
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 5 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
1 PROCESS SUMMARY To manage crane and lifting operations in order to minimise or eliminate the risk of injuries, fatalities and incidents This Safe Operating Procedure addresses the following MCD Golden Rules:
“Never be under a suspended load.”
2 OBJECTIVES This procedure applies to all crane and lifting activities conducted on land within McConnell Dowell controlled sites and activities, and to all McConnell Dowell employees, contractors and visitors when involved in crane and lifting operations.
3 DEFINITIONS Competent Person – A person, who has through training, qualification, experience, or a combination of these, has the knowledge and skill enabling them to correctly perform the required tasks. Lifting equipment – Any equipment or device used or designed to be used directly or indirectly to connect a load to a crane and which does not form part of the load e.g. Wire rope slings, chain slings, synthetic fibre slings, hooks, fittings, swivels, shackles, eye bolts, rigging screws, wedge sockets, plate clamps and lifting beams. SWL – Safe Working Load WLL – Working Load Limit
4 RESPONSIBILITIES 4.1 • •
4.2
PROJECT MANAGER (PM) Ensure that this procedure is communicated to relevant Project personnel. Ensure that all relevant aspects of this procedure are implemented by McConnell Dowell and contractor personnel.
SENIOR PROJECT OHS REPRESENTATIVE (SPOHSR)
•
Assist the Project Manager, Superintendents, Supervisors and Contractor Representatives to implement this procedure
•
Modify this procedure to meet any project specific contractual and legislative requirements
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 6 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
Monitor compliance with the procedure and report noncompliance to the Project Manager
4.3 • •
SUPERINTENDENTS AND SUPERVISORS (S) Prepare and supervise crane and lifting operations in accordance with this procedure Ensure that sufficient resources are available to conduct a safe lift
4.4 •
MCCONNELL DOWELL AND SUBCONTRACTOR PERSONNEL Comply with all relevant aspects of this procedure
4.5
CONTRACTS AND PROCUREMENT PERSONNEL
•
Make sure that all purchased or hired-in lifting equipment to be used on MCD projects, complies with the relevant standards of the country, and is fit for purpose.
•
All contracts awarded comply fully with the requirements and intent of this procedure.
4.6 •
CRANE LIFT SUPERVISOR Review all technical details and plans for lifts
5 PROCESS DESCRIPTION 5.1 5.1.1
PLAN THE JOB Review legislation, standards, other related MCD SOPs and Project Risk Register
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Review the Project OH&S Legal & Other Requirements to identify any legislation that is relevant to this procedure
Start of project
SPOHSR
Project OH&S Legal & Other Requirements Refer to Compliance with Legal & Other Requirements (MMS # 000-D004-000), and Project Compliance with Legal & Other Requirements (MMS # 300-E012-100).
Identify any Standards, Codes of Practice etc relevant to this operation
Start of project
SPOHSR
Review MCD SOPs to identify any that are relevant to this operation
Start of project
SPOHSR
SOP MMS# 020-T005-100 Height SOP MMS# 020-T009-100 Overhead Power Lines
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 7 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
SOP MMS# 020-T003-100 Workbox Use Plan works using the HSE Risk Register. (Create Construction Execution Procedures, JSEA/SWMS and ITPs, or refer to existing risk assessments and documents).
Start of project and ongoing
SPOHSR Project Manager Construction Manager
Project Risk Register will identify phases in the project where this SOP is applicable. Refer to procedure HSE Risk Management (MMS # 020-D012-100)
5.1.2
Select lifting equipment that is fit for purpose
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Select crane
Commencement of project and ongoing
Project Manager
See section 6.1 cranes (below) for selection criteria
Project Engineer
Where possible employees undertaking lifting operations should be consulted.
Supervisor Select rigging and lifting equipment
Commencement of project and ongoing
Project Manager Project Engineer
See section 6.7.1 rigging and lifting equipment (below) for selection criteria
Lifting Supervisor Supervisor
5.1.3
Identify licence or competency requirements for crane and lifting personnel
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Once the types of cranes to be used on the project are known, the specific licence requirements to operate these vehicles are identified.
Commencement of project and ongoing throughout project
SPOHSR
Crane operators must hold appropriate certification or license for the country state or region relevant to the project
Record the licence and competency requirements
See Appendix A – Certificates of Competency (below) for Australian competency tickets Record any licence requirements in Project Training Plan – Legislation Compliance Identify the specific licence requirements for the range of persons assisting crane operations Record the licence and competency requirements Identify whether any additional training is required to operate the plant
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
Commencement of project and ongoing throughout project
SPOHSR
See Appendix A – Certificates of Competency (below) for Australian competency tickets.
Commencement of project and ongoing throughout project
SPOHSR
Difficult site conditions may mean that operators need additional training even though they have the requisite licenses.
PAGE 8 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Record any additional training requirements in Project Training Plan (use MMS # 030-J008-100).
5.1.4
Select Plant operators
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Employ crane operators and other personnel and check their licence and training.
Commencement of project and ongoing throughout project
SPOHSR
See 6.2.2 Training and Competency below for selection criteria. HR to arrange a fitness for work medical examination as part of the employment process. Photo copy operator licences and competency tickets and record in the appropriate project Operator Competency Registers: File the photo copies of licenses etc in the employee personal file.
Arrange training and/or test competency
Record competencies of each plant operator.
Commencement of project and ongoing throughout project
SPOHSR
Commencement of project and ongoing throughout project
SPOHSR
Plant Operator Assessment (MMS # 030F047-100) or Assessment by external training organisation Competency Register (MMS # 030-F044-100, and Competency Register – By Person MMS # 030-F045-100).
Notification of loss of license or onset or medical condition that could make it unsafe to operate mobile plant
Immediately the employee becomes aware.
Or mobile plant operators
It is the responsibility of a plant operator to notify their Supervisor if they have a medical condition that may affect their ability to operate plant safely, or if any medication has been prescribed that may affect their ability to operate plant safely.
12 monthly fitness for work medical examination.
Rescind the authority to operate plant
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
As soon as management becomes aware
Supervisor to be immediately notified of the expiry or loss of license by any person.
Supervisor SPOHSR
Where there is a medical condition the issue is to be discussed with the employee before any decision is made.
PAGE 9 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
5.1.5
Initial inspection and approval to bring plant on site
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
When plant arrives on site
Lifting Supervisor
Incoming Plant Inspection Checklists (MMS # in the number sequence 045Fnnn-100).
Initial inspection and approval to bring plant on site Carry out an inspection of all lifting equipment before commencement of work. For external hires, service records, inspection records, log books etc. must be checked
SPOHSR
For items supplied internally by [McConnell Dowell entity], obtain and review inspection & service records. Once lifting equipment has been inspected
Supervisor SPOHSR
Plant & Equipment Register (MMS # 045F136-100 or equivalent).
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Write-down all defects and damage in the inspection report.
As required
Plant operator
Mobile Equipment Daily Inspection Report
Record approval of cranes.
5.1.6
Report defects
If the defect requires immediate attention or endangers the safety of employees, phone the supervisor immediately.
(MMS # 045-F030-100).
If plant is unsafe to operate tag with an ‘Out of Service’ tag.
Immediately
Supervisor
Arrange for repairs.
As required
Supervisor
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Identify any statutory requirements for Plant inspection or any requirements listed in relevant Standards
At project commencement
SPOHSR Lifting Supervisor
See 6.5 Maintenance, Inspection and repairs – Crane (below) for MCD requirements
5.1.7
Refer to procedure Tagging and Locking (MMS # 020E015-100)
Statutory plant inspections
See 6.9 Maintenance, Inspection and repairs -Rigging and lifting Equipment (below) for MCD requirements. Record any statutory inspection requirements in Project Legal & Other Requirements (MMS # 020-J004-YYYY and MMS # 025-J001-YYYY) Schedule inspections on the project plant maintenance and inspection schedule
At project commencement
SPOHSR
Project plant maintenance and inspection schedule
Arrange inspections
See schedule
SPOHSR
Record completed inspections in the project plant register
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 10 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
5.1.8
Develop a plant maintenance schedule
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Develop a project plant maintenance and inspection schedule that complies with legal requirements MCD requirements and manufacturers’ recommendations for all cranes and lifting equipment
Commencement of project and ongoing throughout project
Plant Manager
See 6.5 Maintenance, Inspection and repairs – Crane (below) for MCD maintenance and repair requirements See 6.9 Maintenance, Inspection and repair Rigging and lifting Equipment (below) for MCD maintenance and repair requirements Project plant maintenance and inspection schedule
5.1.9
Arrange maintenance and refuelling
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Project commencement and ongoing
Project Manager
Refer to Storage Maintenance & Refuelling of Machinery
Arrange maintenance and refuelling Source Plant maintenance and refuelling suppliers.
Plant Manager
(MMS # 025-L007-100). Potential suppliers are to provide information on safe operating procedures for tasks such as refuelling, plant isolation systems, elevated work, qualifications of maintenance personnel etc. Potential suppliers must provide evidence of being able to meet the environmental conditions of the project Maintenance companies are to provide a written assurance that all work is performed by appropriately trained and competent persons and that all work is done in accordance with any relevant legislation or standards. Modification to lifting Equipment Ensure that all modifications to lifting equipment if required are designed and carried out by a competent Engineer and in accordance with the relevant legislation and standard.
As required
Project Manager
Obtain the engineers certification before returning any modified lifting equipment to service
As required
Supervisor
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
See 6.9 (below) for MCD requirements on modification of lifting equipment
PAGE 11 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
5.2
DO THE JOB
5.2.1
Plan the lift
WHAT HAS TO BE DONE
WHEN
WHO
Review the work pack
When planning the lift
Lift Supervisor
Inspect the work site
When planning the lift
Supervisor
INFORMATION
Check for issues such as overhead services existing structures. proximity to excavations Underground services other cranes and mobile plant etc in the vicinity.
Develop the lift plan.
When planning the lift
Supervisor
See section 5.11(below) for MCD lift plan requirements
Obtain the Ground Load Bearing Capacity Calculations for Outrigger placement
When planning the lift
Supervisor
See section 6.13 (below) for MCD requirements
Identify additional equipment required
When planning the lift
Lift Supervisor
Develop Safe Work Method statement (SWMS)
Prior to the lift
Supervisor
Communicate SWMS to workgroup
Prior to the lift
Supervisor
Set up crane and inspect crane and all lifting equipment
Prior to the lift
Lift Supervisor
See section 6.1 (below) for inspection requirements after crane has been mobilised.
Supervisor Rigger
See sections 6.8 (below) for MCD requirements on executing the lift.
Lift and place the load
5.2.2
Daily plant inspections
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Carry out and record daily pre-start checks of all lifting equipment. Submit check sheets to the project office weekly.
Daily or at start of each shift.
Plant operator
Mobile Equipment Daily Inspection Report (MMS # 045-F030-100).
Pre-start checks are to be performed when taking over from another operator..
5.2.3
Report defects
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Write-down all defects and damage in the inspection report.
As required
Plant operator
Mobile Equipment Daily Inspection Report
If the defect requires immediate attention or endangers the safety of employees, phone the supervisor immediately.
(MMS # 045-F030-100).
If plant is unsafe to operate tag with an ‘Out of Service’ tag.
Immediately
Supervisor
Arrange for repairs.
As required
Supervisor
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 12 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
5.2.4
Prepare work area and evaluate weather
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Identify and barricade ‘no-go’ zones.
Prior to the lift
Supervisor
Traffic controllers may be required where loads are lifted over access roads
Check weather forecast and current wind speeds
4 hours prior to the lift
Supervisor
Check manufacturers manual for safe wind speeds.
Notify other workgroups in the immediate area
Prior to the lift
Supervisor
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Check that slings, ropes chains etc are correctly attached to the load.
Immediately before the lift
Lift Supervisor
See section 6.8 (below) for MCD requirements on safe lifting.
5.2.5
Conduct the lift
Rigger
General Safe Use requirements Executing the Lift
5.3 5.3.1
SUPERVISE AND MONITOR LIFTING OPERATIONS Supervise the lifting operation
WHAT HAS TO BE DONE
WHEN
WHO
INFORMATION
Observe the lifting operations of both MCD employees and contractors
Ongoing
Supervisor
Monitor compliance with this standard.
Conduct regular inspections of lifting operation
Weekly
Rigger Lift Supervisor Supervisor Rigger SPOHSR
5.4 5.4.1
Check that a JSEA/SWMS has been completed for the job. Stop the job if no JSEA/SWMS is available. Refer to HSE Inspections and monitoring (MMS # 020-D010-100).
TAKE ACTION WHEN SAFETY RISKS ARE IDENTIFIED Report and Take Action
WHAT HAS TO BE DONE
WHEN
WHO
Report any defective equipment to the supervisor.
Immediately
All employees
Turn off the equipment
Immediately
Supervisor
Fix an “Out of Service” tag to the suspect equipment.
Immediately
Supervisor
Send the equipment for repair.
Immediately
Supervisor
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
INFORMATION
Refer to procedure Tagging and Locking (MMS # 020E015-100)
PAGE 13 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Report inappropriate or unsafe operations involving crane use and lifting operations
As required
All site management and employees
Stop the job if unsafe
Immediately on the identification of unsafe activity
Supervisor
As required
Project Manager
Initiate disciplinary action were required.
Complete hazard report form
HSR SPOHSR Disciplinary action may include suspension of authority to operate plant for a period of time, retraining, termination of employment etc
6 TECHNICAL STANDARDS 6.1
CRANE SELECTION AND PLANNING
Before selecting a crane for service, the following criteria are to be taken into account:
• • • • •
The result of an appraisal of an existing crane, if applicable. The maximum permitted forces on the supporting structure. Power supply. Rated capacity of the crane. Classification of the crane taking into account the application, including; -
type of loads to be lifted; mass of loads to be lifted; speed of lifts; and frequency of lifts.
• • • • • • • • •
The maximum load that will be imposed on the crane.
• •
Projected upgrades of plant.
The maximum load moment that will be imposed on the crane. The nature of the rigging or slinging to be used. The position from which the load is to be lifted. The position in which the load is to be placed. The movement limitations of the crane and the load. Other limitations of the crane. Multiple crane lifting. Working environment including hazardous gases, corrosive atmospheres and high ambient temperatures including full speed operation against in-service wind load. The provision of additional crane capacity to cater, where necessary, for changes in the site environment, for example, increases in lifted load mass due to manufacturing tolerances, rapid changes in weather conditions.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 14 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
6.1.1
Pre-Mobilisation
The following planning activities are to be carried out by a competent person(s):
• • • • • • • • • • • • • • • • • • • • • • • • •
Selection of cranes
•
Suitable equipment is available for the installation, maintenance, operation and dismantling of the crane.
• • •
Condition monitoring of the crane and associated equipment.
6.1.2
Crane location planning – vicinity, visibility
Lightning protection Earthing for the conditions – e.g. static build up due to EMR, wind etc Site access and crane siting Safety of personnel and public entering into the site and the lift area Procedures for setting up of the crane Procedures for lifting operations Procedures for dismantling of the crane Selection of the personnel Communication systems(s) Weather conditions Ground conditions Proximity of excavations Selection of lifting gear to the appropriate standards PPE requirements Emergency procedures Procedures for non-routine lifts – Multiple Lifting Operations For multiple crane lift MCD Insurance underwriters require notification Night Operations Parking & Storage facilities for crane components Marking of crane and ancillary equipment e.g. rated capacity, safety signs Access for servicing Interface with existing plant and traffic Obtaining of approvals from statutory authorities or other relevant parties Appraising an existing crane for suitability for use, and ensuring that the appraisal is carried out by a competent person.
The maintenance, inspection and safe operation of the crane and associated equipment. The preparation, availability and maintenance of instructions for the assembly, operation, maintenance and inspection of the crane.
Assess the risks of the following:
• • •
Overhead Power Lines Underground services Wind loading is to be taken into account, including increased funnelling effects between adjacent buildings or structures.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 15 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
• • • • • • • •
Nearby structures or other cranes
• •
The crane should be sited so that the crane operator has optimum visibility
6.1.3
Ground Support
•
For Heavy Lifts, e.g. Bridge Beams; Tilt-up Panels and other lifts where the load is 50 tonnes or more, certification of the ground bearing capacity must be obtained from a geo-technical engineer before performing a lift.
•
A competent person must make sure that loads imposed by the crane can be sustained by the ground or any other means of support and that the crane can operate within the levels and other parameters specified by the manufacturer.
•
Where the crane is required to work in the vicinity of an excavation or an embankment, the possibility of slip or collapse of the supporting surface is to be evaluated by a competent person – and where applicable the embankment or excavation is to be reinforced.
•
Loads are not to be imposed on any new concrete supporting structure until the structure has reached sufficient strength.
6.1.4
Cranes on Suspended Surfaces
•
An assessment should be carried out by a structural engineer when planning to position a crane on a suspended surface. A suspended surface could include but not limited to the following; suspended concrete slabs, wharfs, jetties, barges or any other instance where the surface integrity or rating is unknown.
•
The assessment should ensure that the supporting surface is capable of supporting loads imposed by the crane, and the loadings it would apply to the supporting surface during its proposed operation.
•
The structure needs to be assessed during various stages of the job, including driving to the set up location on the structure, set up, use and, if different or the structure is changed during the job, dismantling and removal of the crane.
•
Where there is a requirement to use a propping system for the supporting structure, a structural engineer must advise of the correct location and ensure the design considers all loading factors that will be imposed upon it. A competent site representative is to ensure the propping system is functioning and maintained in line with the engineer’s advice.
• •
If the crane cannot be set up in the planned location than full assessment is to reoccur.
Excavations Fixed hazards – (Trees, poles, protruding objects) Personnel movement within the crane working area/s Mobile equipment movement within the crane working area/s Public access areas including roadways, railways, rivers and aircraft flight paths Effects of EMR (e.g. busbars, strobe lights, welding) on radio, infra-red or electronic controls The vicinity of airfields (High operating Cranes) maybe required warning lights and jibs painted high visibility colours. Precautions should be taken against the effects of noise, exhaust gases, hydraulic fluids, lubricants, fuel, dust and other environmental pollutants emitted by the crane.
Assessment items to address, but are not limited to the following include; - Crane model
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 16 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
- Crane configuration - Any crane de-ratings - Maximum outrigger loadings - Type of dunnage to be placed under outriggers - Principal Contractor details and representative - Structural Engineer completing assessment
•
The crane operator has the right to refuse to operate, where the above assessment cannot be validated and provided on site.
6.1.5
Weather Conditions
Prior to commencing crane and lifting operations the Crane Operator is to review the prevailing weather conditions (wind speed and direction, visibility, etc.). Crane and lifting operations shall not commence if the weather or environmental conditions are likely to jeopardise the safety of the activity – refer to Appendix F Adverse Weather Guidelines, for a comprehensive guide to the effects of varying wind speeds on land and water. 6.1.6
Marine Conditions
Crane and lifting operations occurring in a marine environment may be subject varying conditions (such as swell or unexpected wave action) which have potential to shock or dynamic load lifting plant and equipment, particularly when loading or unloading equipment to and from barges or vessels. If a load suddenly comes onto the lifting equipment, or if a load being lowered is suddenly stopped, the weight of the load borne by the equipment is effectively increased. The movement of the vessel and the hoist motion of the crane can combine to produce severe dynamic loading of up to three times the static weight of the load. Shock loading is not only experienced by the crane: the lifting accessories between the load and crane will also be subject to increased loading and, in the case of chains, shackles, etc. this may result in deformation known as permanent set. Twist may be induced in lifting equipment leading to the whole lifting assembly becoming tangled and shackles becoming jammed in their attachment points. Such deformation prevents the shackles being pulled into line with the sling and they become loaded in the wrong direction. In addition, the length of the slings can become uneven, causing unequal load distribution. The inherent risks associated with lifting operations in a marine environment, including the dynamic loading described above, mean that agreed requirements in the risk assessment are adhered to. 6.1.7
General Operation of Cranes on Floating Barge
Crane lifting operations on floating barges and vessels are inherently dangerous activities and McConnell Dowell requires the highest standards of planning and operation when these activities are being performed. The requirements of all relevant local legislation and regulations are to be complied with in all circumstances The crane manufacturers’ requirements for operating their specific cranes on floating barges and vessels must always be followed.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 17 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Cranes will be tied down in all conditions except within smooth water limits, and only where site specific conditions permit. In such situations a documented risk assessment must be undertaken. The risk assessment is to fully describe the particular activity or lift to be performed and when and how the crane can be used without the tie downs. Cranes on barges shall be appropriately de-rated for all conditions. Where a project specific assessment shows that an amendment to the guidelines below is warranted, such an amendment is to be considered for that project only. 6.1.8
Guidelines for Crane De-rating and Tie Down/securing
Cranes on floating barges shall be de-rated as follows: a) Dynamic Factors All loads to be lifted shall be factored as indicated and the factored load shall be used when checking against the crane’s current applicable load chart, including any de-rating as derived below. 1. 2. 3. 4.
All lifts in Smooth Waters – 1.1; All lifts in Partially Smooth Waters with wave heights ≤1m – 1.35; All other cases, but wave height ≤3m – 2.4; Where wave heights exceed 3m, no lifts shall be performed.
b) Inclination Factors Manufacturers Crane Maximum Load Charts shall be derated as applicable to the heel and trim inclinations derived in the vessel’s stability booklet that applies to the barge/crane combination intended to be used and for the lift/no lift condition being contemplated. Manufacturers Crane Maximum Load Charts shall be derated as applicable to the heel and trim inclinations derived in the vessel’s stability booklet that applies to the barge/crane combination intended to be used and for the lift/no lift condition being contemplated. Unless a rigorous crane/barge combination stability analysis has been performed and using specific inclination crane capacity data provided by the crane manufacturer, the following factors shall be adopted: 1. 2. 3. 4.
For inclinations < 1% - no change; For inclinations >1% and <1° - 20% de-rating applies; For inclinations >1° and <2° - 35% de-rating applies; For inclinations >2°- do not lift or operate the crane.
Note: the manufacturer’s recommendations may vary from these requirements and, if more stringent, they must be followed. 6.1.9
Crane Tie Down
The tie down system for a crane shall be designed for the following loads:1. 2. 3.
Smooth Waters – 0.1g lateral force in any direction; Partially Smooth Waters - 5° heel, 2.5° trim, 0.1g heave, 0.1g lateral force in down heel/trim direction; Other areas – special analysis is required by independent certified naval architect.
Friction between the crane and the barge is not to be taken into account to mitigate these forces.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 18 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
These provisions do not apply to any coastal or ocean tow, any tow longer than 4 hours in duration, any extreme environmental event (e.g. cyclones) or any operations outside of Inshore Operational Areas. Tie downs/sea fastenings are to be specifically designed for such tows. Refer to USL Code of Australia for definitions.
6.2
CRANE OPERATION
6.2.1
General Safe Use requirements
• • •
The crane will only be operated within the rated capacity and design classification
• • •
All cranes are to be kept clean
•
The crane is to be inspected daily by the crane operator to identify maintenance or repair items that may affect the efficient or safe operation of the crane.
• • • •
The SWL is to be stencilled on the crane.
•
Persons entering a crane operating area must make contact and be acknowledged by the person in charge of the area prior to entering the area. Crane operators should never be approached directly.
• • •
Barricades or guarding may be required where necessary.
•
Clearances are to be maintained and procedures developed to prevent unplanned contact between any parts of cranes working in the same site (refer to AS 1418 or AS 2550)
• •
The crane driver is not to use a mobile telephone whilst operating the crane.
6.2.2
Competency
•
The crane operator is to hold a valid license and/or certification, specific to the type and size of the crane and/or lifting equipment that is been used.
•
All operators who operate any crane are to be familiar with the following:
Power supply is compatible with the crane requirements (Gantry Cranes) Clear safe and defined pathways for cranes operated by pendant or wireless control is to be provided and maintained (Gantry Cranes) Tools and loose objects are to be stowed and secured The crane is to be inspected in accordance with the Operations and Maintenance Manual and/or local regulatory requirements
All cranes be fitted with “Christmas Tree Lights” No repair work or maintenance or refuelling is to be carried whilst the crane is operating. Only one competent person (certified dogman/ rigger or local equivalent) is to give signals to the crane operator.
The crane is not to be left unattended in the operating mode. The crane driver is to be familiar with any electrical power cables or conductors in the lift area and any other potential hazard.
When travelling a crane without a load, all chains and slings must be removed from the hook unless it is either tied to the crane to ensure it cannot bounce or twist: or independently tied back to the hook in such a way that any possible dislodgement caused by the movement of the jib is prevented.
-
Safe operation of the particular crane Locations and operation of all safety backup systems
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 19 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
-
Reading and understanding of load charts Capabilities of the machine Any peculiarities pertaining to that particular crane Safe operation near overhead power lines.
Appendix A Licensing Persons Performing High Risk Work lists the Certificates of competency relevant to the crane industry - Australia Only. Project management is to identify the specific local licensing/certification requirements for persons undertaking crane operations.
6.3
COMMUNICATION
At all times, there is to be adequate communication between all personnel involved in the lifting operation. Either hand signals or radio equipment appropriate for the relevant lifting operation is to be used. 6.3.1
Hand Signals
Crane Operators and dogman/ riggers or local equivalent must be familiar with the system of signalling being used for the operation. The signals presented in Appendix C are recommended for adoption in Australia. The local equivalent should be consulted when operating outside of Australia. The Crane Operator must:
•
Ensure that the signalling system to be used is clearly agreed between the crane crew prior to commencing any crane and lifting activities.
•
Only respond to signals given by the dogman/ rigger or local equivalent or ‘STOP’ when given a signal by other persons in an emergency situation.
• •
Maintain visual contact with the dogman/ rigger or local equivalent at all times.
•
Cease crane operations if inclement weather or darkness impairs the ability to see the dogman/ rigger or and operations cannot continue safely.
6.3.2
Radio Communication
Cease lifting operations if contact is lost and only recommence when a clear line of communication is re established.
The Crane Operator is to reach a clear understanding with the dogman/ rigger or local equivalent before lifting operations begin on the protocols to be used. If there is any interruption to the communication (e.g. third-party transmission) the Crane Operator must STOP the lifting operation immediately, only resuming when communication with the dogman/ rigger or local equivalent is re-established. Radio checks shall be carried out prior to the start of the lifting operation. When directing the load, instructions shall be clear and precise. Where appropriate, a communication method can be used whereby the signaller gives a continuous signal to continue the movement. The equipment operator shall stop immediately if he does not receive the signal. During periods of no radio communication, all lifting operations should be reviewed with suitable controls identified and agreed by personnel involved to enable safe execution of the operation. The following protocol is recommended for radio communication during lifting operations:
•
Call signs should be set up and adhered to.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 20 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
• •
Call signs must be used at all times to establish the authenticity of commands or directions.
• •
The receiving operator should indicate understanding of any dialogue through the response ‘roger’.
•
If the receiving operator is unsure regarding a message, the operator must not acknowledge but should repeat the message as he understands it and ask for confirmation or simply request the transmitting operator to repeat.
•
At the close of communication the transmitting operator should indicate the end of the transmission with the command ‘over and out’.
•
For single function operations the dogman/ rigger or local equivalent should relay to the Crane Operator using terminology such as: ‘up on the hoist’, ‘Boom up’, ‘Slew right’, etc. Where it is necessary to carry out an operation slowly the dogman/ rigger or local equivalent should instruct the Crane Operator accordingly. To stop a function the dogman/ rigger or local equivalent should instruct the Crane Operator to ‘Stop’. To stop all operations the dogman/ rigger or local equivalent should instruct the Crane Operator with ‘All stop’.
•
For simultaneous function operations the dogman/ rigger or local equivalent should relay to the Crane Operator using terminology such as: ‘Come up on the load and boom down’, etc. To stop a function the dogman/ rigger or local equivalent should instruct the Crane Operator to ‘Stop on the boom, slew right only’, etc. To stop all operations the dogman/ rigger or local equivalent should instruct the Crane Operator with ‘All stop’.
• •
Under no circumstances should profane language be used while transmitting.
•
Radio messages should reflect work requirements only; general conversation should not be carried out over the air waves.
•
Always ensure that you fully depress the transmission button before speaking into the microphone. Speak clearly at all times and do not release the button until a few seconds after completing your message.
•
When directing the crane, ensure that any accompanying colleagues’ radios are switched off – if more than one radio is switched on in close proximity interference and distortion of the signal will take place when an instruction is transmitted.
•
During blind lifts when the load is being hoisted or lowered for a long time do not maintain the transmission button in the depressed position for the duration of the lift – the dogman/ rigger or local equivalent should give the initial instruction and then talk to the Crane Operator as required to reassure the Operator that the line of communication is still active and that the lift remains under control.
•
During high winds, ensure that the area of the microphone you speak into is not exposed to the wind as background noise created may distort the transmission.
•
Ensure that the radio microphone is not exposed to rain. If a plastic carrying case offering full protection of the radio is not available, a simple precautionary measure such as a small plastic bag or a piece of cling film around the microphone will ensure that it remains dry.
At the end of an instruction or enquiry the transmitting operator should indicate the end of the message by the command ‘over’. Under no circumstances should the transmitting operator assume understanding without acknowledgement (‘roger’) from the receiving operator.
Should the radio antenna become damaged exposing the central core, the antenna must immediately be replaced in order to maintain not only optimum performance but to ensure user safety.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 21 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
6.4
Do not carry the radio in a pocket always ensure that they are carried on the body by either a belt clip or protective holster. Consider using the protective holster when working at height or climbing ladders to ensure that the radio does not become a dropped object if dislodged.
LIFT CATEGORIES
6.4.1
Travelling Loads (Pick and Carry)
•
No person is to walk between the load and the crane whilst the load is being carried on site roads or within any work area.
•
Dogman/ Riggers are to escort the cranes when travelling with loads on site, and must not travel in the crane cab under any circumstances.
• •
Use of tag lines to tie load to crane at >2.5o side slope gradients is prohibited.
•
Loads are to be kept as close to the ground as possible when travelling.
•
If unstable ground conditions or obstructions in travel path are present, the control methods for these hazards are to be included in a specific JSEA.
When travelling without a load, the hook block is to be secured to prevent swinging and damage to boom sections. Where this is impractical the hook block should be held fast against the boom head.
Pick and Carry cranes shall be de-rated as follows:
• • •
0.0 – 0.6 o manufacturer approved load charts and specifications apply.
•
>5.0 o the activity is to cease and be reassessed to identify another means of load lifting or transportation.
>0.6 – 2.5 o de rate in line with manufacturer approved load charts and specifications. >2.5 - <5.0 o de rate by a full 60% of normal SWL capacity, regardless of boom position and length*.
* Additional MCD safety factor exceeding manufacturer’s instructions 6.4.2
Multiple hoist or crane operation
Requirements for multiple crane hoisting
• •
All multiple crane lifts are to comply with the relevant Australian Standard as a minimum
•
The following minimum capacity requirements for each crane is to apply (where hoisting operation is not designed):
• • • •
For 2 cranes -
20% greater than the calculated share of the load.
For 3 cranes -
33% greater than the calculated share of the load.
Other than for designed lifts, lifting operations using two or more cranes will use cranes of the same type.
For 4 or more cranes-
50% greater than the calculated share of the load.
Where load is suspended from more than one hoist line the load must be handled in such a way that: -
The rated load for each line is not exceeded
-
The load being handled does not exceed the rated capacity of the crane.
-
Supervision is to be provided by a competent person, who is not one of the crane operators.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 22 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Planning for multiple crane hoisting When planning, determine: the accurate proportion of the load to be carried by each crane how the proportioning is to be maintained whether each crane has appropriate additional capacity over the portion of the load to be lifted the operating characteristics of the cranes e.g. speed of hoisting. The allowance that should be made for manufacturer’s tolerances (if the load information is taken from technical drawings) The mass and distribution of the lifting gear on cranes and crabs Manitowoc and Grove cranes require the weight of any wire below the head sheave to include in the total load weight. Weather conditions, and access the prevailing conditions (such as wind) before commencement of and during the multiple hoisting operations. Synchronisation of the crane and crab motions
• •
Crane and crab motions are to be synchronised or one crane placed in free slew mode
•
NOTES:
To allow for the probability of the motions of the cranes or crabs not being accurately synchronized, particularly if the cranes or crabs have dissimilar operating characteristics, the operation must be performed at slow speeds with extreme care being exercised to maintain the hoist ropes as close to vertical as possible. -
-
1. The rated capacity of a crane is calculated on the assumption that the load will be raised and lowered in a vertical plane. The crane structure will have been designed to withstand any lateral loads imposed by accelerations in the various crane and crab motions, but it is unsafe to rely on this lateral strength to withstand horizontal components of non-vertical lifts. 2. In practice, there will always be some variation due to differences in response to the activation of the motion controller and the setting and efficiency of the braking system
Pick and Carry (Multiple Cranes)
•
In pick and carry operations, the axis of both or all cranes or crabs is to be kept aligned in the same direction where possible. The possibility is that once out of alignment especially during cornering; the movement of one crane or crab may push or pull either the other crane(s) or crab(s) and cause loss of stability. Load chart limitation during articulation is to adhered to
•
NOTE: Instruments are available to monitor constantly the angle of the load, and the verticality and force in each hoist rope throughout the lifting operation. Their use is recommended.
•
Tag lines must be used on loads when in pick and carry operations with the exception of dual crane operations
• •
Cranes will not pick and carry loads on a fly or with a fly in the un-stowed position
6.4.3
Controls
•
All lifts require JSEA/SWMS to be completed and reviewed by the Crane Crew and responsible Supervisor prior to commencing the activity.
Dual crane pick and carry is a critical lift requiring a lift study
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 23 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
Lifting of persons in workboxes (Refer MMS Safe Operating Procedure # 020-T003-100 Workbox Use).
•
Working near overhead power lines (Refer MMS Safe Operating Procedure # 020-T009-100 – Overhead Power Lines)
•
Documentation specific to the operation being carried out should accompany the Crane Lift Plan. This includes items such as erection sequences, relevant drawings, fixings etc.
6.4.4
Crane Lift Plans
Crane Lift Plans are to show weight, radius, crane capacity and % of SWL and a drawing showing the plan view of the crane and load. Crane Lift Plans (MMS # 600-F003-100) are required to be completed when any of the following conditions apply:
• •
The client requires one or the crane operator requests one;
• • • • • • • •
The load is 50 tonnes or more;
•
The suspended load passes over any operating facility, or passes over or within 6 meters of any electrical installation such as transformers and substations. In addition, lifting activities near overhead aerial conductors are to comply with SOP MMS # 020-T009-100;
•
Drawings of existing facilities at the site show that the movement of the crane or any operation of the crane may damage underground services.
•
Singapore - All lifts (Refer to WSH Operation of Cranes Regulations 2011)
6.5
The total suspended load including rigging equipment exceeds 85% of available crane capacity (refer to crane load chart); A Bridge Beam is to be lifted during bridge installation work; A Tilt-up Panel is to be lifted; Pre-cast Concrete Panels are to be erected; A Tower Crane is to be erected; A Mobile Crane is to used on a Barge; Lifting large pressure vessels or tanks More than one crane is to be used - either in shared lift configuration or when one of the cranes is to be used as a `tailing' crane;
MAINTENANCE, INSPECTION AND REPAIR - CRANES
Maintenance, inspection and repairs are to be carried out by a competent person in accordance with the requirements listed below and as identified in AS.2550.1 or its local equivalent. 6.5.1
Maintenance
•
A preventative maintenance program will be established giving consideration to the manufacturer’s recommendations. It will be based on the working environment and the frequency and severity of use of the crane.
• •
Ensure all subcontractor contracts include maintenance schedules When parts and components are replaced, replacements will be identical or equivalent to the original equipment parts and components.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 24 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
Where past experience has shown particular problems with a crane, a specific rectification program will be instigated and documented.
• • • •
All malfunctions and problems will be corrected before the crane is returned to service.
6.5.2
Inspections
Maintenance is to be carried out in accordance with the Manufacturer’s recommendations. A documented record is to be maintained for any maintenance completed. Routine inspections should take place at intervals not exceeding those shown in the operator’s handbook.
The following items should be checked for compliance with manufacturers’ specifications and safe operation as part of a pre-operational inspection of a crane:
• •
Check the oil levels, fuel level and lubrication of all moving parts.
• •
Check that all water is drained from air reservoirs.
•
Visually inspect structural members and other critical components such as brakes, gears, fasteners, pins, shafts, wire ropes, sheaves, locking devices and electrical contacts.
•
Check the security of the counterweight. Where this is in the form of removable weights, check that the weights correspond to those shown on the counterweight chart for the operating condition in use.
•
Check that the load moment system where fitted is correctly set or fitted (or both) with the program appropriate to the boom or jib length, and fly-jib lengths and falls or parts of rope.
• •
Check that the indicator appropriate to the boom, jib or fly-jib length is fitted.
• • • • •
Check the pneumatic systems and hydraulic systems including their safety devices.
• • •
Check signage, including warning signs and control markings.
6.5.3
Periodic inspections
•
Inspection is to include all items specified by the manufacturer for annual inspection along with all routine inspection and maintenance items.
•
As the result of a periodic inspection, a competent person may recommend a major inspection.
Check the ropes, rope terminal fittings and anchorages, rope drums and sheaves for any damage and wear. Check the crane for any loose or damaged structural component including supports and outriggers where fitted. Loose joints may be readily noticed by flaking or marking on the paint surface or by rust marks. Similarly, cracks may often be detected by rust runs.
Check that the crane cabin is in a tidy condition and free from grease and oil, rags, tools and materials other than those for which storage provision is made. Check the operation of the crane through all motions with particular attention to brakes. Check the operation of all limit switches or cut-outs, emergency and safety devices. Exercise caution in making the checks in the event of non-operation. Check that, where radio communications are being used, the calling signal is functioning and any messages may be clearly heard. Check that fire extinguishers are in place and satisfactory for use. Additional items nominated in the manufacturer’s instructions or operator’s handbook.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 25 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
• •
For details of inspections for particular types of cranes, refer to relevant Part of the AS 2550 series.
•
Vacuum and magnetic devices are to be fitted with failsafe devices where available
6.5.4
Major inspection to assess a crane for continued safe operation.
• •
All cranes are to be inspected and repaired as per AS2550.1
Where the crane has a non-positive lifting attachment, (vacuum, magnetic etc) suitably qualified personnel are to carry out maintenance according to the manufacturer’s recommendations. If such recommendations are not available, then twice-yearly maintenance is to be carried out. Permanent and electro-permanent lifting magnets are to undergo a yearly residual magnetism check of the magnet core. Where vacuum lifting attachments are used, the frequency of inspection is to be twice daily to ensure no seal damage the machines continue to function as designed.
Where third-party inspections are conducted, the following requirements apply: -
-
6.6
As part of this inspection, the maintenance records of the crane must be reviewed prior to the inspection. After the inspection, a report on the condition of the crane is to be compiled on the current condition of the crane. The usage of the crane must be verified for compliance with the design classification. The inspection is to include checking electrical, mechanical and structural components for safe condition and function. Opening of cover plates and removal of guards is to be as considered necessary by the inspector due to the existing condition. Particular attention must be paid to any component with a recent or existing history of repeated failures.
REPAIRS
Any part of a crane that becomes worn beyond manufacturer’s tolerances, damaged as to constitute a hazard, impairs the operation of the crane, or constitutes a hazard before the next routine inspection, must be repaired or replaced. The repairs and parts must comply with the manufacturer’s recommendations and specifications, or the recommendations of a competent person, taking due cognizance of the Standard to which it was designed and must be carried out by competent persons under competent direction and supervision. The repairs are to be appropriately tested. All repairs are to be adequately documented and recorded. 6.6.1
Assessment for repair procedure
•
• •
A competent person is to make an assessment of the defects and damage requiring repair based on the manufacturer’s tolerances and in accordance with AS 2550.1. The assessment is to be recorded and form a report. The report should contain the following: Details of how the incident happened or circumstances leading to the discovery of the defective parts. Nature and extent of the damage and defects. Proposed action based on the manufacturer’s recommendations.
6.6.2
Management of repairs.
•
Following the review of the competent person’s report, the equipment may only be repaired or scrapped. Where any component is scrapped, arrangements should be made to dispose of the damaged component in a manner that ensures it remains unusable as a load-carrying component.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 26 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Where it is decided to implement the manufacturer’s recommendations, instructions incorporating such recommendations will be prepared. Such instructions must be followed. Following repairs, the crane will undergo the load and operational tests specified in the appropriate part of AS 1418 to an extent commensurate with the type of alteration or repair. 6.6.3
Repair work
•
The repairer selected to carry out the work must be acceptable to the competent person. Repair work is to be carried out according to the following: Personnel with the necessary qualifications and experience will be engaged on the work. Work instructions will be provided. All work is to be in accordance with manufactures recommendations Sign off line manufacturers prior to work commencing All work to be managed by ITP, SMP, QMP, QC checklists. All work will be conducted in accordance with relevant Australian Standards or other applicable national or international Standards. All final non-destructive testing will be conducted by a competent person. A records management system is to be established for the documentation produced by repairers and received from other bodies for transfer to the owner.
• • • • • • • •
6.6.4
Welding repair examination
•
The examination of welding repairs must be carried out in accordance with the manufacturer’s repair procedure, or the appropriate weld inspection Standard. Preapproval for the welding procedures and qualifications of welders is required.
• 6.7 6.7.1
RIGGING AND LIFTING Competency
The slinging method is to be determined by a person who is competent in load slinging in accordance with local Safety Regulations. Project management is to identify the specific local licensing requirements for persons undertaking lifting operations. Within Australia the Riggers licence capabilities are defined as;: Dogging – consists of the application of slinging techniques to move a load (including the selection and inspection of lifting gear) and/or the directing of a crane/hoist operator in the movement of a load when the load is out of the view of the crane/hoist operator. Basic rigging – consists of dogging and rigging work involving: •
Movement of plant and equipment
•
Steel erection
•
Hoists (including mast climbing hoists)
•
Placement of pre-cast concrete
•
Safety nets and static lines
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 27 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
Perimeter safety screens and shutters, and Cantilevered crane-loading platforms.
Intermediate rigging – consists of all basic rigging work including rigging work involving: •
Cranes, conveyors, dredges and excavators
•
Tilt slabs
•
Hoists with jibs and self-climbing hoists
•
Demolition
•
Dual lifts
Advanced rigging – consists of all intermediate rigging work including rigging work involving: •
Gin poles and shear legs
•
Flying foxes and cableways
•
Guyed derricks and structures
•
Suspended and fabricated hung scaffolds
Australia Only Appendix A Licensing Persons Performing High Risk Work lists the Certificates of competency relevant to the crane industry -.(Refer to National Standard for Licensing Persons Performing High Risk Work.) 6.7.2
Equipment Selection & Planning
Before selecting any rigging and lifting equipment, the following should be taken into account;
• • • • • • • • • •
Load Headroom Frequency of use- life of sling Type of load – Steel, Machinery, timber, crates, shipping container etc Current inspection certificate Cost versus efficiency Length of sling Method of slinging Environment – corrosion, heat etc Storage requirements
6.7.3
General requirements- Lifting Equipment
•
A visual inspection will be conducted prior to use of rigging and slinging equipment.
• • • • • •
Never combine different types of slings.
• •
Inspections must be conducted by a competent person and be recorded by that person.
Shackles are to be used where slings are attached to eyebolts or lugs. Shackle diameter must not be less than sling diameter. Multiple individual slings are to be shackled together on the hook. All hooks are to be supplied with devices to prevent load movement. Lifting clutches are to be proof load tested at least at twelve (12) monthly intervals, with a record kept on site to verify such testing. All rigging and lifting equipment either purchased or hired on a project, must have all certifications relevant to the item in accordance with the relevant local standard.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 28 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
Items to be kept include but not limited to records from the manufacturer or supplier, identifying that the equipment has passed all relevant testing and has been supplied in accordance with the relevant local standard. Items include equipment such as; slings, shackles, eyebolts, lifting clutches, chain blocks etc.
•
All rigging and lifting equipment certification and inspection/test records are to be maintained and readily available.
•
Suitable storage arrangement available for the particular types of equipment – typically hung up off the ground in a covered, dry, clean, well ventilated place, away from direct sunlight.
•
If one or more of the defects, listed in Error! Reference source not found. is identified, the item is to be removed from service immediately, tagged out and condition fully assessed prior to being discarded.
6.7.4
Chains
Care
• • • •
Compliance certificate for chains should be available in project files. Store chain slings in a clean dry place, preferably on A-frames or wall racks. Lightly oil chains before prolonged storage. Never heat treat alloy chain or fittings.
Use
• • • • • • •
Minimum size chain for lifting purposes is to be 6mm.
•
The user should seek advice from the manufacturer regarding a reduction in WLL, where chain is to be used at temperature hotter than 200°C or colder than -10°C.
• •
Commence the lift slowly, taking up the slack gradually. Avoid shock loads.
Alloy steel chain Grade (T) 80 or higher is to be used for lifting. Always visually inspect that a chain sling is free from damage or wear before use. Ensure the weight of the load is known and is evenly distributed on the sling legs. Ensure that the chain is free of twists and is protected from any sharp corners on the load. Avoid crushing the chain. Do not use a chain in a manner that will exceed the WLL of the chain for the particular conditions of use.
When lowering, avoid the possibility of crushing the chain by ensuring the load does not land on it. Use packing, timber or similar.
Inspection
• • •
Clean the chain thoroughly.
•
Master links and hooks should be inspected for any sign of wear at their load bearing points and for any signs of distortion, such as widening of hook throat opening.
Lay the chain out on a clean surface or hang it up in a well lit area. Every chain link should be individually inspected for any signs of wear, twisting, stretching, nicks, or gouging and any worn link measured to determine degree of wear using vernier callipers.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 29 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
•
Coupling links should be inspected for any signs of wear at their load bearing points, for excessive play of the load pin within the body halves and for impaired rotation of the body halves around the load pin.
•
Chain links or fittings having any defects should be clearly marked to indicate rejection and the chain sling should be withdrawn from service until properly repaired and retested prior to returning to service.
Remember - Every link must be examined 6.7.5
Steel Wire Rope
Care and Use
• •
Minimum size wire rope for lifting purposes is to be 8mm
• •
All slings must be visually inspected prior to each lift.
Continuous wire rope slings with large diameter soft eyes must not be used. Wire rope slings with a ferrule secured thimble eye are acceptable A thorough inspection of all slings in use must be made at regular intervals.
Inspection Inspections must be conducted by a competent person who will inspect for the following:
• • • • • •
Broken Wires (refer to Australian Standards for quantity breaks).
• • • • •
Stretching or extended lay.
Corrosion (rust). Kinks Crushed or flattered sections. Bird-caging and high stranding. Damage to Wire Rope Terminations such as; sockets, wire rope grips, thimbles, ferrules, swage buttons, cable stockings etc. >33% wear on individual wires. Adjacent broken wires. Heat damage. Other obvious damage.
If in your opinion a sling has sufficient damage of any type, don’t use it report it! 6.7.6
Synthetic Slings
Round Sling – an endless sling comprising a load-bearing core of high-tenacity continuous-multifilament yarn that is completely enclosed in a woven cover, with or without fittings or coupling components. Flat Webbing Sling – a sling made of flat woven synthetic-fibre webbing, which may incorporate end fittings complying with AS 3585 or AS 3776 or local equivalent for the lifting and handling of loads. Care and Use
• • • •
Never overload equipment Do not use if WLL tag is removed or illegible. Inspect sling for damage prior to use. Do not use if there is any sign of cut webbing, snagging, heat or chemical damage, excessive wear, damaged seams, any other defects or presence of grit, abrasive materials or other harmful matter.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 30 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
• • • • • •
Do not tie knots in sling webbing. Protect sling webbing from sharp edges. Use protective sleeves. Do not expose sling to temperatures above 90°C. Do not allow abrasive or other damaging grit to penetrate fibres. Consult with manufacturer’s recommendations before immersing a sling in a chemical solution. Keep away from strong alkalis and phenolic compounds.
Note: A nylon sling loses 15-18% of its strength on wetting with water, but regains that loss of strength after drying out. Inspection Synthetic slings should be inspected for the following prior to use:
•
One major disadvantage of woven webbing slings is that when used to lift loads such as concrete slabs, grit can penetrate the sling causing internal fibre damage, which is not always obvious.
•
Internal wear, caused by repeated flexing, particularly where particles of grit have penetrated into the fibres.
•
Damage to a fixed protective coating or sleeve can allow abrasive grit easy access to the sling fibres.
•
Melting or shrinkage of fibres due to exposure to high temperatures. Remember that high temperatures can result from friction as well as from a hot environment.
•
Prolonged exposure to ultra violet light, generally from sunlight, will weaken synthetic fibres - this may be indicated by powdering of the outer layer.
•
Chemical attack may also cause fibres to break down and soften. Surface fibres may be plucked or rubbed off and there may be local stiffening of the sling.
6.7.7
Lifting Hardware
Shackles Shackles are used for interconnecting components in lifting, tensioning and staying systems. A shackle consists of a body, a removable pin and any applicable locking device.
• • • • • • • • •
All shackles are to be Alloy steel shackles of grade S or better
•
The pin is screwed tightly with the collar and the pin is bedded evenly on the surface of the shackle eye.
•
The correct type of pin is used for the application.
Commercial grade shackles are not to be used for lifting purposes. Stainless steel shackles are not to be used for lifting purposes. All shackles are to have the SWL cast or stamped into the shackle body Compliance certificate for the batch supplied is to be available in the Project plant files Ensure that all markings are clearly legible. Ensure pin is the correct type. Never replace the pin of a shackle with a bolt. The threads of the pin and body are undamaged and the pin screws freely into position. The body and pin is not unduly worn and free from distortion, nicks, gouges, cracks and excessive wear and corrosion.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 31 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
• • •
A bolt type shackle has a split cotter (safety pin) attached correctly. Shackles should not be heat treated as this may affect their working load limit. Never modify, repair or reshape a shackle by welding, heating or bending as this will affect the working load limit.
Eye Bolts
• • • • • • • • • •
Eyebolts of 12mm or smaller should not be used in general lifting, staying or tensioning purposes. Commercial grade eyebolts are not to be used for lifting purposes or to support loads. Stainless steel eyebolts are not to be used for lifting purposes. Eyebolts should be screwed down fully to the face of the load to be lifted. WLL markings are clear and suit the application. Conduct a visual inspection for deformation and cracking. Conduct a visual inspection of the inside eye for wear. Conduct a visual inspection and check for damaged threads. Ensure the thread centre is aligned with centre of eye. Ensure the eyebolt’s thread form and the thread form in the corresponding hole or nut is the same.
• • •
Avoid excessive tightening of eyebolts.
•
A continuous sling should not be used with pairs of eyebolts. When lifting with pairs of eyebolts supported by slings, always use slings with individual lengths.
Metric and imperial eyebolts that conform to the Australian Standard have a safety factor of 6:1. When using eyebolts in pairs, it is essential that care be taken to properly align them. Eyebolts must not be forced into alignment as overstress will cause a reduction in the WLL.
Eyebolts should be inspected periodically by a competent person as per AS2317 or local equivalent.
Lifting Beams There are three (3) types of lifting beams: Lifting Beam - a lifting beam that is placed in bending by the applied load(s). Spreader Beam or Bar - a spreader beam or bar that is placed in axial compression by the applied load. Combination Beam - a beam that combines both bending and axial compression loads in the one beam.
•
All spreader and lift beams are to comply with AS.4991 or the local equivalent.
When using lifting beams, the following shall be observed:
• • • •
The method by which the load is attached to the beam. The method by which the lifting beam is attached to the crane. Checking the security of the attachment of the load to the lifting beam. Alignment of the centre of gravity of the load to the lifting means.
NOTE: Open sections (UB, UC, PFC) are relatively flexible in torsion and care should be taken to avoid twisting these components by eccentric loading.
•
Checking the security of the attachment of the lifting beam to the lifting means, e.g. crane hook.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 32 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Sundry Equipment
•
6.8
All sundry rigging equipment is to fully comply with the relevant Australian standard or local equivalent as a minimum.
LIFTING THE LOAD
6.8.1
Slinging the Load
• • • • •
The slinging method is to be determined by the shape, size and weight of each load.
• • • • • • •
For large or long loads (12m+) attach 2 taglines and controllers or more if required
6.8.2
Executing the Lift
Slings are to be positioned over flat surfaces not over sharp edges or corners. Use protective padding when using any sling around sharp corners. Secure the lifting area from unauthorised entry. Tag lines of 16mm natural fibre rope or equivalent are to be used as necessary to control load sway. Dual crane lifts do not require tag lines Loads are to be balanced. Ensure no part of the load can slide or fall out during lifting. Don’t stand between the load and other obstructions. Keep hands and feet well clear of pinch points. Loads are not to be lifted over personnel.
While undertaking the lift, the operator and the dogman/ rigger must:
• • •
Coordinate the lift with other operations in the area
• • • • •
If the weight of the load is unknown, do not guess, but seek further advice
• • • • • •
Before lifting any load, ensure all loads are secured to prevent any items falling
Confirm wind speeds immediately prior to the lift Refer to the cranes load chart for load-reach relationship, working within the crane’s lifting capacity at all times No loads in excess of the safe working load shown on the load chart are to be lifted The load chart is to be kept in the cab of the machine at all times Never switch off or override the lift computer during a lift The crane driver is responsible for the overall safety of the lift and must discuss the lift with the dogman/ rigger prior to commencing the lift. The crane driver is to obey the dogman/ riggers directions during the lift Avoid any sudden starts and stops to prevent shock loading of the crane and lifting equipment Tag lines must be attached directly to the load – not the rigging gear Tag lines are to be clean and dry and checked safe before use Tag lines are to be at least 16mm in diameter and made of non-conductive material. Lifting gear is not to be used as a tag line.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 33 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
• • • • • • •
Before giving direction to hoist up, ensure the boom is positioned directly over the load
6.8.3
Management of change during a lift
•
If the operation cannot continue in accordance with the agreed procedure, the operation shall stop and the procedure reassessed to take into consideration the reason for the stoppage.
•
If the reassessment is considered a relatively minor deviation from the agreed procedure the documentation (SWMS) shall be clearly marked with the actions considered appropriate and agreed prior to operations recommencing.
•
If the reassessment is considered a major deviation from the agreed procedure then the appropriate actions shall be taken, as a minimum will require the documentation to be marked and amended in accordance with the revised proposals agreed. If the deviation is significant it may require production of a drawing revision, calculations or other information as applicable.
Loads are to be lifted slowly to prevent swing Loads are to be lifted just high enough to clear obstacles Operators must not leave the load suspended in the air when leaving the cab No person is allowed to climb on or off a moving crane or load Do not allow anyone to stand under a suspended load or near lines under stress No person is to enter the fall zone until the load is as close as practicable to the landing point
6.9 6.9.1
INSPECTION, REPAIR AND MODIFICATION Inspection
All chains and slings purchased new are to be accompanied by manufacturers testing certificates and tagged appropriately as per the equipment’s required standard. Used equipment coming to site, must have records that it has satisfactorily passed inspections by a competent person in the previous twelve (12) months. The person performing annual inspections is to be a person employed by an accredited third party specialist testing and inspection organization (such as Bullivants, Nobles or a local equivalent) that has completed appropriate training and has the skills and knowledge to carry out such inspections. Quarterly inspections (3 monthly) are to be carried out on lifting equipment by a competent person. Records of outcomes from these inspections are to be kept and maintained with the equipment’s records. A person deemed competent to carry out these inspections is someone who has the practical and theoretical knowledge and relevant experience, sufficient to enable the person to detect and evaluate any defects or weakness that may affect the intended performance of the equipment. The visual inspection checklist is located in Error! Reference source not found.. If any of the items fail to meet any of the required checks, the equipment should be tagged out of service and not to be used and upon assessment either discarded or repaired.
Rigging and Lifting Equipment - Testing/ Inspection Frequency Requirements Equipment Type
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
Test/ Inspection
Frequency
Who
PAGE 34 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
All Rigging and Lifting Equipment
Chain Slings –Grade T
Steel Wire Rope
Round Slings – Synthetic Fibre
Flat Synthetic – Webbing Slings
Lifting Devices
Certificates of equipment certification and test results to be provided with new or used within last twelve (12) months Re-inspect equipment annually or as per manufacturer’s recommendations or relevant Australian Standard or local equivalent.
Manufacturer/Supplier Before initial introduction to service
Certified lifting testing/inspecting authority
Manufacturer/Supplier If not specified – twelve (12) monthly as minimum interval.
Certified lifting testing/inspecting authority
Inspect condition of equipment
Prior to each use
Competent Person
Inspect equipment and record results
Quarterly Intervals
Competent Person
Inspect condition of equipment
Prior to each use
Competent Person
Inspect equipment and record results
Quarterly Intervals
Competent Person
Inspect condition of equipment
Prior to each use
Competent Person
Inspect equipment and record results
Quarterly Intervals
Competent Person
Inspect condition of equipment
Prior to each use
Competent Person
Inspect equipment and record results
Quarterly Intervals
Competent Person
Inspect condition of equipment
Prior to each use
Competent Person
Inspect equipment and record results
Quarterly Intervals
Competent Person
6.9.2
Repair and Modification
•
All repair and modification to lifting equipment is to be designed and fabricated in accordance with applicable standards and the modified design registered by the design authority.
•
After repair or modification, lifting equipment must be tested by application of a proof load, specified by a competent person, and then thoroughly examined. A test certificate stating the Working Load Limit and the proof load is to be obtained and retained on site.
•
The design and specifications of purpose made lifting equipment must be approved by the design authority.
• •
A report of the examination is to be produced. Modification and repair of lifting equipment is to be in accordance to the applicable standards.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 35 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
7 OTHER EQUIPMENT USED FOR LIFTING 7.1
EARTHMOVING EQUIPMENT USED FOR LIFTING
The requirements from AS 1418.8 or its local equivalent are to apply when earthmoving equipment including backhoes, front-end loaders, excavators, tool carriers and similar units are used for lifting freely suspended loads as a secondary function associated with the normal application of the equipment. Where it is intended to use the earthmoving equipment for cranage operations other than those indicated above, or where variable rated capacities are specified, all requirements of AS 1418.5 or its local equivalent are to apply. Lift point - A lifting lug located on the boom, arm, linkage, front end loader bucket or quick-hitch as specified by the manufacturer, to which a load may be attached for lifting freely suspended loads. Lift point radius/reach - The lift point radius/reach is the horizontal distance from either the centre-line of the front wheel or equivalent position on track, or the axis of rotation or the centre-line of the load supporting axle as appropriate, to the vertical load line. Where a non-slewing machine is fitted with stabilizers, the reach shall be measured from the centre-line of the stabilizers nearest to the load. Rated lift bucket position - The bucket attitude with the bucket fully rolled forward and the load suspended from the bucket as recommended by the manufacturer. 7.1.1
General requirements for lifting with earth moving equipment
•
The earthmoving equipment shall be travelled only with arm and boom retracted to minimum practicable radius.
• •
No person is permitted under the boom or suspended load.
•
The person slinging the load or directing the operator is to have a certificate of competency for dogging or rigging.
• • • •
No persons are to be lifted by earth moving equipment.
• • •
Loads are not to be suspended from bucket teeth or adaptors.
All persons operating the earth moving equipment are to have the appropriate certificate of competency and/or training
Lift points are to be arranged such that accidental unhooking of the load cannot occur. Operational speed is to be reduced from high-speed mode. Where the sling or tackle is wrapped over the back of the bucket, it is not to come into contact with any sharp projection or sharp edge. Reference is to be made to the manufacturer’s manual for correct operation. A service record (logbook) is to be used to record servicing, maintenance and repair work, and details of any malfunction that may occur with the machine.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 36 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
7.1.2
Requirements for rated capacity at maximum reach/radius
The rated capacity is the maximum mass (expressed in kilograms) that may be handled at the maximum lift point radius, or reach, expressed in metres in the most adverse configuration for each lift point without the strength, hydraulic, and stability requirements being exceeded. The rated capacity comprises of the mass of the lifted load and the lifting attachments. Where a bucket is fitted, the rated capacity is to be established at the rated lift bucket position that results in the maximum radius. A rated capacity chart, identifying the lift point location(s) and the corresponding rated capacity at that position, is to be mounted inside the operator’s cab and is to show the following:
• • • • •
Manufacturer’s name and model.
• •
Tyre track and size (in millimetres) and inflation pressure (in kilopascal), where applicable.
• •
NOTE: Buckets and quick hitches should have their mass marked on them.
• • •
The maximum permitted slope for lifting and pick and carry operations.
7.1.3
Controlled lowering devices
Boom identification (length in metres), where applicable. Arm identification (length in metres), where applicable. Shoe width (in millimetres) and track gauge and length (in metres), where applicable. Deductions for attachments such as a bucket, lifting devices or quick hitch device to allow determination of the net load that can be lifted. Bucket mass (in kilograms) and width (in millimetres), or quick hitch mass (in kilograms), as applicable. Ground speed limit for pick-and-carry rated load for rubber-tyred equipment (in kilometres per hour). Where controlled lowering devices are fitted, a notice of the effect to be displayed. Any other equipment conditions that may impact on rated capacity.
Earthmoving equipment that is used to lift freely suspended loads that have a rated lift capacity at maximum radius/reach greater than 1 t is to be fitted with a controlled lowering device on the raising boom cylinder(s). The control-lowering device is to meet the requirement of ISO 8643, to protect against hydraulic hose failure. Where control lowering devices are not provided, the following is to apply:
• •
A load greater than 1 t shall not be lifted.
•
Suspended loads shall not be lifted over personnel, in any circumstances.
7.1.4
Stability
Controls shall be in place to ensure that uncontrolled lowering shall not result in injury or death to persons in the area.
Stability of earthmoving equipment is to be such that the rated capacity is not greater than the appropriate percentage of the tipping load that has to be applied to tip the earthmoving equipment within AS 1418.8 Section 5 or it is local equivalent. Where the earthmoving equipment requires the use of stabilizers in order to achieve stability, the equipment is to be supported by such stabilizers.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 37 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
7.1.5
Rated hydraulic capacity
The rated hydraulic lift capacity of earthmoving equipment is to be such that the rated capacity is not greater than 87% of the hydraulic capacity at maximum reach/radius. The rated capacity at each lifting point is to be prominently marked at the lifting point. This is not to be exceeded under any circumstance, that is, the lifted load plus any attachments (bucket, etc.) shall not exceed the rated capacity. Deductions from the rated capacity for larger than standard buckets or quick hitch devices are to be considered to determine the maximum allowable mass of the item that may be lifted. Reference is to be made to the manufacturer’s manual for correct operation. 7.1.6
Quick-hitches
Quick-hitches that are fitted to earthmoving equipment used to lift freely suspended loads are to comply with the requirements in AS 4772 or its local equivalent. (Safe use of earth moving machinery fitted with a quick-hitch) Where equipment is used and is fitted with a quick hitch, the following requirements apply:
•
Loads only to be suspended from the manufacturer’s designated lift point on the quick-hitch unless a designated lifting attachment is fitted.
• •
All non-lifting attachments to be removed before any lifting operation is undertaken.
• •
Host machine load rating charts to allow for the additional mass of the quick-hitch.
7.1.7
Marking and Labelling
Quick-hitches to be used only to support attachments specifically designed to fit and specifically designed for the duty to be undertaken. Quick-hitches to be maintained in proper working order at all times.
The earthmoving equipment configured to lift freely suspended loads is to display at a readily accessible and prominent location and on permanent and legible notices the following information, where appropriate:
• • • •
Name or mark of the supplier. Model designation. Serial number. Where earthmoving plant is to be used for lifting a freely suspended load, all controls shall be labelled in accordance with ISO 7000.
8 RECORDS Daily inspection records Lift Plans Maintenance records Plant incoming inspections – internal and external inspections
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 38 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
9 REFERENCES Competency Register Competency Register – By person Compliance with Legal & Other Requirements Crane Lift Plan Height HSE Risk Management Mobile Equipment Daily Inspection Report Overhead Power Lines Project Training Plan Plant & Equipment Register Plant Operator Assessment Project Compliance with Legal & Other Requirements Storage Maintenance & Refuelling of Machinery Workbox Use
030-F044-100 030-F045-100 000-D004-000 600-F003-100 020-T005-100 020-D012-100 045-F030-100 020-T009-100 030-J008-100 045-F136-100 030-F047-100 300-E012-100 025-L007-100 020-T003-100
Cranes and Lifting Equipment Elevated Work Platforms ES&H Aspects of Plant and Machinery ES&H Training and Competency Forklift Trucks Procurement
ESH-047 ESH-111 ESH-057 ESH-003 ESH-048 ESH-021
Singapore - Code of Practise for Safe Lifting Operations at Workplaces Singapore - WSH Operation of Cranes Regulations 2011 Management Systems Australia. Environment, Safety and Health Management System ES&H Compliance Guidelines. See Section 8 ‘External References’ in the guidelines listed below for relevant legislation, standards and guidance material.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 39 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
10
APPENDICES
APPENDIX A – LICENCES TO PERFORM HIGH RISK WORK The following is a list of the licenses for high risk work, as given in the National Standard for Licensing Persons Performing High Risk Work (April 2006), that are relevant to the crane industry in Australia: (DG) (RB) (RI) (RA) (CT) (CS) (CP) (CB) (CV) (CN) (C2) (C6) (C1) (CO) (WP) (HM) (HP) (BP)
Dogging Basic rigging Intermediate rigging Advanced rigging Tower crane operation Self-erecting tower crane operation Portal boom crane operation Bridge and gantry crane operation Vehicle loading crane operation Non-slewing mobile crane operation Slewing mobile crane operation (up to 20 t) Slewing mobile crane operation (up to 60 t) Slewing mobile crane operation (up to 100 t) Slewing mobile crane operation (open/over 100 t) Boom-type elevating work platform operation Materials hoist (cantilever platform) operation Hoist (personnel and materials) operation Concrete placing boom operation
NOTES: 1. The above list was correct at time of publishing. 2. The National (Australian) Standard for Licensing Persons Performing High Risk Work can be downloaded from the Safe Work Australia website at: www.safeworkaustralia.gov.au 3. For crane operations conducted outside of Australia, local regulations should be consulted to determine any specific local requirements.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 40 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
The is no excessive gouging or wear - no more than 8%
✓
Winches
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Clamps
✓
Hoists
Clean before use and inspection
Eye Bolts
Rigging screws and turnbuckles Sockets
Shackles
✓ ✓ ✓ ✓ ✓
Broken wires are no more than one broken at an end connection, two at areas beyond end connection There is no deformation of deformation such as bending twisting, knotting, stretching, kinking, nick and cracking
Sheave blocks
✓
Hooks
Synthetic Slings
SWL or WLL is clearly legible
and Lifting equipment
Chains
Wire Rope
Pre-Use Inspection/Check for rigging
✓ ✓ ✓ ✓ ✓ ✓ ✓
✓
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
✓ ✓
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
No Corrosion or chemical attack
✓
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
End fittings, terminal attachments or links are not deformed/damaged
✓
✓
✓
✓
✓
No wear to external or internal cover No Heat Damage (Discolouration) No holes in cover
✓
No Local Abrasion
✓
No Sunlight degradation
✓
No Deterioration to stitching
✓
Safety catch fully functioning
Increase in throat opening is less than 15% Moving parts have free movement Any threads to be in good working order
✓
✓
✓
✓
✓
✓ ✓ ✓
✓ ✓
✓
✓ ✓ ✓ ✓
✓
All pins and attachments are the correct type and size and free of damage
✓ ✓ ✓
✓ ✓ ✓ ✓ ✓ ✓
There is an end stop fitted
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
✓
✓
PAGE 41 OF 50
✓
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
APPENDIX C – COMMUNICATION SIGNALS AND ALARMS
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 42 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
APPENDIX D – WORKING NEAR OVERHEAD POWER LINES - NO GO ZONE
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 43 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
APPENDIX E – FREE FALL FEATURES ON CRANES
Definition A feature fitted on some mobile cranes that allow the hook and load to fall under gravity in an uncontrolled manner. Background There have been a number of serious accidents caused by loads dropping in a free fall manner. The free fall feature has been traditionally fitted on cranes for activities such as clam shell dredging and dynamic pile compaction. However, the risk associated with an inadvertent activation of the free fall feature can be high and the provision is rarely needed. Most mobile crane manufacturers dot not provide this feature on new cranes. The risk to workers from falling loads and potential damage to the crane and crane operator is considerable. McConnell Dowell Policy McConnell Dowell policy is that no crane is to operate with an active free fall feature. This policy can only be relaxed with written approval of the relevant Executive/General Manager. The policy applies to both McConnell Dowell and hired in cranes. Requirements for McConnell Dowell Cranes The free fall capabilities on McConnell Dowell cranes are to be permanently deactivated. This deactivation of the free fall should include removal of free fall switches on the crane and a certificate from the crane manufacturer or a competent person (preferably a professional engineer) to state that the free fall function has been permanently removed. Requirements for Hired-in Cranes Owners of cranes with free fall features that do not have a physical lockout arrangement to prevent inadvertent activation are to engage a competent person to install a lockout and test the arrangement. Owners are also to engage a competent person to inspect and test to ensure that the lockout has been correctly installed and free fall cannot be inadvertently activated. Guidelines for Relaxation of Policy The use of the free fall function on a mobile crane should be extremely rare and only be permitted where a documented safe work method statement has shown there is no other reasonable alternative. A documented risk assessment is to be prepared for this situation and submitted to the relevant Executive /General Manager with a request for a waiver of the policy.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 44 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
APPENDIX F – TYPICAL ADVERSE WEATHER GUIDELINES
Beaufort Scale
Ave. Wind Speed (knots)
Ave. Wind Speed (km/h)
Ave. Wind Speed (m/s)
Effects of wind speed over land
0
Calm
Less than 1
Less than 1
0 - 0.2
Calm, smoke rises vertically.
Sea like mirror
1
Light Air
1-3
1-5
0.3 – 1.5
Direction of wind shown by smoke drift, but not by wind vanes.
Ripples with the appearance of scales are formed, but without foam crests
2
Light Breeze
4-6
6-11
1.6 – 3.3
Wind felt on face; leaves rustle; ordinary wind vane moved by wind.
Small wavelets, still short, but more pronounced; crests have a glassy appearance and do not break
3
Gentle Breeze
7-10
12-19
3.4 5.4
Leaves and small twigs in constant motion; wind extends light flag.
Large wavelets; crests begin to break; foam of glassy appearance; perhaps scattered white horses
4
Moderate Breeze
11-16
20-28
5.5 – 7.9
Raises dust and loose paper; small branches moved.
Small waves, becoming longer; fairly frequent white horses
5
Fresh Breeze
17-21
29-38
8.0 – 10.7
Small trees in leaf begin to sway; crested wavelets form on inland waters.
Moderate waves, taking a more pronounced long form; many white horses are formed (chance of some spray)
6
Strong Breeze
22-27
39-49
10.8 – 13.8
Large branches in motion; whistling heard in telegraph wires; umbrellas used with difficulty.
Large waves begin to form; the white foam crests are more extensive everywhere (probably some spray)
13.9 – 17.1
Whole trees in motion; inconvenience felt when walking against the wind.
Sea heaps up and white foam from breaking waves begins to be blown in streaks along the direction of the wind
17.2 – 20.7
Breaks twigs off trees; generally impedes progress.
Moderately high waves of greater length; edges of crests begin to break into the spindrift; the foam is blown in well-
7
8
Near Gale
Gale
28-33
34-40
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
50-61
62-74
Effects of wind speed over water
Operating Information
Normal Lifting Zone for most cranes: Confirmation of operating parameters should be sought from the crane operations manual and reviewed by the crane operator.
Review and Assess Zone: Review crane operation limits and effects on loads lifted. Agreement to continue with entire crane crew and person in charge of lifting operations. No Lifting Zone:
PAGE 45 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
Beaufort Scale
Ave. Wind Speed (knots)
Ave. Wind Speed (km/h)
Ave. Wind Speed (m/s)
Effects of wind speed over land
Effects of wind speed over water
Operating Information
marked streaks along the direction of the wind 9
Strong Gale
41-47
75-88
20.8 – 24.4
Slight structural damage occurs (chimney pots and slates removed).
High waves; dense streaks of foam along the direction of the wind; crests of waves begin to topple, tumble and roll over; spray may affect visibility
10
Storm
48-55
89-102
24.5 – 28.4
Seldom experienced inland; trees uprooted; considerable structural damage occurs.
Very high waves with long overhanging crests; the resulting foam, in great patches, is blown in dense white streaks along the direction of the wind; on the whole, the surface of the sea takes a white appearance; the tumbling of the sea becomes heavy and shock-like; visibility affected
11
Violent Storm
56-63
103117
28.5 – 32.6
Very rarely experienced; accompanied by widespread damage.
Exceptionally high waves (small and medium sized ships might be for a time lost to view behind the waves); the sea is completely covered with long white patches of foam lying along the direction of the wind; everywhere the edges of the wave crests are blown into froth; visibility affected
12
Hurricane
64 and over
118 and over
32.7 – 36.9
Severe and extensive damage.
The air is filled with foam and spray; sea completely white with driving spray; visibility very seriously affected
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 46 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
APPENDIX G - COMMONLY USED TERMS AND ALTERNATIVE NAMES Cranes TERM
COMMONLY USED TERMS
Crawler
Crane with tracks.
Spragg / spragging
To turn left or right on tracks
Jib Boom / Mast
The main section of the crane used for lifting. It has 3 or 4 chords and lattice sections.
Headache Ball
Used above the hook to weight down and steady the hoist line. (Auxiliary Hook)
Main Block
A sheave block above the main hook used to take multiple parts of the hoist rope.
Rooster
Usually the part at the top or tip of the boom that holds the auxiliary line or whip hoist rope.
Whip / Auxiliary Line
The secondary line for doing smaller or lighter lifts.
Tip
The working end of the boom holds the rooster and the main hoist rope sheaves.
Bridle
Holds the pendant ropes and is connected to the luffing ropes allowing the boom to move up and down.
Pendant/ Pendant Ropes
The main supports holding the boom or jib in place.
Rams Horn
Usually on the main block. This is a double hook used partly to balance the load but it is made to put multiple slings on it for big or awkward lifts and spread weight out more evenly.
Traming / Tracking / Travelling
The forward or backward motion of a crawler crane.
Butt
The bottom section of the boom. This is the part that is connected to the crane that has pins to pivot up or down the crane.
Carbody
This is the part that holds the engine winches and boom of the crane as well as the cab and counterweights
Base / Chassis
This frame supports the car body through the slew ring and the tracks are also fixed to the base
Counter Weights
These provide the balance that the crane requires to lift objects.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 47 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
TERM
COMMONLY USED TERMS
Belly Weights
This provides extra weight to the crane to perform larger lifting capacity.
Mobile-hydraulic / Oilcan
As the name implies it can be setup quickly to move around a site(s). Not for pick and carry these cares usually have some of the attributes of a crawler crane however the boom is telescopic and retracts; it has outriggers for stability and usually has rubber tyres.
Rough Terrain / Roughie
These usually are similar to mobile cranes however they usually have a pick and carry capability. They are sometimes very quick to set up.
Franna
This is proprietary name however they usually have a pick and carry capability.
Tom Thumb
A small hydraulic crane used to set up in very tight or small areas however they cannot pick up large amounts of weight or sizes.
Tower Cranes
These are fixed on top of a frame or tower and are self climbing using extra pieces on the tower. There are usually two types. Luffing Boom Meaning the luffing boom can either move up or down on a pivot point on the main boom Saddle Jib or Hammer Head Meaning the jib is in a horizontal position and a trolley or saddle moves in and out along the boom carrying the hoisting rope with hook below.
Fibre Rope Slings TERM
COMMONLY USED TERMS
Rope
Polypropylene, polyethylene, hemp, sizal, cotton, dyneema. These are some of the types mentioned above. There are numerous others, too may to mention. They should be used as per specifications, recommendations or regulations. They can be used for all of the below.
Taglines
To tie to a load to control load (16mm minimum)
Shark Hook
A hook sometimes connected to the tagline. They alleviate the need to tie the rope to the item being lifted.
Sheep Shank
A rope hitch used to shorten the rope and can be also used to give you purchase when tying a load down.
Clove Hitch
A rope hitch to secure a load.
Bowline
A rope hitch in conjunction with a tagline.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 48 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
TERM
COMMONLY USED TERMS
Figure of 8
A rope hitch to join two ropes together.
And many more knots and stitches. Wire ropes TERM
COMMONLY USED TERMS
Snotter
Is a sling with an eye either hand or machine spliced at each end.
Sheave
This is a grooved wheel used to run a wire over. Usually used on cranes, however can be used for rigging applications.
Stinger
1. Beam between crane and super lift tray or trailer 2. A sling or oblong ring used on the hook for ease of attaching rigging
Grommet
Is formed into a circle and is either hand spliced or machine spliced. These types of wire rope slings can be used for stingers. However they are generally used to increase capacity without increasing the size of the wire rope.
FSWR
Flexible steel wire rope.
IWRC
Independent wire rope core.
FC
Fibre core.
Bulldog Grip
For temporarily joining two ropes together or making an eye.
Thimble
A piece of formed or cast metal formed into an eye to help support the way rope sits and stops deformation of the rope.
Ferrule
Is a piece of metal to clamp two pieces of rope (called a swage) together to form an eye grommet.
Superflex
Is a woven wire rope generally used where a tight bend cannot be overcome or on painted items reducing paint damage.
Flemish Eye
Is a type of splice to form an eye. It is used when steel ferrules are used in making FSWR slings. These should never be used for lifting without being swaged and tested first.
Swage
Is the term used for a ferrule compressed to form an eye in a wire rope.
Hambone / Wedge Socket
Is a fitting generally used on the hook of a crane by wrapping the rope around a wedge and welding the rope into a socket.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 49 OF 50
CRANE AND LIFTING OPERATIONS MMS # 020-T001-100 REVISION 5 OCTOBER 2015
TERM
COMMONLY USED TERMS
Spelter Socket
Is a socket that a rope terminates in. It is usually used in conjunction with either hot metal or two pack epoxy type compound these have an efficiency rating of 100%, based on the catalogue strength of wire ropes.
Chains TERM
COMMONLY USED TERMS
Latch Lock Hook
Is a hook attached usually to chains. It is a hook with a positive latch closing mechanism.
Sling Hook
Has a spring latch.
Shortening Hook
Small hook to shorten chain assembly.
Grab Hook
Same as above (safer).
Oblong Ring
Usually a fitting incorporated into chain sets.
Hammer Lock / Connecting Link
An important link to make up a chain set or join to equipment.
Multi
Large oblong with two smaller ones permanently fitted to it.
Shackles TERM
COMMONLY USED TERMS
Safety Bow
Bow type, has a pin and nut.
Bow
Same as above however has a screw type pin.
Dee
As the name implies is good for thickened pad eyes.
Other lifting gear TERM
COMMONLY USED TERMS
Cumalong / Lever Hoist
Hoist for short lift jobs.
Chain Block / Chain Hoist
Hoist for short to long lift jobs.
Tirfor / Creeper Winch
Used in communication with wire rope for guy wires or temporary stays.
COMMERCIAL-IN-CONFIDENCE MCCONNELL DOWELL
PAGE 50 OF 50
More Documents from "NURLINURLINDA"
