Document owner and change code Document Owner Aaron Perronne Title HSSE Manager Mark X Change Code Description X N/A First Issue A Typographical/Grammatical correction; formatting change; text clarification-no action required B Change requiring minor adjustment to process and/or records; users to be informed-no retraining required C Major change to the process and/or records; retraining of involved personnel to be conducted Table of Contents Document Owner and Change Code...1 1. Objective..2 2. Definitions..2 3. Responsibilities..... 2 4. Safe Operating Requirements. 2 5. General Safety Rules..4 6. Rigging..6 7. Crane Overloading 7 8. Working at Heights on Cranes or Hoists..7 9. Hand Signals.8 10. Inspection, Maintenance and Testing 8 11. Applying Wire Rope Clips.10 12. General Precautions for Riggers.10 13. Rigging Equipment Inspections 12 Page 1 of 17
1 OBJECTIVE Various types of cranes, hoists, and rigging devices are used at Mechanical Systems, Inc. for lifting and moving materials. Mechanical Systems, Inc. s policy is to maintain a safe workplace for its employees. Therefore, it cannot be overemphasized that only qualified and licensed individuals shall operate these devices. The safety rules and guidance in this program apply to all operations at Mechanical Systems, Inc. that involve the use of cranes and hoists installed in or attached to buildings and to all company employees, supplemental labor, and subcontractor personnel who use such devices. 2 DEFINITIONS Qualified Person - A designated individual who is competent (trained and experienced) in those conditions and applicable standards for the inspection of rigging and hoisting equipment and accessories. This individual should be responsible for, but not limited to, and have the authority to initiate prompt corrective measures to eliminate unsafe conditions and repairs. 3 RESPONSIBILITIES User - Personnel engaged in the use of any type of rigging equipment (slings, hoists, etc.) must conduct a visual inspection of all rigging equipment they may be using prior to the use of that equipment. These individuals must be properly trained and experienced to perform inspection tasks. Qualified Person - Personnel engaged in the monthly inspection of any type of rigging equipment and accessories. 4 SAFE OPERATING REQUIREMENTS All workers who use any Mechanical Systems, Inc. crane or hoist shall have an operator's license. The company issues licenses for authorized employees who have been specifically trained in crane and hoist operations and equipment safety. Crane and Hoist Operators To be qualified as a Crane and Hoist Operator, the candidate shall have received hands-on training from a licensed, qualified crane and hoist operator designated by the candidate's supervisor. Operators must meet the physical qualifications, pass a physical, a written examination, understand and be able to use a load chart as well as calculate loads for the crane type. Upon successful completion of training, the licensed crane and hoist operator and the candidate's supervisor will fill out and sign the Qualification Request Form and Crane Safety Checklist and send them to the Safety Office for approval. The candidate Page 2 of 17
will be issued a license upon approval by the Safety Manager. Crane and Hoist Operators must renew their license every three years by satisfying the requirements described above. Crane and Hoist Safety Design Requirements Following are the design requirements for cranes and hoists and their components: The design of all commercial cranes and hoists shall comply with the requirements of ASME/ANSI B30 standards and Crane Manufacturer's Association of America standards (CMAA- 70 and CMAA-74). Manufacturer's specifications and limitations applicable to the operation of any and all cranes and derricks will be followed. Where manufacturer's specifications are not available, the limitations assigned to the equipment will be based on the determinations of a qualified engineer competent in this field and such determinations will be appropriately documented and recorded. Attachments used with cranes must not exceed the capacity, rating, or scope recommended by the manufacturer. Modifications or additions which affect the safe operation of the equipment may only be made with the manufacturer's written approval. All crane and hoist hooks shall have safety latches. Hooks shall not be painted (or re-painted) if the paint previously applied by the manufacturer is worn. Crane pendants shall have an electrical disconnect switch or button to open the main-line control circuit. Cranes and hoists shall have a main electrical disconnect switch. This switch shall be in a separate box that is labeled with lockout capability. Crane bridges and hoist monorails shall be labeled on both sides with the maximum capacity. Each hoist-hook block shall be labeled with the maximum hook capacity. Directional signs indicating N-W-S-E shall be displayed on the bridge underside, and a corresponding directional label shall be placed on the pendant. A device such as an upper-limit switch or slip clutch shall be installed on all building cranes and hoists. A lower-limit switch may be required when there is insufficient hoist rope on the drum to reach the lowest point. All cab and remotely operated bridge cranes shall have a motion alarm to signal bridge movement. All newly installed cranes and hoists, or those that have been extensively repaired or rebuilt structurally, shall be load tested at 125% capacity prior to being placed into service. Page 3 of 17
If an overload device is installed, a load test to the adjusted setting is required. Personnel baskets and platforms suspended from any crane shall be designed in accordance with the specifications in 29 CFR 1926.550(g). An accessible fire extinguisher of 5BC rating, or higher, shall be available at all operator stations or cabs of equipment. 5 GENERAL SAFETY RULES Operators shall comply with the following rules while operating the cranes and hoists: 1. Do not engage in any practice that will divert your attention while operating the crane. 2. Respond to signals only from the person who is directing the lift, or any appointed signal person. Obey a stop signal at all times, no matter who gives it. 3. Do not move a load over people. People shall not be placed in jeopardy by being under a suspended load. Also, do not work under a suspended load unless the load is supported by blocks, jacks, or a solid footing that will safely support the entire weight. Have a crane or hoist operator remain at the controls or lock open and tag the main electrical disconnect switch. 4. Ensure that the rated load capacity of a crane's bridge, individual hoist, or any sling or fitting is not exceeded. Know the weight of the object being lifted or use a dynamometer or load cell to determine the weight. 5. Rated load capacities, and recommended operating speeds, special hazard warnings, or instruction, will be conspicuously posted on all equipment. Instructions or warnings must be visible to the operator while he/she is at his control station. 6. Check that all controls are in the OFF position before closing the main-line disconnect switch. 7. If spring-loaded reels are provided to lift pendants clear off the work area, ease the pendant up into the stop to prevent damaging the wire. 8. Avoid side pulls. These can cause the hoist rope to slip out of the drum groove, damaging the rope or destabilizing the crane or hoist. 9. To prevent shock loading, avoid sudden stops or starts. Shock loading can occur when a suspended load is accelerated or decelerated, and can overload the crane or hoist. When completing an upward or downward motion, ease the load slowly to a stop. Page 4 of 17
Operation Rules Pre-operational Test At the start of each work shift, operators shall do the following steps before making lifts with any crane or hoist: 1. Test the upper-limit switch. Slowly raise the unloaded hook block until the limit switch trips. 2. Visually inspect the hook, load lines, trolley, and bridge as much as possible from the operator's station; in most instances, this will be the floor of the building. 3. If provided, test the lower-limit switch. 4. Test all direction and speed controls for both bridge and trolley travel. 5. Test all bridge and trolley limit switches, where provided, if operation will bring the equipment in close proximity to the limit switches. 6. Test the pendant emergency stop. 7. Test the hoist brake to verify there is no drift without a load. 8. If provided, test the bridge movement alarm. 9. Lock out and tag for repair any crane or hoist that fails any of the above tests. Moving a Load 1. Center the hook over the load to keep the cables from slipping out of the drum grooves and overlapping, and to prevent the load from swinging when it is lifted. Inspect the drum to verify that the cable is in the grooves. 2. Use a tag line when loads must traverse long distances or must otherwise be controlled. Manila rope may be used for tag lines. 3. Plan and check the travel path to avoid personnel and obstructions. 4. Lift the load only high enough to clear the tallest obstruction in the travel path. 5. Start and stop slowly. 6. Land the load when the move is finished. Choose a safe landing. Page 5 of 17
7. Never leave suspended loads unattended. In an emergency where the crane or hoist has become inoperative, if a load must be left suspended, barricade and post signs in the surrounding area, under the load, and on all four sides. Lock open and tag the crane or hoist's main electrical disconnect switch. Parking a Crane or Hoist 1. Remove all slings and accessories from the hook. Return the rigging device to the designated storage racks. 2. Raise the hook at least 2.1 m (7 ft) above the floor. 3. Store the pendant away from aisles and work areas, or raise it at least 2.1 m (7 ft) above the floor. 4. Place the emergency stop switch (or push button) in the OFF position. 6 RIGGING General Rigging Safety Requirements Only select rigging equipment that is in good condition. All rigging equipment shall be inspected annually; defective equipment is to be removed from service and destroyed to prevent inadvertent reuse. The load capacity limits shall be stamped or affixed to all rigging components. Mechanical Systems, Inc. policy requires a minimum safety factor of 5 to be maintained for wire rope slings. The following types of slings shall be rejected or destroyed: Nylon slings with Abnormal wear. Torn stitching. Broken or cut fibers. Discoloration or deterioration. Wire-rope slings with Kinking, crushing, bird-caging, or other distortions. Evidence of heat damage. Cracks, deformation, or worn end attachments. Six randomly broken wires in a single rope lay. Three broken wires in one strand of rope. Hooks opened more than 15% at the throat. Hooks twisted sideways more than 10deg. from the plane of the unbent hook Page 6 of 17
Rigging a Load Do the following when rigging a load: 1. Determine the weight of the load. Do not guess. 2. Determine the proper size for slings and components. 3. Do not use manila rope for rigging. 4. Make sure that shackle pins and shouldered eye bolts are installed in accordance with the manufacturer's recommendations. 5. Make sure that ordinary (shoulderless) eye bolts are threaded in at least 1.5 times the bolt diameter. 6. Use safety hoist rings (swivel eyes) as a preferred substitute for eye bolts wherever possible. 7. Pad sharp edges to protect slings. Remember that machinery foundations or angle-iron edges may not feel sharp to the touch but could cut into rigging when under several tons of load. Wood, tire rubber, or other pliable materials may be suitable for padding. 8. Do not use slings, eye bolts, shackles, or hooks that have been cut, welded, or brazed. 9. Install wire-rope clips with the base only on the live end and the U-bolt only on the dead end. Follow the manufacturer's recommendations for the spacing for each specific wire size. 10. Determine the center of gravity and balance the load before moving it. 11. Initially lift the load only a few inches to test the rigging and balance. 7 CRANE OVERLOADING Cranes or hoists shall not be loaded beyond their rated capacity for normal operations. Any crane or hoist suspected of having been overloaded shall be removed from service by locking open and tagging the main disconnect switch. Additionally, overloaded cranes shall be inspected, repaired, load tested, and approved for use before being returned to service. Page 7 of 17
8 WORKING AT HEIGHTS ON CRANES OR HOISTS Anyone conducting maintenance or repair on cranes or hoists at heights greater than 1.8 m (6 ft) shall use fall protection. Fall protection should also be considered for heights less than 1.8 m. Fall protection includes safety harnesses that are fitted with a lifeline and securely attached to a structural member of the crane or building or properly secured safety nets. Use of a crane as a work platform should only be considered when conventional means of reaching an elevated worksite are hazardous or not possible. Workers shall not ride a moving bridge crane without an approval from the Safety Manager, which shall specify the following as a minimum: Personnel shall not board any bridge crane unless the main disconnect switch is locked and tagged open. Personnel shall not use bridge cranes without a permanent platform (catwalk) as work platforms. Bridge catwalks shall have a permanent ladder access. Personnel shall ride seated on the floor of a permanent platform with approved safety handrails, wear safety harnesses attached to designated anchors, and be in clear view of the crane operator at all times. Operators shall lock and tag open the main (or power) disconnect switch on the bridge catwalk when the crane is parked. 9 HAND SIGNALS Signals to the operator shall be in accordance with the standard hand signals unless voice communications equipment (telephone, radio, or equivalent) is used. Signals shall be discernible or audible at all times. Some special operations may require addition to or modification of the basic signals. For all such cases, these special signals shall be agreed upon and thoroughly understood by both the person giving the signals and the operator, and shall not be in conflict with the standard signals. 10 INSPECTION, MAINTENANCE AND TESTING A competent person must inspect all machinery and equipment prior to each use, and during use, to make sure it is in safe operating condition. Any deficiencies must be repaired, or defective parts replaced, before continued use. All tests and inspections shall be conducted in accordance with the manufacturer s recommendations. Page 8 of 17
Monthly Tests and Inspections All in-service cranes and hoists shall be inspected monthly and the results documented. Defective cranes and hoists shall be locked and tagged "out of service" until all defects are corrected. The inspector shall initiate corrective action by notifying the facility manager or building coordinator. Annual Inspections The Maintenance Department shall schedule and supervise (or perform) annual preventive maintenance (PM) and annual inspections of all cranes and hoists. The annual PM and inspection must be documented and must cover: Hoisting and lowering mechanisms. Trolley travel or monorail travel. Bridge travel. Limit switches and locking and safety devices. Structural members. Bolts or rivets. Sheaves and drums. Parts such as pins, bearings, shafts, gears, rollers, locking devices, and clamping devices. Brake system parts, linings, pawls, and ratchets. Load, wind, and other indicators over their full range. Gasoline, diesel, electric, or other power plants. Chain-drive sprockets. Crane and hoist hooks. Electrical apparatus such as controller contractors, limit switches, and push button stations. Wire rope. Hoist chains. Load Testing Newly installed cranes and hoists shall be load tested at 125% of the rated capacity by designated personnel. Slings shall have appropriate test data when purchased. It is the responsibility of the purchaser to ensure that the appropriate test data are obtained and maintained. Page 9 of 17
Re-rated cranes and hoists shall be load tested to 125% of the new capacity if the new rating is greater than the previous rated capacity. Fixed cranes or hoists that have had major modifications or repair shall be load tested to 125% of the rated capacity. Cranes and hoists that have been overloaded shall be inspected prior to being returned to service. Personnel platforms, baskets, and rigging suspended from a crane or hoist hook shall be load tested initially, then re-tested annually thereafter or at each new job site. All cranes and hoists with a capacity greater than 2722 kg (3 tons) should be load tested every four years to 125% of the rated capacity. Cranes and hoists with a lesser capacity should be load tested every eight years to 125% of the rated capacity. All mobile hoists shall be load tested at intervals to be determined by the Manager of Safety. Monitoring Whenever internal combustion engine powered equipment exhausts in enclosed spaces, tests shall be made and recorded to see that employees are not exposed to unsafe concentrations of toxic gases or oxygen deficient atmospheres. Records The Safety Manager shall maintain records for all cranes, hoist and rigging equipment. Number and Spacing of U-Bolt Wire Rope Clips Number of Clips Drop Number of Clips Other Forged Material ½ 3 4 3 5/8 3 4 3 ¾ ¾ 4 5 4 ½ 7/8 4 5 5 ¼ 1 1/8 6 6 6 ¾ 1 ¼ 6 7 7 ½ 1 3/8 7 7 8 ¼ 1 ½ 7 8 9 Improved Plow Steel Rope Diameter Inches Minimum Spacing (inches) Page 10 of 17
11 APPLYING WIRE ROPE CLIPS The U-bolts of all clips should always be on the short (dead) end of the rope. Tighten nuts evenly to manufacturer's recommended torque. Before lifting, be sure that all clips have been torqued. After lateral lifts, re-torque all clips. 12 GENERAL PRECAUTIONS FOR RIGGERS Know the safe working capacity of all rigging and equipment. Do not exceed this limit. Know the load weight, this includes the weight of the rigging. Avoid sudden snatching, swinging or stopping of loads. Inspect all rigging before use and remove any defective equipment from service. Rigging equipment that is not in use shall be removed from the work area so as not to present an additional hazard to employees. When the temperature is below freezing, extreme caution must be exercised to prevent shock loading any rigging. Brittle fracture of the steel can occur at these temperatures. The most frequent killer in the rigging operations is electrocution caused by contacting overhead power lines. Always maintain at least a ten (10) foot safe working distance from any power line. Discontinue operations during thunderstorms. Always keep the load line plumb to maintain a stable load. When using slings: Never use kinked or otherwise damaged slings. Each sling should be marked with its rated capacity. Never sharply bend a sling as this will kink and permanently weakening it. Whenever two or more rope eyes are placed over a hook, use a shackle with the shackle pin resting on the load hook. This will prevent the spread of the sling legs from opening the throat of the hook. Loads must be kept under control at all times. Tag lines should be used to stop spinning or guide the load unless their use creates an unsafe condition. Loads must be safely landed and stable before unhooking. Chocks, blocks or other means must be used to prevent movement of materials while hooking or unhooking. Stay clear of slings when they are being pulled out from under a load. The hook may catch and suddenly fly free. Do not give signals to the operator unless it is an emergency stop or you are the designated signal person. Always use a double sling when rigging loads like pipe, rebar or lumber over 12 feet long. Never ride the load or headache ball. Page 11 of 17
Employees are not allowed under suspended loads. Do not swing a load over someone. Keep hands off suspended loads whenever possible. Rigger's Guidelines Safety is a continuing concept, requiring daily attention to every detail. It takes only an instant to become "unsafe" and this very instant may cause an accident or injury. The following rigging guideline establishes the minimum requirements to be followed prior to making a lift. Lifting equipment general condition - Inspect all equipment for proper working condition. Check for damaged cables, safety devices, fluid levels and operator qualifications. Verifying load weight - Know the weight of the load to be lifted. Check vendor drawings or equipment tags for shipping weights. If necessary, estimate weights from material weight charts. Check equipment capacity - Calculate motorized equipment capacity from approved load charts. Check equipment tags for rated capacity. All outriggers down and locked - Be sure all equipment outriggers are down and locked on mobile cranes. Check for proper outrigger matting when required. All safety latches and guards must be in place. Inspect safety latches for proper operation. Latches must be in place on all hooks, eliminating the hook throat opening. Shackle capacity - Verify shackle size, which is imprinted on the side of the shackle. Use your shackle chart to determine adequate safe load capacity. Rig load for proper balance - Calculate load center of gravity. When in doubt, use multiple sling rigging. Crane load line over load center - Load line position should be such that load cannot swing into personnel or equipment. Secure the load from swinging free - When lifting a load free from a previously anchored position, such as cutting out piping that has been in service, removing equipment from foundations or dismantling structural members, attach a security device such as a come-a-long, chainfall or rope. Tag line installed and manned - Have a tag line installed and adequately manned before attempting to swing or transport any load. Plan the sequence of the work - Have your lift planned, including the swing path and laydown area. Review this work sequence with your flagman, operator and tag line personnel. Make sure all concerned fully understand the sequence of events prior to making the lift. Be sure to maintain at least a 15 foot clearance from any electric service lines. Page 12 of 17
13 RIGGING EQUIPMENT INSPECTIONS Wire Rope A. Rigging equipment will be inspected by the user before each use and as necessary during its use to ensure that it is safe. Defective rigging equipment will be removed from service immediately and be repaired or destroyed. B. All rigging equipment including, but not limited to, slings (wire and nylon), chain-falls, come-alongs, spreaders, lifting beams, etc., shall be inspected on a monthly basis by a qualified person. Records should be maintained using the Rigging Equipment Inspection Report. All rigging equipment found to be in good condition when inspected shall be color coded in accordance with the Assured Equipment Grounding Conductor Program, suggested color cycle for each quarter. Defective rigging equipment will be tagged "DO NOT USE" and removed from service immediately and be repaired or destroyed. The inspection will be conducted by the tenth (10th) day of that month. Wire rope (slings or hoist rope) shall be immediately removed from service if any of the following conditions are present: A. Wire rope slings shall not be used if there are ten randomly distributed broken wires in one rope lay; five broken wires in one strand in one rope lay. B. Wire rope used as hoist cable on a mobile crane shall not be used if there are six randomly distributed broken wires in one rope lay; three broken wires in one strand in one rope lay. C. Wire rope that shows signs of damage such as excessive wear - wear or scraping of one-third the original diameter of outside individuals wires. D. Kinking, crushing, birdcaging or any other damage resulting in distortion of the rope structure. E. Evidence of heat damage. F. End attachments that are cracked, deformed or worn. G. Corrosion of the rope or end attachments. Synthetic - Web Slings All slings shall be removed from service if any defects, such as the following, are visible: Page 13 of 17
A. Acid or caustic burns. B. Melting or charring of any part of the surface. C. Snags, punctures, tears or cuts deep or severe to result in red threads being observed. D. Broken or worn stitches. E. Wear or elongation exceeding the amount recommended by the manufacturer. F. Distortion of fittings. G. Other apparent defects which cause doubt as to the strength of the sling should be referred to the manufacturer for determination. Hooks A. Daily Inspection 1. Items such as the following shall be visually inspected by the user daily or prior to use: a. Crack(s), nick(s), gouge(s). b. Deformation. c. Damage from chemicals. d. Damage, engagement or malfunction of latch (if provided). e. Evidence of heat damage. 2. Deficiencies shall be examined by a qualified person and a determination made as to whether they constitute a safety hazard and whether a more detailed inspection is required. B. Monthly Inspection 1. Hooks having any of the following conditions shall be removed from service until repaired or replaced: a. Deformation - Any bending or twisting exceeding 10 degrees from the plane of the unbent hook. Page 14 of 17
b. Throat Opening - Any distortion causing an increase in throat opening exceeding 15%. c. Wear - Any wear exceeding 10% of the original section dimension of the hook or its load pin. d. Crack(s). e. If a latch is provided, and it becomes inoperative because of wear or deformation, or fails to fully bridge the throat opening, the hook shall be removed from service until the device has been repaired or replaced; and the throat opening has been assessed per above. 2. Dated and signed inspection records shall be kept on file and available. C. Hooks shall receive an NDE in accordance with applicable ASTM standards annually. Rigging Accessories A. A visual inspection shall be conducted at the beginning of each work shift or prior to use by the user for the following: 1. Wear 2. Corrosion 3. Crack(s) 4. Nicks and gouges 5. Distortion such as bending or twisting 6. Evidence of heat damage B. Documented monthly inspections shall be conducted for the following: 1. Crack(s) 2. Distortion or deformation exceeding 15% of new conditions 3. Any sign of incipient failure in shear for shackle pins 4. Wear exceeding 10% of original dimensions Page 15 of 17
5. Excessive corrosion 6. Excessive heat damage 7. Shackles not marked with the manufacturer's name or trademark, size, and rated capacity. Chain Falls Lifting chain falls are low-speed, geared for precision lifting and have built-in, no-slip brakes. There are two lifting hooks; one swivel hook mounted on the housing and the other located at the end of the lifting chain. Chain falls are available in a variety of weight capacities ranging from 1/4 ton to 10 tons with assorted pulling chain lengths for longer reaches to the work area. Chain falls are designed primarily for vertical lifting. The lifting hooks on the housing and chain are tempered but can be bent or partially straightened and must therefore be provided with a safety clip latch to prevent hooks from being dislodged. Before making a lift with the chain fall, be sure the load is rigged properly and the lift area is barricaded and free of personnel. Make all lifts true vertically to prevent shifting, swaying load and undue wear on the hoist. Never use a chain fall for a horizontal pull. The designated chain sprocket engagement will not be obtained. Come-A-Longs This compact hoist offers efficient use in close quarters, tool box size storage and versatility in almost any lifting and pulling situation. The come-a-long is more popular because of its heavy duty construction and greater lifting ability. The lifting chain or cable is moved by a ratchet lever. The lever has three positions: Forward for lifting or pulling, neutral for free gear travel and reverse for lowering or releasing tension. Come-a-longs have one hook attached to the gear housing and one at the end of the lifting chain or cable. They are available in various lifting chain and cable lengths for longer reaching pulls and lifts. They range in capacity from 1/4 tons to 6 tons. Considered the most versatile of the hand-operated hoists, the come-a-long can be used in vertical lifting, pulling and binding on any plane and in tugging heavy objects. Pulling or releasing is accomplished by a ratchet movement of the hand lever, even under tension. Therefore, if it takes two men to crank the hand lever, the hoist is overloaded for the job. Avoid using cable-type lever hoists if the cable is frayed or damaged. Never use a cheater bar on the handle of the come-a-long. Page 16 of 17
Drums and Sheaves Check the groove diameter of all sheaves with a "groove gauge" only. Using wire rope in an oversized sheave causes the rope to become flattened or distorted; using undersized sheave causes the rope to become flattened or distorted; using undersized grooves will pinch and tear the rope. Check the sheaves and blocks for worn bearings; allowing the sheaves to wobble on the pins will cause the rope to rub and wear the sides of the sheaves throat. Page 17 of 17