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PROCEDURE:
Lifting Operations

Issu Date Description Prepared By Checked By Approved By

Issue for Review &

00 Jan. 2023 POSHM HSEM PD
Approved
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Table of Contents
1- Purpose ............................................................................................................................................................ 3
2- Scope ................................................................................................................................................................ 3
3- Responsibilities ................................................................................................................................................ 3
4- Definitions ........................................................................................................................................................ 4
5- References ....................................................................................................................................................... 4
6- Forms ............................................................................................................................................................... 4
7- Procedure ......................................................................................................................................................... 5
7.1. General ......................................................................................................................................................... 5
7.2. Critical lifts .................................................................................................................................................... 5
7.3. Crane and Rigging Safety .............................................................................................................................. 6
7.4. Operator Qualifications ................................................................................................................................ 6
7.5. Operating procedures .................................................................................................................................. 7
7.6. Mobile Cranes .............................................................................................................................................. 9
7.7. Documented Information ........................................................................................................................... 10
7.8. Rigging Requirements ................................................................................................................................ 10
Rigging Examination .............................................................................................................................................. 13
Hooks ..................................................................................................................................................................... 14
Shackles ................................................................................................................................................................. 14
Eyebolts ................................................................................................................................................................. 14
Blocks..................................................................................................................................................................... 15
Plate Clamps .......................................................................................................................................................... 15
Wire Ropes ............................................................................................................................................................ 16
Temperature ......................................................................................................................................................... 16
Chemical resistance............................................................................................................................................... 16
Wetting .................................................................................................................................................................. 17
7.9. Tower Crane Safety .................................................................................................................................... 18
7.10 Third Part Inspection Criteria ..................................................................................................................... 21
7.11 Personnel Hoist/ Elevators: ........................................................................................................................ 21
7.12 Crane Man baskets ..................................................................................................................................... 23
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1- Purpose

The purpose of this procedure is to provide information, instruction and guidance on the standards
to be applied for all TCC lifting operations to be carried out during construction.

2- Scope

The contents of this procedure will apply to all TCC lifting operations during the construction phase
of the project irrespective of whether they are carried out by Contractor, Subcontractor, Owner or
Vendor personnel.

3- Responsibilities

The Project Manager:

Shall be responsible for providing the necessary resources to implement this procedure, to ensure all
lifting operations are carried out in a safe manner on the site.
Will provide specific training for each employee which has the potential to be exposed to a fall hazard.
All training must be conducted by a competent person designated by senior management. All training
must be documented.
Project Manager and Front Line Supervision are to support and enforce this program to ensure 100%
compliance by all personnel.

Supervisors:
Will actively question their employees’ knowledge of the systems being utilized, its proper methods
of use and emergency procedures associated with the task. Supervisors will conduct “10 minutes
training” prior to all work at height.
The "competent person"
Is responsible for regular inspections of lifting appliances or Lifting gears. He shall be appointed by
the site and properly trained with relevant practical experience.

Crane operator:
Is responsible for operating the crane correctly and safely and have final responsibility and control
over the crane operations. Whenever there is any doubt as to safety, the operator shall have the
authority to stop and refuse to handle loads until safety has been assured. Be familiar with the crane
and its care, the operator’s manual, and load charts. The operator shall be responsible for notifying
his supervisor of any needed adjustments or repairs, and for logging his findings in the crane log;

Slinger:
Is responsible for attaching and detaching the load to and from the crane
Inspecting the lifting gear to ensure that no damage has come to the gear during the days operations
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TCC HSE Department:

Supports the craft ownership of the program and will assist in any training deemed necessary to
ensure that personnel have sufficient understanding of the program for successful compliance.
Will ensure that a log of all lifting gear is kept on site and is up to
date Will during periodic inspections check the following:
 Lifting plans are used when required
 Lifting gear is certified by a reputable 3rd party organization
 Crane is certified
 Operatives involved in lifting operations have been trained and are competent
 Risk assessment and JSA have been implemented
 STARRT cards have been initiated and are sufficient to the task

4- Definitions

The Safe Working Load (SWL) for operating the crane shall be specified according to the results of
test and examination certificates, and such loads must not be exceeded during the lifting
operation.
The lifting gears include a chain sling, rope sling, ring or similar gear, link, hook, plate clamp, shackle,
swivel or eyebolt.

5- References

Occupational Health and Safety Administration 1926-

Subpart N LEEA (Lifting Equipment Engineers Association)

6- Forms

Critical Lift Checklist F/HSE /013

Daily (Frequent) Sling Inspection Checklist F/HSE /014
Lifting Plan Method & Risk Assessment F/HSE /015
Tower crane thorough examination checklist F/HSE/087
Daily inspections of tower cranes F/HSE/088
Man Basket Inspection Checklist F/HSE/126
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7- Procedure

7.1. General
The following requirements are minimum standards and are not to be seen as replacing any
legal requirements, or the following of any locally or internationally recognized codes of
practice.
In all cases, no lifting operations shall be permitted over any areas where personnel are
working. Clearly designated exclusion zones shall be established for all lifting operations. This
zone should include the crane and with due consideration to other activities in the
surrounding areas. The only persons allowed inside this zone will be the person performing
the works and designated banks man who shall at all times wear a high visibility top and be in
constant communication with the crane operator. In situations where lifting over personnel is
impossible to avoid, suitable and sufficient controls shall be established to minimize the risks
to personnel from the lifting operation.
7.2. Critical lifts
Critical lifts requiring lifting plan include:
 Lifts requiring two or more cranes to be
used for a single lift.
 Lifts carried out over operating facilities
where personnel may be endangered and
within 5.5 m of power lines
 Lifts requiring personnel in cages/man-
baskets attached to equipment not
designed for the explicit purpose of lifting
people.
 Lifts between 90 % and max, rated capacity described in the load chart.
 Loads greater than 10 tons (30,000 lbs).
 Lifts while the operator does not see the load at all times during the lift.
 Lifts requiring special material handling (e.g. dangerous goods, size/shape, requires non-
standard rigging, or is of high monetary value).
 Lifts operating in wind velocity (including gusts) greater than 30 Km/h.
 Lifts requiring crane set-up closer to an excavation/water body than the
excavation/water body in deep.
 Lifts requiring traveling with a load greater than 50% of capacity in a given set-up – or as
recommended by the manufacturer (for crawler cranes)
 Lifts requiring two or more cranes in proximity where the booms or loads could make
contact.
 Offshore lifting operations and lifting of loads from/ into water (submerged).
All critical lifts will be subjected to a computerized rigging study, lifting plan and a
comprehensive Job Safety Analysis before work commences. All operations will be
required to have a valid permit detailing the requirements and limitations of the lift. A
copy of the permit must be in the crane operator’s possession at all times. The timing of
the lifts will be coordinated with the operations and logistics groups in order to minimise
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disruption to normal plant operations.

Equipment involved in lifting operations shall, as a minimum, comply with the following conditions
prior to use:
- Valid test certificates for all equipment used, issued by the competent authorities, and
approved third part must be carried in the cab of the vehicle at all times. All such
documentation must be clearly traceable to the machine/equipment in question by, for
example, a coding number in a register maintained by the subcontractor.
Note: Any crane attempting to enter the site without a valid certificate shall be refused.
- Manufacturers operating manual and load charts are to be carried in the cab in a
language understood by the operator.
- All safety and override devices are to be operational.
- Operator is to be certified for the particular type of machine.
- Equipment is to be inspected by a competent person prior to use.

7.3. Crane and Rigging Safety

7.3.1. Crane Set-Up / Ground Stability
One of the critical factors of proper crane set-up is a “firm supporting surface”. For maximum
capacity, the crane shall be level. However, to maintain a level condition, the ground surface
shall be adequate to support the dynamic load of a “working crane”.
Four basic elements that are to be considered and checked prior to the lifting operation:
(i) Total imposed load;
(ii) Supporting surface area;
(iii) Cribbing to be used;
(iv) Ground stability

7.4. Operator Qualifications

Only the following personnel shall operate Cranes:
- Designated operators who have been licensed and qualified by an approved agency;
- Inspectors certified for crane inspection;
- Test and maintenance personnel, when necessary;
- No one other than the above mentioned personnel shall be inside or on the crane during
operations.
- Assignment as the operator shall pass in theoretical examination and practical
assessments.
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7.5. Operating procedures

The operator shall:
- Not engage in any practice that
may divert his attention while
engaged in crane operations.
- Not operate his crane if physically
or mentally unfit, or if taking
prescription drugs that may impair
judgment.
- Not respond to any signal that is
unclear or is given by anyone other
than an appointed signalman;
Exception: The operator shall respond to any emergency stop signal given by anyone.
- Perform the first lift to determine lift stability, crane function, and safety in general;
- Have final responsibility and control over the crane operations. Whenever there is any
doubt as to safety, the operator shall have the authority to stop and refuse to handle
loads until safety has been assured.
-Be familiar with the crane and its care, the operator’s manual, and load charts. The
operator shall be responsible for notifying his supervisor of any needed adjustments or
repairs, and for logging his findings in the crane log.
- Upon request, demonstrate his ability to determine total load weight and its relationship
to the crane load charts.
- Conduct and document pre-work daily equipment checks as required.
- Handle the Load.

7.5.1. Load Weight

No crane shall be loaded beyond its
rated capacity

7.5.2. Attaching the Load

The load shall be attached to the hook by means of slings or other approved devices. No
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open hooks shall be used for lifts higher than one (1) meter. Hooks used for lifts in excess of
one (1) meter shall have hook safety latches or be safety wired.
7.5.3. Moving the load
The operator shall determine that the crane is level to within one (1) degree and, where
necessary, is properly cribbed and blocked.
The operator is responsible for determining that the load is properly secured and balanced
before making the hoist.
The operator shall position the hook over
the load in such a manner as to prevent load
swing.
The operator shall make sure that the rope is
properly seated on the drum and in the
sheaves, the load line is not kinked, and
multiple part lines are not twisted around
each other.

7.5.4. Hand Signals

Signals to the operator shall be in accordance with standard hand signals unless voice
communication 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
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and thoroughly understood by both the person giving the signals and the operator, and shall
not be in conflict with the standard signals.
7.6. Mobile Cranes
7.6.1. Crane Set-up

The operator shall be responsible for:

- The proper placement of the crane in relationship to the load to be handled and the
landing area so as to obtain the best rated lift capacity;
- Levelling the crane to within 1 degree of level and rechecking the level a minimum of
three times during the 8-hour work shift;
- The proper placement and use of outriggers, where provided, for all lifts except where
the manufacturer permits otherwise for assembly of boom only;
- The determination of stable or unstable ground or footing. Should additional floats,
cribbing, timbers, or other structural members be needed, they shall be of proper design
and sufficient to uniformly distribute the load;
- The installation and maintenance of crane swing radius protection.
7.6.2. Load Ratings
The weight of all auxiliary handling devices such as hoist
blocks, headache balls, hoods and rigging shall be
considered as part of the total load.
Additionally, the weight of all items added to the load at
the site shall be determined and added to the total load
weight.
Some manufactures require the load cable also to be
considered as part of the total weight.
Whenever possible, the operator shall be provided
with a copy of the Bill of Loading with the item weight clearly legible. This shall be used to
determine total load weight.
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7.6.3. Crane Inspection

Cranes shall be inspected;
 After set-up and prior to initial lift
 Before each shift
 After any malfunction
 During and after extreme weather conditions
7.6.4. Daily Inspections to check
 All control mechanisms for maladjustment interfering with proper operation;
 All control mechanisms for excessive wear of components and contamination by
lubricants or other foreign matter;
 Fluid levels;
 All safety devices for malfunction;
 Deterioration or leakage in air or hydraulic system;
 Crane hooks with deformation or cracks, slings and chokers for broke strands,
fraying or linking;
 Electrical apparatus for malfunctioning, signs of excessive wear, dirt and
moisture accumulation;
 Other items as required under manufacture guidance/instructions.
 Periodic and annual inspections shall be performed in accordance with the manufacture’s
recommendations.
7.7. Documented Information
All records pertaining to the crane inspections shall be kept on-site at all times whilst the
crane is present. In addition, each Subcontractor should keep copies of all such records in his
site office.
If during any safety inspection or at any other reasonable time, the operator or supervisor
cannot produce the required crane inspection sheets, the crane shall, as soon as possible, be
shut down and inspected.
All crane operators shall at all-time carry documentary evidence that they are competent to
operate the crane that they are using.

7.8. Rigging Requirements

7.8.1 Riggers qualifications

A qualified rigger is a rigger who meets the criteria of a qualified person. Each qualified rigger may
have different credentials or experience.
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A qualified rigger is a person that:

 Possesses a recognized degree, certificate, or professional standing.
 Has extensive knowledge, training, and experience.
 Can successfully demonstrate the ability to solve problems related to rigging loads.
 The person designated as the qualified rigger must have the ability to properly rig the load for
a particular job.

7.8.2 General

 All rigging equipment shall be inspected prior to each shift and as necessary during the
shift to ensure safety. Damaged or defective slings (as identified above or otherwise
judged by a competent person) shall be immediately removed from service. Personnel
must not pass under suspended loads. Contractor reserves the right to remove from
service and/or destroy any damaged or defective rigging equipment;
 All rigging devices including slings shall have permanently marked identification stating
size, grade, rated capacity, and manufacturer;

 Rigging equipment not in use shall be removed from the immediate work area when
not in use and correctly stored.
 Wire rope slings shall be lubricated as necessary during use. Slings shall be lubricated no
less than every four (4) months when in storage;
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 “Shop-made” grab hooks, clamps, or other lifting devices shall not be used unless
proof- tested to 125 percent of their rated load by an approved testing agency.
Approved devices shall have the capacity permanently affixed;
 Slings shall not be left lying on the ground or otherwise exposed to dirt;
 Eyes in wire rope bridles, slings, or bull wires shall not be formed by wire clips or knots;
 Protruding ends of stands in splices on slings or bridles shall be covered or blunted.

7.8.3 Safe Operating Practice

 Slings in use shall not be shortened by knots, bolts, or other makeshift devices;
 Wire rope slings shall be padded or softeners shall be used to protect from damage
due to sharp corners;
 Slings used in a basket hitch shall have the loads balanced to prevent slippage;
 Loads handled by slings shall be landed on cribbing or dunnage under the load to avoid
slings crushing;
 Slings subjected to shock loading shall be immediately removed from use and destroyed.
When U-bolt wire rope clips are used, manufacturer instructions shall be used to determine
number and spacing of clips.
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7.8.4 Inspection and Record Keeping

Thorough inspection of slings in use shall be made on regular basis (6 months) as determined by:
- Severity of service conditions;
- Frequency of sling use;
- Nature of lifts being made;
- Experience gained on the service life of slings used in similar use;
- Inspection shall be carried out at least once every six months;
- A record of all inspections shall be kept at HSE site office and be available for inspection
at all times;
- Periodic inspection of cranes hoists and lifting accessories shall be performed by third party.
All inspection certificates shall be kept at site HSE and Mechanical departments.

Rigging Examination Sample

Chain slings:
- During the examination of chain slings the following should be checked:

1. The chain should articulate freely.

2. The maximum permissible wear is 8% reduction in material diameter for the
chain, components and fittings.
3. The maximum elongation, mainly due to seating and interlink wear, is 5%.
4. Unless the sling is specifically designed otherwise, the legs of multi-leg slings should
be of equal length so that the seat of hooks, or bearing point of other fittings, is equal.
This is an important matter to check, particularly if a leg of chain has been replaced, as
the pitch may vary from the original.
5. There should be no signs of bending, twisting or other distortion to the chain,
master link or other fittings. Particular attention is necessary at the point of choke.
6. There should be no signs of bending, twisting or other distortion to the chain,
master link or other fittings. Particular attention is necessary at the point of choke.
7. There should be no signs of bending, twisting or other distortion to the chain,
master link or other fittings. Particular attention is necessary at the point of choke.
8. There should be no signs of nicks, cracks, corrosion or chemical attack.
9. Hooks should show no signs of opening or of distortion and, where fitted, safety
catches should be undamaged and operate freely.
Hooks should show no signs of opening or of distortion and, where fitted, safety catches
should be undamaged and operate freely.
10. Marking should be clear and legible; it must give all of the necessary information
for the particular grade and type of sling.
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Hooks
Examine and check for:
1. Opening of hook against manufacturer's catalogue, 1/10th maximum (if it exceeds
this, scrap hook). Other distortion.
2. Wear in eye, saddle etc, ie 8% reduction in thickness.
3. Cracks, nicks, scores and gall marks in the body of the hook.
4. Shank for alignment, swivel for free running, soundness and completeness of thread etc.
5. Corrosion and chemical attack.

Shackles
Examine and check for:
1. Sizes for loads to be lifted.
2. Correct pin fitted, free working of pin.
3. Wear of the pin thread.
4. Alignment of holes in shackle.
5. Wear in pin and bow (as per steel chain, ie 8% reduction in diameter).
6. All parts for nicks, cracks, corrosion and chemical attack.

Eyebolts
Types of eye bolts

1. Shouldered Eye Bolt

2. Non-Shouldered Eye Bolt

3. Swivel Hoist Ring

4. Machinery Eye Bolt

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Examine and check for:

1. Size for loads to be carried.
2. Thread for completeness, wear and alignment. Correct undercut or relieving at the
base of the shank.
3. Alignment of shank and eye.
4. Cracks in shank and eye.
5. Wear in eye and link etc., i.e. 8% reduction in diameter.
6. Corrosion and chemical attack.

Blocks

Block inspection points:

- Wear and deformation of side plates
- Misalignment or wobble in sheaves
- Security of all nuts, bolts and all retaining pins
- Clearance between hocks and swivel case.
- Ensure the block is designed for lifting, i.e.
some tools are designed for pulling activities only such as some types of “Tirfors”.
Remove from service criteria includes:
- Loose pins and axles
- Daylight between gage and base or sheave groove
- Rope print in sheave groove
- Wobble of sheave bearings or bushing
- Misalignment of sheaves
- Any weld or cracking or corrosion, of welded side plates or sheaves
- Missing or modified SNAP rings on locking devices
- Sheave pin nuts should be checked for proper positioning. Pins for tapered
rollers bearing should be tightened to remove all end play during sheave
rotation.
- Pins for bronze bushing and straight roller bearing should have a running
clearance of 0.031 per sheave of end play and should be adjusted accordingly,
remove from service if cannot be adjusted.
- Deformation or corrosion of hook and nut threads
- Deformation of hook
- Missing or defective latch.

Plate Clamps
- The operator shall inspect clamp before and
during every lift for any indication of damage.
- Ensure the plate surface if free of scale,
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grease, oil, paint, ice, dirt and coating that

might impede the contact of the teeth with
plate
- Ensure the pivots and casement are free of dirt, clean if necessary
- Press locking latch and verify adequate spring tension
- When hoisting eye is released the clamp should freely return to closed position
- For all lifters inspect: (if any of these conditions are apparent, the clamp
should be removed from service)
- Deformation, cracks or excessive wear on any part of the lifter
- Loose or missing fasteners, covers, stops, or nameplates
- All functional operating mechanism.

Wire Ropes
Examine and check for:
1. Size of loads to be lifted.
2. Kinks in the rope.
3. Wear in rope.
4. Change in diameter (increase or decrease) and increase in length.
5. Lubrication and internal condition.
6. Broken wire (maximum 5% in any length equal to 10 times the diameter). Remember
that, in certain applications, even one broken wire presents a hazard to the user or
equipment.
7. Condition of splices, ferrule secured eyes etc.
8. Corrosion and chemical attack. NB: With some constructions of wire rope,
internal corrosion can cause an increase in diameter.
Fibres used for textile slings: (textile slings are three type’s polyamide, polyester and
polypropylene).

Temperature
1. Polypropylene, manila, sisal and hemp fibres are suitable for use in temperature
range- 40C to 80C.
2. Polyester and polyamide are suitable for use in temperature range -40C to 100C.

Chemical resistance
1. Polyimide is immune to the effect of alkalis but is attacked by acids
2. Polyester is resistant to acids but damaged by alkalis.
3. Polypropylene is little affected by acids or alkalis but is damaged by solvent, tars,
paints, etc.
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Wetting
1. Polyimide loses about 10% of its strength when wet
2. Polyester is unaffected when wetted.
3. Polypropylene shows in increase in strength when wet and it will float.

7.8.5 Inspection Criteria (For Rejection)

- Sling hooks that have opened more that 15% of the normal throat opening or twisted
more than 1 degree off centre;
- Stretch that exceeds 5% of the original reach;
- Slings that have been exposed to temperatures in excess of 315-degree C (600 degrees F);
- Only the manufacturer or an equivalent shall repair or condition slings covered in this section;
- Mechanical coupling links of ‘cold sheets’ bolts or clevis pins shall not be used for chain repairs.
- Wire rope slings shall be removed from service when:

- Wear or scraping is found on one-third of the original diameter of outside individual wires.
- Kinked, crushed, bird caged.
- End attachments are cracked, deformed, or worn.
- Rope or end attachments are significantly corded.
- Natural and synthetic fibber rope slings shall be removed from service when:
- Abnormal wear is observed;
- Powered fibbers are found between strands;
- Fibbers are cut or broken.
- There are variations in the size or roundness of strands.
- There is discoloration or rotting.
- There is distortion of sling hardware.
- Exposed to temperatures in excess of 82 degrees C (180 degrees F).
- Wear or scraping on one-third of the original diameter of outside individual wires is present.
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- Synthetic web slings shall be removed from service when:

- Subjected to acid or caustic burns.
- Subjected to melting or charring of any part of the sling surface occurs.
- Subjected to snags, punctures, tears, or cuts are observed.
- Stitches are worn or broken.
- Fittings are distorted.
- Exposed to temperatures in excess of 82 degrees C 180 degrees F) (synthetic web) or 93
degrees C (200 degrees F) (polypropylene web)
- The following is a brief selection of safety considerations, more information on this
subject can be found in the relevant BS Codes of Practice.
7.8.6 Safety Factors of slings and fittings:
- Chain and fittings: 04
- Wire rope : 05
- Webbing& round slings: 07

7.8.7 Termination efficiency:

- 100% is achieved by swage and spelter sockets
- 90% or better is achieved by Flemish eye and turn back eye.
- 80% is achieved by wedge sockets and wire rope clips.

7.8.8 marking master links and shackles:

- use low stress or DOT faced stamps of appropriate size on
indicated area
- indications no deeper than 0.5mm
- don’t stamp fitting less than 13mm nominal size
- VIBRA- each tool may be used on all surfaces.
- Specify stamps as (round face- full character or round
face, DOT design)

7.9. Tower Crane Safety

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- A tower crane should only be erected or dismantled and tested by competent persons,
i.e. an engineer and erection crew trained in the erection and dismantling of that type of
tower crane.
- A tower crane should only be operated by a trained and competent operator who is
physically fit, including eyesight and hearing, conversant with the type of crane, and
able to cope with the conditions existing on site.
- Where the operator is required to move loads under the control of another person, a
suitable slinger/signaller should be provided who is conversant with the lifting capabilities
of the tower crane and able to communicate clearly with the driver via hand or radio
signals.
- Any method of lifting other than the recommended vertical lifting of loads should be
actively discouraged, as damage may be caused to the crane.
- The crane operator should carry out a daily visual inspection through the form F-HSE-088.
- The tower crane must always be in a position to rotate (slew freely) when it is placed into
the out of service condition. The slew brake should not be left on under normal
conditions.
- When the selection of a tower crane is being made against particular environmental
considerations, the following are an example of what might have to be taken into account.
1. Overall area to be covered.
2. The height of the building.
3. The required speed of the lift.
4. Weight of critical loads.
5. The type of base or mounting.
6. Existing ground conditions.
7. All proximity hazards.
8. Types of jib.
9. Erection.
10. Dismantling.

The working height of a free-travelling crane is limited (see the manufacturer specifications).
- A free travelling crane can move along its track only at a low speed, and careful planning
of the daily work program may be necessary for obtaining the maximum production.
- When two or more tower cranes are employed on a site, each should be erected to a
different working height to prevent the possibility of collision between the jibs.
- Smaller tower cranes with lighter lifting capacity are usually more suitable on projects
where traditional methods of building in brick, concrete etc. are employed. In these
situations, the lorry or crawler mounted tower crane may be the right one for the job.
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- The bigger cranes, with their greater lifting capacities, are more suitable for projects
where constant off-loading and placing of heavy prefabricated units occur. Here, speed
may have to be sacrificed in the interests of precision lowering and placing.
- The tower crane should be periodically inspected (not more than one year) by approved
third party, the thorough examination criteria should be followed, see the guideline
inspection form F-HSE-087, the thorough examinations should be monitored by the
equipment workshop and HSE team.

Limit switches and Safety devices of Tower cranes

- All tower cranes of every configuration should be equipped with built-in safety devices
which operate automatically to prevent damage to the machine should the operator
make an error. The following limit switches should be installed and assure that properly
functioning:
- A hook height limit switch that causes the hoist drum to stop whenever the load hook
reaches a predetermined maximum height position.
- Luffing jib limit switches that cause the derricking drum to stop whenever the jib is raised
to an angle too high or lowered to an angle too low.
- Trolley limit switches that cause trolley motion to stop whenever the trolley reaches a
predetermined maximum out or maximum in position.
- Overload limit switches that cause the hoist drum to stop whenever the load being lifted
exceeded the maximum rated load for any radius or jib angle.
- Travel limit switches for rail-mounted cranes that apply the carriage brakes whenever the
crane is near the end of the track.

Other Safety Devices:-

- Effective braking system(s) that is fail-safe with the brake automatically applied whenever
there is power failure, or when there is free falling of the luffing jib or the hoisted load;
- An efficient or locking mechanism installed directly onto the luffing drum to prevent the
free-falling of the luffing jib (for luffing crane);
- A radius and safe working load indicator that shows at all times the working radius and
the corresponding safe working load and gives an audible alarm and visual warning signal
when the radius or the working load is unsafe;
- Safe access (ladder with hoop guards or equivalent) to the operator’s cabin with rest
platforms at every interval not exceeding 9 meters of the climbing mast. For vertical
climbing masts without rest platforms, adequate safety line(s) with fall-arresting device(s)
for the attachment of the safety lanyards shall be provided and maintained;
- A basket fixed to the trolley or walkway fitted along the jib. A handrail or guard/safety
line, to which a worker’s safety harness can be attached, shall be fitted all along the
length of the walkway.
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- A device that will prevent automatic restarting of motors at the resumption of power
during power interruption;
- Adequate aircraft warning lights;
- Anemometer
- Lighting arrestor

7.10 Third Part Inspection Criteria

Third-party Inspection should be carried out on lifting equipment in the following cases:
- After installation and before being put into service for the first time; or
- After assembly at a new site or in a new location.
- After any modifications or heavy maintenance including replacing of critical parts.
- After any incident requiring maintenance.
- Periodically every 6 months.

7.11 Personnel Hoist/ Elevators:

General safety requirement:
- User manual should be provided and safety requirements as per the manufacturer
recommendation should be followed.
- The Personnel hoist should be operated by a qualified operator.
- Daily inspections should be carried out by the operators and periodic inspections should
be carried
- Maintain a regular maintenance program as per the manufacturer’s recommendation.
- No changes or modifications shall be made to the hoist, without prior consulting the
manufacturer.
- The surface on which the machine stands shall be stable enough to support the weight of
the machine, the mast, and the lifting capacity.
- The hoist should be assembled and disassembled in accordance with the manufacturer’s
manual.
- Use a suitable fall protection program during the assembly and disassembly of the
personnel hoist as per the risk assessment.
- Install the ground cage around the machine, to prevent persons from unintentionally
walking under the machine and protect them against falling objects.
- Material and/ or tools shall never extend beyond the outer limits of the cabin. Material
that can roll shall be properly secured. Never stack material against the fencing.
- Use the hoist for the purpose it is designed for: The vertical transportation of personnel
and material not exceeding the maximum permitted weight.
- Illuminate the appropriate area (machine and landings) adequately, if the hoist is used
during darkness. This is to provide the operator a good view under all conditions.
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The hoist should be fitted with all the required safety devices and limit switches as the following:
- Phase sequence relay in the cabin roof switch box which checks the phase sequence of
the power supply.
- In the event of a power failure, the motor brakes will be automatically activated to
prevent the hoist from descending by itself.
- In case of a power failure, it is possible to lower the cabin by releasing the motor brakes
manually.
- If the limit switch 'UP' does not function and the hoist keeps on ascending, the emergency
limit switch 'UP' will stop the hoist.
- If the limit switch 'DOWN' does not function and the hoist keeps on descending, the
emergency limit switch 'DOWN' will stop the hoist.
- The motor carrier should be equipped with a mast detector, to provide a higher level of
safety.
- Failsafe brake: if the determined speed of descent is exceeded, the failsafe brake will
interfere and stop the cabin. The failsafe brake also cuts the power to the drive system.
- Overload protection: if the hoist is overloaded, further operation is impossible until the
overloading is removed.
- Motor protection: if the motor temperature exceeds a determined value, the motors will
be switched off.
- Roof hatch: the roof hatch is checked by a limit switch. If the hatch is not closed the hoist
cannot be operated.
- Cabin door protection: the cabin doors should have both electrical and mechanical
protective devices. The cabin doors can only be opened when the hoist is stationary at
the ground station or at one of the landings.
- Ground cage door protection: the ground cage door(s) are fitted with electromechanical
protection device(s). They can only be opened when the hoist is present at ground level.
If the doors are not closed, the hoist cannot be operated.
All limit switches and safety devices should be operative and any defects or signs of damage
will cause the equipment to be rejected until getting repaired or equipped with the missing
devices and then inspected by the authorized certification body (3rd party).
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7.12 Crane Man baskets

General Safety Requirements:

 Any personnel or man basket must have been designed by a certified engineer as such baskets
be able to support their own weight as well as five times the weight of the maximum intended
load. Both of these weight loads must be marked clearly on the basket itself. (Each basket
should be provided with design and calculation).

 Personnel baskets should be equipped with a guard rail that

encompasses the entire rim of the basket. The rail’s height
should be solid to mid-rail in order to prevent personnel
falls and also to help prevent tools from falling on anyone
below the basket. The basket’s access gates must open
toward the inside of the basket and must have safety
latches that will keep the gate from opening accidentally.
The floor of the basket shall be slip resistant, in addition, the
basket’s design should provide enough headroom for
personnel.

 When it comes to the basket’s bridles that attach the personnel basket to the derrick or crane
should allow for the basket’s load to be positioned evening among bridle legs so that
disproportionate strain on one leg can be avoided. The rigging system – which is comprised of
the aforementioned bridles, as well as by links and shackles – that support the personnel
basket must be used only to support the basket. All attachment mechanisms and hooks must
be able to close and lock in order to ensure that a hook won’t open by accident. Suspended
baskets shall be attached to the crane hook with flexible load lifting attachment(s) consisting of
steel wire rope slings or chain slings complying with EN 13414-1 or EN 818-4 respectively But
with an enhanced safety factor of at least: 8 × (weight of basket + rated capacity) for chains;
and 10 × (weight of basket + rated capacity) for steel wire ropes including the end termination.

 When it comes to load restrictions, they must not exceed the maximum load that’s designated
(marked) on the personnel basket. Lines that support the basket must be able to support at
least seven times the intended load. In addition, materials, as well as tools, are secured and
spread uniformly on the basket’s floor in order to avoid tipping. Only those personnel
members who are trained in the task to be performed should be allowed in the personnel
basket when it is raised. When the suspended basket is designed to be used in situations
where falling objects can be a hazard, the basket shall be provided with a roof. Any aperture in
the roof of the basket shall have dimensions, which shall not allow a sphere with a diameter of
20 mm to pass through.

 When it comes to inspecting and testing the basket, the basket should be loaded to its
expected weight before the approaching job. It also should be raised to the anticipated height
of each location where work will be made. All safety devices as well as controls on the basket
as well as the crane/derrick also should be checked.
 In addition, the basket should be lifted slightly (a few inches) whenever a worker enters the
basket, but before the basked is lifted fully, in order to make sure the rigging lines aren’t
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kinked and are clear of any impediments.

 Personnel platforms must be used only for employees, their tools, and the materials necessary
to do their work. Platforms must not be used to hoist materials or tools when not hoisting
personnel.

 The number of employees occupying the personnel platform must not exceed the maximum
number the platform was designed to hold or the number required to perform the work,
whichever is less.

 A crane driver should always be present at the normal crane control station when the basket is
occupied. Visible and audible communication should exist between the persons in the basket
and the crane driver at all times during the lifting operation.

 The man basket should be provided with a fifth wire so as to be attached to the crane hook
and the individuals in the basket.

 Regular inspection should be carried out prior to each lift. (F-HSE -126)

Rescue basket:

The basket must be designed by a professional engineer in accordance with good manufacturing
processes to withstand all loads to which it may be subjected and be in appropriate width and it
should be marked with the basket should be painted in a high visibility yellow, reflective lettering on
both sides spelling out EMERGENCY RESCUE which makes the basket easy to find and identify. The
basket dimension should be (220cm Length*120cm width * 144 cm height). It must be kept on site at
all times in an accessible location where it is clear of material or other equipment. Fit the rescue
basket with appropriate rigging for a quick hook-up by the crane operator.

Material Baskets/ skips:

it should be fabricated from suitable steel grade according to the approved design and calculation
and therefore the anticipated capacity taking into consideration the safety factors, furthermore such
materials skips to meet the above requirement e.g. Lifting techniques, and inspection criteria.
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Concrete Buckets:
 Concrete buckets fabricated locally should be provided with an approved design.
 Concrete buckets shall be designed to prevent concrete from hanging up on top and the sides.
 Inspect the bucket thoroughly for cracks, breaks, or defects that would adversely affect its
performance prior to every pour.
 Concrete buckets equipped with hydraulic or pneumatically operated gates shall have positive
 Safety latches or similar safety devices are installed to prevent premature or accidental
dumping.
 The buckets shall be designed to prevent material from accumulating on the top and sides of
the bucket.
 The buckets should never weld, drill or work on the bail in any way without the manufacturer’s
approval.
 Keep the bucket very clean inside and out so a proper visual inspection can be made.
 Concrete buckets equipped with hydraulic or pneumatic gates shall have positive safety latches
or similar safety devices installed to prevent premature or accidental dumping.
 Thorough examination should be conducted by a third party every 6 months.

Bucket Rigging:
 Inspect wire slings and shackles used in lifting the bucket prior to every pour.
 Make sure these components are sized properly for the weight of the bucket plus its contents.
 The concrete bucket should be designed so as to be lifted via four lifting lugs for more stability.
 Follow all safety requirements related to the crane’s capacity, inspection, and safe lifting
operations.

Bench points:
 Every moving bail should have "bail stops" to keep the bail from slamming down on top of the
bucket if suddenly released.
 Be careful of the bucket jaws. Keep hands and feet back from the pinch points.
 Have only one bucket person operating the handle to avoid confusion.

Bucket Handling:
 Double-check with the crane operator regarding crane capacity and reach.
 Train all bucket handlers in landing the bucket and working with the crane operators.
 Maintain eye contact with the operator and never get behind the bucket or out of site.
 Install handles on the bucket for tenders to guide it.
 Keep hands away from the bail and other pinch points.
 Have only one crane signal person to avoid confusion.

Watch Overhead
 Plan the crane swing route. Inform all crew members and have the crane operator sound the
horn to notify crews that the bucket is being flown.
 Stay out from beneath the bucket until it is down close, then approach to handle it.
 Have an escape path planned and clear of obstructions and tripping hazards. The crew must be
able to get clear of the bucket at all times.
 Control the lifting operation via qualified riggers.