section 6 crane and erection safety...

Copyright ©ISM 2013

International Environmental Health and Safety (IEHS)

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Section 6 Crane and Erection Safety Program

Any material referenced in this manual from ANSI/ASME or OSHA should have the

referenced material noted.

6.1 Objective

The Crane and Erection Safety Program has been developed to protect IEHS project employees

working on site, under contract to IEHS, and provide safety requirements to be followed

during lifting operations that could cause injury to personnel or pose a threat to the

operational integrity of the construction site. This program, along with the applicable OSHA

and ANSI/ASME B30.5 regulations and standards, has been reviewed and considered in the

establishment of this program. The H&S requirements are considered to be the minimum

standards governing crane operations and erection activities for IEHS employees and

subcontractors. This program provides operational, safety guidance, and direction for cranes,

derricks, and other lifting equipment. It does not supersede good work practices, and general

safety procedures.

Note that the program content is intended to address the requirements associated with lifting

and erection operations. In addressing the overall work hazards represented by a given project

scope, the project team should also reference all other applicable IEHS H&S programs,

ANSI/ASME and OSHA regulations.

6.2 Roles and Responsibilities

Competent Person/Erection Superintendent

The competent person/erection superintendent will work in conjunction with the Site Safety

Officer to successfully implement the following program requirements:

Assist in the overall planning, scheduling, clarifying site‐specific details or hazards,

and coordination of the project.

Ensure any necessary Federal Aviation Administration (FAA) permits are obtained.

Assist in the determination of the load weight.

Determine the commercial terms and requirements associated with any purchase orders

or contracts to suppliers of cranes and/or support services.

Ensure that all personnel involved in the operation understand their jobs,

responsibilities, and safety‐related aspects.

Keep all non‐essential personnel clear of the crane during operation.

Control the movements of all personnel within the area affected by the lift.


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Issue proper permits for all crane operations including Critical Lift Plans.

Identify lifting/erection operations that will require the development and

implementation of a Critical Lift Plan.

Perform approval of critical lifts using the Critical Lift Evaluation Form.

Provide on‐site guidance for crane/erection safety issues and questions.

Observe the implementation of all lifting/erection procedures and perform

monthly inspections/audits regarding Crane and Erection Safety Program

implementation.

Lifting/Erection Crew Foreman

The lifting/erection crew (including all employed management and supervisory personnel) is

responsible for the identification and assignment of specific responsibilities of the operating

crews. The lifting/erection crew shall be equipped with equipment and personnel capable of

completing the job in a safe and efficient manner, in accordance with all applicable

regulations, procedures, and guidelines. This shall include:

Ensuring that crane operators are trained, experienced, and competent in operating

the designated crane they are assigned to on the particular job and that proper crane

lifting logs are maintained in the crane.

Ensuring that all personnel involved in maintaining, repairing, transporting,

preparing, assembling, and operating the equipment are trained, experienced, and

competent to handle their specific jobs in a safe and efficient manner.

Ensuring that a crane maintenance and inspection program is established and

maintained. This involves developing crane lifting logs that facilitate the reporting of

all work needed to be completed on the crane.

Ensuring that the client and other site supervisors are aware of necessary work to

prepare the site for erection/lifting operations.

Ensuring that the crane and associated equipment are in compliance with

the manufacturer’s requirements and all applicable regulations.

Ensuring that the crane operator completes daily inspections that are documented

and available for audit by site management.

Providing qualified supervision for each job.

Crane Operator

The crane operator is generally responsible for the safety of the crane operation. If there is

reasonable cause to believe that the lift might be dangerous or unsafe, the operator must

refuse to lift until the concern has been reported to the supervisor. All hazards are to be

rectified, and safe conditions assured before a lift is continued. All crane operators must be


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certified through the National Commission for the Certification of Crane Operators (NCCCO)

or an equivalent training certification program. Documentation of this training must be

provided to the Site Safety Team prior to the start of erection/lifting operations.

The crane operator is responsible for:

Knowing the machine well. He/she must understand its functions and limitations as

well as its particular operating characteristics.

Being certified to operate the piece of equipment that he/she is assigned to.

Knowing and understanding the information contained in the crane’s operating manual.

Knowing and understanding the crane’s load chart. They must understand the correct

meaning of all notes and warnings and be able to calculate or determine the crane’s

actual net capacity for every possible configuration of the machine. The crane

operator must complete the crane lifting log for each lift.

Confirm crane’s electronic safety alarms and interlock is operating accurately.

Inspecting and maintaining the crane regularly as prescribed by both the owner and

the manufacturer.

Ensuring that IEHS’s Lockout/Tagout (LOTO) Program is implemented prior to

maintenance work.

Performing thorough inspections of all wire rope (stationary and running) on a monthly

basis or sooner (i.e., when a rope is put into service when new, has been stored or

otherwise dormant). Look for reduction of rope diameter, internal or external

corrosion, cracked, bent, worn or improperly spliced end connections, severe kinking,

crushing, cutting, or unstranding.

Informing the owner of any problems, required maintenance, or necessary repairs to

the machine. This should be done in writing, preferably in the crane’s log book.

Recording, in the log book, the details of all inspections and maintenance done on the

crane while in the field (including daily and monthly inspections of all critical items

including, but not limited to brakes, crane hooks, hoist chains, ropes, etc., identifying

by serial number where applicable). The crane log book should be provided by the

manufacturer or crane owner and kept with the crane at all times.

Supervising and training the crane oiler position.

Knowing, understanding, and being aware of any site conditions that could affect the

crane operation particularly the presence of power lines.

Checking that the site is adequately prepared for the crane.

Reviewing the planned operation and requirements with the site supervision.

Knowing and understanding the load and rigging weight where the load is to be placed.


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The crane operator is not responsible for determining the weight of the load.

However, if he/she does so or if he/she lifts it without checking the weight with site

supervision, he/she becomes responsible for the lift and the consequences that may

derive from his/her actions.

Determining the number of parts of hoist line required.

Checking the load chart to ensure that the crane has sufficient net capacity every lift.

Adequate headroom to ensure manufacturer’s minimum allowable two block

distance is maintained for configuration of the reeve used.

Ensure outriggers can be deployed per manufacturer’s load chart requirements.

Selecting from the Critical Lift Evaluation Form the best boom, jib, and crane

configuration to suit the load, site, and lift conditions.

Supervising the proper assembly, set‐up, and rigging of the crane.

Following the manufacturer’s operating instructions in accordance with the load chart.

Considering all factors that might reduce the crane’s capacity and adjusting the load

chart weight, as necessary, to perform a safe lift. (Accumulation of ice, snow, etc.)

Knowing basic load and rigging procedures and ensuring that they are applied.

Maintaining communication with the signal person.

Ensuring that the crane oiler is in a safe place during operation.

Operating in a smooth, controlled, and safe manner when moving or transporting

the crane.

Only taking signals from one pre‐determined individual on a lift.

Shutting down and securing the machine properly when leaving the crane unattended.

When calculating lift, weight of item to be lifted shall be obtained from the item

nameplate, item engineering data sheet, or estimated by the employee(s) requesting

the lift. When using an estimated weight or calculating the lift, add 25 percent to the

estimated weight or attach a load cell to determine actual weight.

Being fit for duty. All crane operators shall have a documented annual medical exam

and drug and alcohol screening, valid state issued driver license. Annual

demonstration of abilities verified by a competent person shall also be included in the

training documentation for crane operators. All training and fitness for duty

documentation must be provided to the Site Safety Team upon request.

Competent Signal Person

The signal person must:

Be capable of directing the crane and load to ensure the safety and efficiency of

the operation. Knowledge of the international hand signals is required.


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Ensure that all required safety clearances are maintained when the crane is in the

vicinity of power lines or process equipment.

Know and understand all signaling requirements.

Be familiar with crane and safety operating procedures.

Qualified Rigger

The rigger must:

Be capable of establishing weights; judging distances, heights, and clearances;

selecting lifting gear suitable for the loads; and rigging the load safely and

securely.

Be able to utilize the different types of lanyards and harnesses for certain lifts.

Utilize only defect‐free rigging.

Ensure that all rigging hardware been selected to work within the manufacturer’s

safe working load.

Ensure that sling angles flatter than 45 degrees been avoided, and have the slings or

chains and shackles been chosen to allow for increased loads due to sling angles.

Ensure softeners been used to protect the rigging where sharp corners could cause

damage.

Ensure the rigging provides positive control of the load to prevent slipping or shifting.

Ensure shackles and hooks are always used in such a manner as to avoid side

bending in the hardware.

Make a determination on the level of inspection shackles, hooks, slings, etc., will be

subjected to. (i.e., Will a pull‐test be conducted on the slings?)

Ensure that the shackle pins and lifting eyes compatibly sized.

Ensure that all rigging components such as shackles, hooks, and slings, been inspected

for signs of damage or deterioration before use.

6.3 General Requirements

Working Around Cranes

When working outside of and around cranes, PPE required for project‐specific work is

mandatory, at a minimum. Refer to the PTP for more information. A hard hat is not

required if the cab of the crane is covered. Safety glasses, however, are required.

The crane shall be barricaded to warn employees of the rotating superstructure of the crane


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using red danger tapes or cones. Do not walk under the boom of a load or working crane.

Do not enter the area between the outriggers of a crane or directly in front or in back of the

crane. This could be the swing area of the upper works of the crane. All work areas should be

taped or coned off at a distance of one and a half times the boom length. Personnel are not

allowed to enter the taped or coned area without permission and must sign and review the

PTP. Do not stand in close proximity of a working crane. Be extremely cautious when a

crane is working around power lines or electrical equipment. Never stand between the

outriggers of an operating crane.


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Lift Planning and Assessment Processes

Erection/Crane

Procedures

Lift plan developed for each task and

reviewed by Project Manager and Site

Safety Officer

When crane arrives on site but before

crane begins operating,

Site Safety Team must review owner-

qualified crane inspections and

approve crane for use on project.

Each pick will complete Pick Form and

attach to Erection PTP.

If crane is damaged in any way (i.e.,

struck by lightning, live voltage, serious

malfunction, etc.) PM will direct crane

to be shut down and repaired/replaced.

Prior to placing crane back into service

(or introducing new crane to jobsite)

Site Safety Officer rmust review owner

qualified crane inspections and

approve crane for use on project.

All crane walks must have QC

completion proof (i.e., Crane Walk

Checklist) attached to Crane Walk

PTP.

All documentation must be

returned to the Site Safety Team.

Lift Planning Process

The lift planning process is a special type of PTP. The process is a systematic

breakdown of the lift components including load, site factors, a risk assessment, and

risk/hazard mitigation determination for each activity. This process should be followed

regardless of the specifics of the lift. The degree to which it is applied depends on the

results of the lift assessment process.


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Lift Assessment Process

The lift assessment process is necessary to determine if the lift is classified as standard,

non-standard, or critical. Various requirements for the different lift classifications are

outlined in the Lift Assessment Flowchart (Figure 6.3). The Critical Lift Plan and Pre-

engineered Lift Procedure (Figure 6.4) should be used to assist with determining critical

lift procedures and developing Critical Lift Plans as necessary.

1. Standard Lift

Is any lift that is less than 75 percent of the crane’s rated capacity and is not

lifted above or within close proximity of process equipment. See non-

standard lift if conditions warrant lifting over process and/or electrical

equipment.

Does not involve a test lift.

Requires a review of the lift assessment process.

Does not require a Critical Lift Plan.

2. Critical Lift

Is any lift that is neither standard or non-standard and falls into the

categories listed in the Lift Assessment Flowchart for critical

lifts.

Requires a review of the lift assessment process and a PTP to be

conducted.

Requires that a review of the critical lift precautions be addressed with

all involved personnel before the lift begins.

Is over 75 percent of the crane’s rated capacity and requires a test lift.

Is any lift in which the load replacement time exceeds 10 days.

Is any lift in which the loss of the load during installation will cause a loss

of production exceeding 10 days.

Is any lift in which the loss of the load constitutes a risk to the public or the

environment.

Is any lift in which the load must be swung over unprotected equipment,

etc.

Requires a Critical Lift Plan be completed and submitted to the PM, Site

Safety Officer, and/or listed competent person(s) prior to the lift.

Any critical lift greater than or equal to 90 percent of the crane’s rated chart

capacity must be reviewed by a Professional Engineer with knowledge

in the crane field.

Utilizes two cranes to perform a lift. There is a separate Critical Lift Plan

for two crane lifts where the weight of the load to be lifted exceeds 90

percent of the lifting capacity for the main erection crane.


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The following precautions must be taken for all critical lifts:

A pre-lift safety review MUST be held with all parties involved to

review the Critical Lift Plan prior to the lift.

A copy of the Critical Lift Plan must be in cab of crane during

lifting operations.

Outrigger/crawler track loadings must be included in the lift planning.

Underground hazards must be identified (i.e., pits, piping, sewers).

Cranes working with the outriggers extended must have pads or

cribbing regardless of the ground surface.

The machinery deck or boom foot pins must be checked to verify it is

level and within the manufacturer’s specifications.

The load weight must be accurately determined or conservatively

estimated. This must be done by engineering calculations or by

actual scaling of the load. The weight of rigging hardware, blocks,

slings, jibs, etc., must be included in the overall load calculations.

Lifting the load to determine the weight is not acceptable.

Load dimensions must be reviewed to ensure the load will not hit

an obstruction or the boom and to determine the effects of wind

loading.

The location of the load’s center of gravity must be determined to

stable rigging and the crane hook positioned above it.

Rigging attachment points and special rigging requirements must

be included in the lift planning.

The radius must be measured exactly, taking into account boom

deflection.

The boom length must be determined.

The boom angle, if necessary for determining the crane’s capacity, must

be determined.

Wind and weather effects must be considered and the lift delayed if the

wind loads exceed those specified on Figure 6‐8, Wind Speed

Limitations. In addition, crane manufacturer’s recommendations

and the turbine manufacturer’s specifications must be taken into

consideration to determine wind speed limitations and the most

stringent shall be implemented.

Reeving must follow the manufacturer’s specifications.

Check the load rigging for adequacy and security. The weight of

the rigging must be known exactly.


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All control, machine, and load movements must be made as slowly

and smoothly as possible. This is standard practice for all lifts, but

especially important for critical lifts.

3. Multiple Crane Lifts

Lifts involving two or more cranes are complex operations requiring

considerable skill and planning and dramatically increase the possibility of

side loading and/or overloading the cranes. This work must always be

considered a critical lift and a last alternative. Along with the critical lift

criteria, the following planning requirements are required:

For a multiple crane lift, no crane should be loaded to more than 75

percent of its chart capacity without a complete lifting specification

approved by a Professional Engineer with knowledge in the field of

cranes.

The maximum possible load share must be determined for each

crane involved.

Swing and booming motions should be kept to a minimum to reduce

the likelihood of side loading.

All communications during the lift should be made by radio on a

separate channel when possible or by one signal person that is visible

to both crane operators.

It is imperative that one employee direct and control the operation.

He/she must be positioned to view the entire operation and should

maintain radio contact and/or visible contact with the operators during

the entire lift.

Site Conditions, Preparation, and Restrictions

Crane Transportation and Interim Storage Issues

— The responsible manager shall be notified of movement of the load to the lifting

site.

— The responsible manager shall secure any required permits.

— The load transport route to the lift site shall be identified and inspected for

overhead obstructions, bridges, culverts, pipes, etc. prior to traveling. All


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traveled routes must be structurally capable of safely supporting the transported

loads.

— Prior to assembly, a crane assembly site must be identified and inspected.

— The transport route from the lift site shall be identified and inspected for

overhead obstructions, bridges, culverts, pipes, etc. prior to traveling. All

traveled routes must be structurally capable of safely supporting the transported

loads.

Ground Stability and Loading

— The crane will support the load only if the ground will support the loaded crane.

The ground where the crane sits must be reasonably level, (typically for crawler

cranes 1 percent side‐to‐side and no more than 10 percent front‐to‐back) well

compacted, and stable.

— When the pressure on the ground is excessive, additional matting, larger

outrigger pads, or blocking must be utilized to distribute the load across a larger

area.

— Check specifically for the possibility of underground obstructions by utilizing

construction drawings. Obstructive items include piping, electrical duct

banks, valve pits, or sumps, which may be damaged or cause instability for

the crane.

Outriggers, Pads, Matting, and Blocking

— Outriggers should be fully extended on all sides of the crane when making lifts.

The “On Rubber” load chart is a valid chart for lifting if all the riggers are not fully

extended in configuration. Note: There are some cranes that have a mid‐position

or a straight‐down position for their outriggers. The related load chart should be

used in these configurations.

— Outrigger pads (typically wooden) shall be a minimum of three times the

surface area of the outrigger pads. Load‐rated neoprene pads are also

acceptable.

— Subcontractors will be responsible for providing the proper matting and blocking

necessary to provide sufficient load distribution to maintain crane stability for

safe lifting.

Crane Leveling Requirements

— Crane lifting on the project site must be adequately leveled within

manufacturer’s specifications. Crane load charts are only accurate if the crane

has been leveled properly.


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Crane Walk

— The crane path must be roll tested by a forklift with two mats.

— The operator/oiler shall physically drive the planned crane path to

remove obstructions and identify any potential soft spots.

— All power lines in the crane path must be identified. If power lines are in crane

path, procedures in Hazards – Electrical and Power Line Hazards of this section

must be adhered to.

— Proper barricading, traffic control and signage must be in place prior to

crossing any road, highway or intersection.

— Crane mats must be in place and used when crossing any paved road.

— Radio communications between the crane operator and oiler must be on a closed,

non‐chat channel to avoid interference while making long or involved crane

walks.

— When crossing a high pressure pipeline, appropriate crane mats and/or dirt

ramp must be used.

— The grade for the crane path must not exceed the acceptable grade for the crane.

Verification must be recorded on Figure 6‐5, Crane Pre-Walk Checklist.

— All crane walks exceeding one‐half mile requires a

superintendent’s signature/approval.

— All parties involved in the crane walk must review and sign (where required)

The Crane Pre-Walk Checklist.

Hazards

Electrical and Power Line Hazards

When traveling under power lines, the preferred method is always to drop the line. If

line drops are not possible, the secondary method will be to have the line de‐energized

or insulated at points of potential contact. If neither one of these methods are an

option, the competent person and the Site Safety Team must develop a plan to cross

under the

live lines. A qualified spotter must ALWAYS be present while crossing under

energized

power lines. For crossing or passage of a crane under an active power line of 0 ‐

50KV, the minimum distance between any portion of the crane and the power line at

any point shall be no less than five feet. Note other conditions (i.e., voltage greater

than 50KV, wind, and rain) would require additional separation distance between the


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crane and the active power line.

— Before setting up, walking or operating the crane, LOOK FOR POWER LINES.

If power lines are present, STOP and assess the situation.

— The safety of the crane operation is the responsibility of the crane operator

when power lines are present.

— Minimum clearance must be maintained from electrical distribution or

transmission lines designated in the Electrical Safety Program. Working closer

than the posted limits must have prior approval from the competent person and

Site Safety Officer. Actual distances do not need to be calculated, but if the

clearance appears to be within established limits, evaluation of the approach must

be made before proceeding under or adjacent to power lines.

— Some utility companies require notice if work is to be preformed within 100 yards

of transmission lines.

— Use a signal person whenever the crane appears to be within a boom’s length of

the power lines. The signal person must warn the operator when the machine is

approaching the lines (the crane operator may not be able to accurately judge the

distance). In addition to the signal person, a designated line watch person must

be provided when working near power lines. His/her sole responsibility is to

maintain the minimum required distance between the crane and the power line

and to stop work if necessary.

— Except for the crane operator, keep all personnel away from the crane whenever it

is working close to power lines.

— Do not allow anyone to touch the load, the crane, or the crane hook until the

signal person indicates that it is safe to do so.

— Avoid using tag lines except when it is possible for the load to spin into a

power line. Note: All ropes will conduct electricity; dry polypropylene

provides better insulating properties than most commercially available rope.

— SLOW DOWN the operating cycle of the machine by reducing hoisting,

booming, swinging, and travel speeds.

— Exercise extreme caution when the crane is traveling on uneven ground which

can cause the boom to weave or bob and possibly contact power lines.

— Ensure that whenever cranes must repeatedly travel beneath power lines, a

safe route is plainly marked.

— The crane operator must not leave the crane if the boom, when lowered, can

enter the limit of approach. The subcontractor limit of approach is 20 feet.

In the event of contact:

— DO NOT PANIC. Remain inside the cab.


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— If it becomes necessary to exit the crane, such as in the case of a fire, use a small

gate or shuffling motion when moving away from the crane to reduce the risk of

shock. Do not return to the crane for any reason.

— Instruct all other personnel to keep away from the machine, ropes, and load.

The complete machine, load, and the ground around it will be “hot.”

— Caution: If the crane’s cables appear to be welded to the power line do not move

the crane away from the line as it may snap and whip. Stay where you are until

help arrives.

— Try to remove the contact unaided without anyone approaching the crane.

Move away from the line in the reverse direction to that which caused the

contact. For example, if you swung left into the wire, swing right to break the

contact. Remember, once an arc has been struck, it can draw out a considerable

distance before it breaks, so keep moving away from the line until the arc

breaks and then continue moving until you are at least 20 feet away from the

line.

— If the crane cannot be moved away or disengaged from the contact, remain

inside the machine until the electrical personnel de‐energize the circuit and

confirm that conditions are safe.

— Report every incident involving contact with a live line to the appropriate

electrical and safety personnel so that inspections and repairs can be made to

prevent damaged power lines from falling at a later date.

— Completely inspect the crane for possible damage caused by the electrical contact.

Wire rope must be replaced if it touches a line since the arc is usually of sufficient

power to weld, melt, or badly pit the rope. The damaged section of rope will look

like it was burned with a torch. Certified inspection of the crane must be made

after any electrical contact. Pay particular attention to any bearings in the current

path between the contact point and ground.

Underground Hazards

The site must be checked for underground hazards when planning and preparing to

make a lift. The presence of manhole covers, sewer inlets, and red conduit are

indicators of possible covered hazards. Consult construction drawings and stakings

for potential underground hazards. Never set a crane’s outrigger on any part of a

manhole.

Wind and Weather Restrictions

Weather conditions can have an adverse effect on lifting activities and need to be

thoroughly considered both during the planning and execution of a lift. Special


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efforts may be required to ensure adequate warning is provided to avoid a sudden

storm disrupting a lift in progress.

Wind must be considered and the lift delayed if the wind loads exceed those

specified on Figure 6‐8, Wind Speed Limitations. In addition, crane manufacturer’s

recommendations and the turbine manufacturer’s specifications must be taken into

consideration to determine wind speed limitations and the most stringent shall be

implemented.

Critical Lift Plans

Before making a critical lift, a qualified employee must prepare a Critical Lift Plan.

Additionally, the crane operator, lift supervisor, and rigger shall participate in the

preparation of the PTP of each lift. It is not necessary to complete a Critical Lift Plan

for every lift on a construction site where each lift will be performed numerous times, so

long as each lift/erection stays within the tolerances (weight of load to be lifted, boom

angle, boom length, rigging etc.).

Plans shall be documented and a copy shall be provided to the Site Safety Team. The

plan shall be reviewed and signed by all personnel involved with the lift.

The plan shall specify the exact size and weight of the load to be lifted and all crane

and rigging components that add to the weight. The manufacturer’s maximum load

limits for the entire range of the lift, as listed in the load charts, shall also be

specified.

The plan shall specify the lift geometry and procedures, including the crane position,

height of the lift, the load radius, and the boom length and angle, for the entire range

of the lift.

The plan shall designate the crane operator, lift supervisor and rigger and state

their qualifications.

The plan will include a rigging plan that shows the lift points and describes

rigging procedures and hardware requirements.

The plan will describe the ground conditions, outrigger or crawler track requirements,

and the design of mats, if necessary, to achieve a level, stable foundation of sufficient

bearing capacity for the lift.

The plan will list environmental conditions under which lift operations are to cease.

The plan will specify coordination and communication requirements for the lift

operation.

For tandem or tailing crane lifts, the plan will specify the make and model of the cranes,

the line, boom, and swing speeds, and requirements for an equalizer beam.


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Crane-Suspended Work Platforms

General

Do not use crane‐suspended work platforms to hoist or suspend employees except as

a last resort in unique work situations. Use suspended work platforms only if their

use results in the least hazardous exposure to employees. A permit must be obtained

for using a crane suspended work platform that identifies the necessary authorizations

and minimum safety requirements. See Crane Hoisted Personnel Platform Permit

(Figure 6‐6).

The crane supported work platform shall meet or exceed all the requirements of the

Crane‐Suspended Work Platform procedure.

The Construction Manger or qualified designee must approve using a

crane‐suspended work platform and document that other, less‐hazardous methods of

access are not available or practical.

Documentation must be retained on site that verifies that no other less hazardous

methods of access are available or practical, and that all the provisions of this procedure

have been met.

Designing and Constructing a Platform

A crane‐suspended work platform must have the following minimum safety features:

— If the crane supported work platform has an access gate; that swings inward and

is equipped with a working positive latch.

— A grab rail shall be around the entire inside perimeter.

— The capability of supporting its own weight and at least five times its

maximum intended load.

— An enclosed top that is high enough to allow workers to stand upright,

protects them from overhead hazards, and inhibits them from climbing out.

— Perimeter protection consisting of a top rail approximately 42 + 3 inches high, a

toe plate at least 4 inches high, and a midrail located approximately halfway

between the two. The area from the toe plate to at least the midrail with either

solid material or expanded metal having openings no greater than ½ inch.

— Provisions for tying off full body harness lanyards shall be inside the

protected perimeter.

— A rigid suspension system that minimizes tipping when personnel move. The

capacity of suspension systems that use four or more legs must be based on


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any three of the load‐bearing legs.

— A conspicuous plate or other permanent marking that shows the weight of

the empty platform and its rated capacity.

Rigging a Platform

When rigging a platform to a crane, observe the following minimum safety precautions:

— The platform assembly shall be attached directly to a block or hook, not directly

to the load line.

— Attach a wire rope sling (safety line), capable of supporting the weight of the

platform and occupants, from the load line above the highest bicket to the eye of

the lifting lug on top of the platform. The sling design should include shock load.

— Use hooks that can be closed and locked (locking hooks or safety latches) for

ʺheadacheʺ ball assemblies, lower‐load blocks, and other attachment assemblies.

These latches eliminate the hook throat opening.

— When a wire rope bridle connects the platform to the load hook, connect the

bridle to the master link or shackle so that the load is evenly divided among the

bridle legs.

— Ensure the wire rope, shackles, rings, master links, and other rigging hardware

are capable of supporting at least five times their maximum intended loads.

— The use of wire rope clips, wedge sockets, knots, or chains is prohibited.

— All eyes in wire rope slings shall be made with thimbles.

— Rigging and work platforms used for hoisting personnel shall not be used for

any other purpose, but be dedicated only to the hoisting of personnel.

Trial Lifts, Proof Tests, and Inspections

— Immediately before placing personnel in a platform (at the beginning of a new

shift or for the first time at a new location), the operator must perform a trial lift

of the unoccupied platform to each location to which the platform will be hoisted

and positioned.

— In addition, before hoisting personnel on the platform, the operator must proof

test the platform to 125 percent of its rated capacity by holding it, with the test

load evenly distributed on the platform, in a suspended position for two minutes

at each location to which the platform will be hoisted. Be sure to follow the

intended lift route. (This testing can be done concurrent with the trial lift.)

— During the trial lift, the operator must determine that all systems, controls, and

safety devices are activated and functioning properly, that no interferences

exist, and that the equipment can remain under the 50‐percent limit of the


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craneʹs rated capacity in all configurations necessary to reach the work

locations.

— If any deficiencies are detected, they must be corrected, and then another

test performed. Personnel may not be hoisted until the testing

requirements are satisfied.

— A trial lift must be performed after each repositioning of the crane and prior

to hoisting personnel.

Whenever the crane is moved to a new location,

Whenever the crane is returned to a previous location,

Each time the lift route is changed, unless the crane operator

determines the route change is not significant (i.e. the route change

will not affect the safety of the hoisted employees).

At the beginning of each new shift.

— Just before hoisting personnel, the platform must be hoisted just a few inches and a

qualified inspector must ensure that it is secure and properly balanced. He/she

must visually inspect the crane, rigging, personnel platform, and the crane base

support or ground to determine if the trail lift has exposed any defect or produced

any adverse effect on any component or structure.

— The operator shall make a thorough inspection of the crane, lines and rigging

before hoisting any employees on a platform.

Pre-Lift Meeting and Permitting

— Before each trial lift, and each time new personnel are assigned to the operation

the crane operator, the signal person(s), personnel to be lifted, and any other

personnel responsible for the task, including the contactor and client safety, shall

meet to review the requirements of this procedure.

Loading a Platform

Observe the following minimum safety precautions when loading platforms:

— Do not load the platform in excess of its rated load capacity.

— Secure materials and equipment on the platform, making sure their weight is

evenly distributed.

— Load the platform only with the personnel, tools and material required to

perform the task.

— Do not use personnel platforms as material‐hoisting platforms.

— Only the minimum number of people that are required to perform the work,

and the design/capacity of the crane supported work platform is rated for shall


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be allowed to be hoisted.

Signaling and Communications

The signalman must be either in the platform or in a position so that he or she

can always see the platform and communicate with the operator (see

Signaling).

Working in the Platform

Personnel working crane‐suspended work platforms must observe the

following minimum safety precautions:

— Always use a full body harness system with the lanyard attached to the platform.

— Wear appropriate PPE (see Working Around Cranes).

— Remain in the platform to work.

— Never stand on or work from the top rail, midrail, or toeplate.

— Allow only the number of people in the platform that are needed for the work

and that the platform design permits.

— Keep all extremities within the platform when it is being raised, lowered,

or positioned.

— Ensure all tools used outside of the man basket are secured using a tool lanyard

or other approved device.

Inspecting the Crane

— The operator must perform an inspection of the crane prior to the machine

being used to hoist a platform.

— Any structural or functional defect that could adversely affect safety must

be corrected before a platform can be used.

— A crane must meet the following minimum safety criteria:

It must not have a live boom.

The load line must have controlled load lowering (power down) and

automatic brakes. The free‐fall option shall not be used with

suspended work platforms.

A crane with a telescoping boom must be equipment with a device that

indicates clearly to the operator, at all times, the boomʹs extended

length. Alternately, the operator must accurately determine the load

radius before hoisting personnel on the platform.

The total weight of the loaded platform and related rigging must not


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exceed 50 percent of the rated capacity for the radius and

configuration of the crane.

The crane must have a positive‐acting device (anti‐two‐blocking

device) that prevents contact between the load block or ʺheadacheʺ

ball and the boom tip, boom extension, or jib; or the crane must

have a system that deactivates the hoisting action before damage

occurs in the event of a two‐blocking situation.

Crane Operation

— The operator of a crane with a suspended work platform must be a qualified

operator and have demonstrated his or her ability to operate the crane (see

Crane Operator).

— In addition, the crane operator must observe the following minimum

safety precautions:

Hoist the platform slowly and cautiously, with no sudden movements

of the crane or platform.

Remain at the controls at all times when the personnel are in the platform.

Ensure the crane is uniformly level within one percent of level grade

and located on firm footing (see Site Conditions, Preparation, and

Restrictions).

Set and level cranes equipped with outriggers so that the beams and

jacks are fully extended with the outrigger bases on a stable bearing.

Ensure that tag lines are always used.

Never permit the crane to travel when personnel are in a

suspended platform.

Ensure load and boom hoist drum brakes, swing brakes, and locking

devices such as pawls or dogs are engaged when the platform has

been hoisted to a working position.

Do not use work platforms in winds that exceed 20 mph (32 kph),

electrical storms, snow, ice, sleet, or other adverse weather conditions

that could affect the safety of the personnel.

When personnel are suspended on a platform from one of a

crane’s loadlines, no other line shall be used for hoisting.

Signaling

A designated Competent signal person should be used whenever work is being performed

with a crane. The operator should not move a load without signals.


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A signal person must be used whenever the following occurs:

The crane operator cannot see the load.

The crane operator cannot see the load’s landing area.

The crane operator cannot see the travel path of the load or of the crane.

The crane operator is far enough away from the load to make judgment of

distance difficult.

The crane is working within a boom’s length of approach to power lines or

electrical equipment.

The crane is working within the battery limits of a process unit.

The crane operator requests the assistance.

On any critical lift.

When using a crane suspended work platform. Hand signals should be used only when the distance between the crane operator and the

signal person is in clear view and the conditions allow for clear visibility. See Standard

Accepted Crane Signals (Figure 6‐2). All lifts must start with two beeps of the crane horn (or

whistle blasts) prior to lifting the load. This will alert all nearby personnel that the lift is ready

to commence.

If a two‐way radio is utilized or required for communication between the operator and the

signal person, ensure the channel is exclusive to the lifting project. This type of

communication works well when visible hand signals between the signal person and the

crane operator is not working. A clear understanding of the language and radio protocol

must be agreed upon by the crane operator and signal person before the lift begins.

Qualified Rigging

Inspection and Use

Rigging equipment shall be inspected per the manufacturer’s specifications by a

competent person before use on each shift to ensure its safe use. The inspections

must be documented and copies provided to the Site Safety Team. Defective

rigging equipment shall be removed from service. All slings and rigging shall have

the manufacturer tags or markings showing capacity limits or ratings.

The use and maintenance of rigging equipment shall be in accordance with

recommendations of the rigging and equipment manufacturers. Rigging

equipment shall not be loaded in excess of its recommended safe working load.


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Rigging equipment, not in use, shall be removed from the immediate work area

and properly stored and maintained in a safe condition.

Slings

Slings and their fittings and fastenings shall be inspected before use on each shift and

as necessary during use. Protection shall be provided between the sling and sharp

unyielding surfaces of the load to be lifted. The use of slings will be such that the

entire load is positively secured.

Rigging Hardware

Drums, sheaves, and pulleys should be smooth and free of surface defects that may

damage rigging. The ratio between the diameters of the rigging and the drum, block,

sheave, or pulley tread diameter should allow the rigging to adjust itself to the bend

without excessive wear, deformation, or damage. In no case will the safe diameters of

drums, blocks, sheaves, or pulleys be reduced in replacement of such items unless

compensating changes are made in terms of the rigging used and the safe loading

limits.

Drums, sheaves, or pulleys having eccentric bores, cracked hubs, spokes, or flanges

shall be removed from service. Connections, fittings, fastenings, and attachments used

with rigging shall be of good quality, of proper size and strength, and shall be installed

in accordance with recommendations of the manufacturer.

6.4 Training

All project employees will receive training during site‐specific orientation regarding IEHS’s

requirements involving lifting procedure hazards. Additional training for employees

responsible for implementing lifting procedures will be provided during site‐specific

training. This training will include both initial and refresher training. Refresher training is

necessary when duties change, hazards change, or evaluation determines inadequacies in an

employee’s knowledge. Training regarding signaling procedures, critical lifts, fall

protection, LOTO, and appropriate PPE usage is also required for employees involved with

lifting operations, where these hazards are present.

6.5 Audits and Inspections All Critical Lift Plans shall be inspected and approved by the competent person daily prior to


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commencement of project activities. At a minimum, these inspections shall be documented

using the PTP Form (or subcontractor equivalent) and maintained in the project file by the Site

Safety Team. No work involving critical lifts shall be permitted until the Critical Lift Plan

is completed and implemented to the satisfaction of the competent person. Subcontractors

shall ensure that their competent person(s) provide the approval for their Critical Lift Plans,

with documentation provided to the Site Safety Officer.

Cranes shall be inspected daily. This inspection shall be documented by the

designated subcontractor’s competent person and copies provided to the Site Safety

Team.

Monthly audits of crane safety procedures and compliance with established procedures will

be conducted by the Site Safety Team, subcontractor’s H&S representative, or their designees,

as outlined in IEHS’s H&S Inspection/Audit Program. These audits shall be documented in

the project files and deficiencies shall have timely corrective action measures defined. The

auditor will be responsible for ensuring that corrective measures are met within the

established time frame and must report any non‐compliance to the PM for immediate follow

up including, but not limited to, disciplinary action as outlined in IEHS’s H&S Discipline

Program for the affected individuals.

6.6 Documentation

Separate PTPs and Critical Lift Plans will be completed for each lift as required by this

program.

All crane safety training, Critical Lift Plans, implementation audits, crane inspections and

subcontractors’ documentation of the same shall be maintained by the Site Safety Team in

the project file. Records of non‐compliance (personal and company) shall be maintained in

the associated employee’s or subcontractor’s files for the duration of the project.

All documentation generated, as a result of training and Critical Lift Plan creation, shall

be maintained at the project site by the Site Safety Team throughout the life of the contract

and transmitted to the project files for storage upon project completion.


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Figure 6-1

CRITICAL PICK CHECKLIST

DATE: ________________________ SITE:___________________________

TIME: ________________________ PICK: LM UM Top Nacelle Hub

Rotor Base

1. Foreman Responsible _____________________________

2. Tag Line 1 Responsible _____________________________



5. Final Rigging Inspection _____________________________

6. Ground Flagger _____________________________

7. Air Flagger _____________________________

8. Crane Operator _____________________________

9. Max Wind Speed _____________________________

10. Wind Speed _____________________________ OK

________

11. Tagline anchored to hard point? Yes No

12. Crane route reviewed with crew? Yes No

13. Componet route review with crew? Yes No

14. Radio check with crew/flaggers Yes No

15. Crane LMI Radius ______________________________

16. Plan for removing lift tackle reviewed? Yes No

Notes/Comments:

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Figure 6-2 Standard Accepted Crane Signals

EXTEND BOOM DOG EVERYTHING TRAVEL RETRACT BOOM

EXTEND BOOM

(ONE HAND)

USE MAIN HOIST

RETRACT BOOM

(ONE HAND)

USE WHIP LINE

HOIST LOWER

RAISE BOOM LOWER BOOM

6-24


MOVE SLOWLY RAISE THE BOOM &

LOWER THE LOAD

STOP

LOWER THE BOOM &

RAISE THE LOAD

SWING

EMERGENCY STOP


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Figure 6-3 Lift Assessment Flowchart


6-26


6-27

Figure 6-4 Critical Lift Plan and Pre-engineered Lift Procedure

A Critical Lift Plan and a Pre‐engineered Lift Procedure consist(s) of as many drawings,

specifications, and procedures required to accurately assess all important load factors and site

factors relating to a critical lift. These items are included as a guide, but should not be

interpreted as being all‐inclusive in the analysis and preparation of a critical or pre‐engineered

lift. Sound engineering and planning is still the responsibility of the Professional Engineer

and/or PM associated with the lift. Most lifts, however, even some critical lifts, do not involve

all of the factors listed.

The lift plan for a Pre‐engineered Lift Procedure must be a department/division procedure,

subject to the review, approval, and records management policies of the department/division.

This should include the signed reading acknowledgement for individuals performing the

actions of the procedure, specifically the Person‐in‐Charge (PIC) of the lift and the crane

operator. The elements required for a Critical Lift Plan also are required for a Pre‐engineered

Lift Procedure (lift plan).

The following is the minimal level of information required for completing an adequate lift plan:

1. Elevation View Drawing of the crane, load, and any nearby structures which could cause

interference. This drawing must be made to scale and should note:

— Crane manufacturer(s), model(s), and counterweight(s) if variable.

— Boom length(s) and lifting radius(i).

— Maximum load elevation during lifting procedure.

— Any jibs or special lifting devices required.

— Minimum number of parts of crane hoist line required for lifting the load.

— All required slings, shackles, and other rigging components identified by capacity,

size, length, and location.

— Calculated center of gravity of load.

2. Plan View Drawing of the crane, load, and nearby structures, which could cause

interference. This drawing must be made to scale and should note:

— Route that transport will take to position the load for lifting.

— Initial lifting position of the load including radius. Lifting radius must be accurately

determined.

— Final placement position of the load including radius. Lifting radius must be

accurately determined.

— Location of the crane(s) including tail swing limits.


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— Route that crane(s) will take if walking with the load, as well as associated matting

requirements.

— Any utilities located within the work zone. Underground facilities (i.e.,

piping, ducts, etc.) must be accurately located.

— Space that may be needed to assemble crane.

— Planning that must include load transportation considerations, (e.g., how to get the

load close enough to the crane). This may be a function of the type of crane being

used, for example, since some cranes perform better in certain sectors (quadrants) of

operation than others.

3. Lift Analysis including:

— Tabulation of the gross load weight, including the weight of all blocks and rigging

tackle.

— Rigging attachment points and special rigging requirements.

— Gross‐rated capacity of the crane in the configuration specified.

— Calculation of the percentage of the crane’s rated capacity at which the lift will be

made.

— Crane‐imposed soil loads determination. Soil analysis may be needed to verify

crane‐imposed loads can be safely supported.

— Allowable weather conditions for the lift and the effect of wind loading.

— Sequence of work, including lift‐off, steady state conditions, and set‐down of load

(including positions where there is a shift in the location of the center of gravity, for

the pick points). All potential complicating issues for any lift must be addressed in the lift plan; however, for a

relatively simple operation, the above items can provide sufficient information and even be

organized onto one drawing.


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Figure 6-5 Checklist for Lift Planning

PRE-WALK CHECKLIST

Date: ___________________

Yes No N/A

1 Crane path has been roll tested by a forklift with two mats.

2 Operator-Oiler has physically driven the crane path to look for

obstruction or soft spots

3 If power lines are in crane path, have they been cut and dropped?

4 If travel under live power lines, follow crane “Electrical and Power

Line Hazards” procedure.

5 If crossing a highway or county road intersection, are the proper

barricades and signage in place?

6 If crossing a highway or any paved road, are mats in place for road

crossing?

7 Radio channel between operator and oiler is established as a non-

chat channel to avoid interference while making long or involved

crane walks. Ex. Duck-Unders

8 If crossing a high pressure pipeline, are the mats or dirt ramp in

place?

9 Pre-walk checklist signed by crane operator, oiler, and forklift

operator and flatbed operator, if involved?

10 Any crane walk over a half mile requires a superintendant

signature.

11 Grade for path needs to be verified to be less than max acceptable

grade for crane.

Signature of Crane Operator:

Signature of Crane Oiler:

Signature of Forklift Operator:

Signature of Flatbed Operator (if needed):

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Figure 6-6 Crane Hoisted Personnel Platform Permit

JOB NUMBER: DATE:

CLIENT: PERMIT NO.:

LOCATION:

This permit is required by the Company to comply with 29 CFR, OSHA Section 1926.550 (g) (2)

regarding crane hoisted personnel platforms. Prior to the use of any personnel platforms suspended from

cranes or derricks for the hoisting of personnel, the highest level of project management shall determine if

the use of conventional means is more hazardous or not possible because of structural design or worksite

conditions. Reasons shall be stated below:

Reason for platform use:

Work description/location: (include elevation)

Crane inspected/passed

Rigging inspected/passed

Personnel basket inspected/passed

Anti-two block device tested/passed

Max operational radius established Length of radius

Crane capacity at radius above

50% of chart at radius given

Test lift with trial weight completed

Pre-lift safety orientation completed

Who is the designated signal person

Name

The persons below acknowledge that they have participated in a Pre-Lift meeting.

Crane Operator Construction Manager/Designee Approval

Approving Safety Representative


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Figure 6-7 Tagline Specifications and Proper Use Procedures

Required for tag line use of over 100’ or any critical lift.

Minimum requirements for rope shall meet NFPA Two Person Standard Rescue Rope

(covers abrasion/durability and strength).

Minimum 11mm (.5 inch) double braided or kernmantle nylon rope.

Minimum breaking strength 12,000 lbs.

Maximum working load 2400 lbs. (20% of breaking strength).

PTP will specify anchor points, anchor end of rope must be attached to an object weighing

over 6,000 lbs (examples; 3/4 ton pick‐up, forklift, etc.) or a fixed point capable of

supporting a 5000 lbs load (such as a tree over 12’).

Friction control device like a fisk, (minimum; capable of holding 5,000 lbs. of

developing force) or a designed wheel (wheel or sheave blocks shall be 10 times the

rope diameter unless otherwise specified by the manufacturer).

Rope must be inspected by a competent person before each use and taken out of service

if glazed, inconsistent in diameter, discolored, stiffness, charred, showing signs of

excessive abrasion or used with 100 or more picks. Tag line ends shall be inspected

weekly identified via colored tape attached to rope in accordance with the monthly

inspection color coding system referenced in Section 1A.

All attached ends shall have either a manufactured installed eye, bowline on a bite or

a figure eight knot.

A tag or label showing date rope was put into service and date used for each

erection, shall be attached to the rope.

Keep ropes clean and dry as possible, stored in accordance with manufacturers guidelines

(coiled or bundled).

PTP will reference procedures for release of a snagged tag line.


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Figure 6-8 Wind Speed Limitations

ERECTION WIND SPEED LIMIT

Ground to 50 feet heighth = 33 mph

50 feet or more from ground = 25 mph

Wind measurement is the average value of a gust of wind over the duration of three

seconds or the maximum value recorded on the anemometer at the relevant crane boom

height exceeds or are forecasted to exceed the noted limits.

Job Specific Governing Guideline The lowest numeral of (crane rating) or (TSA) or (critical pick qualified) = governing guideline

Manufactures Specifications or Directives will be adhered to when they are more

stringent.

SPEEDS CANNOT BE COMPROMISED!

section 6 crane and erection safety...

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