Symmetrical Group

Policies and Procedures

OHS&E\SAFETY PROCEDURES

SG-PR-33-17 Requirements for Significant Lifts

1.        IMPLEMENTATION GUIDELINES

This standard procedure clearly defines the requirements and responsibilities in relation to the planning implementation and execution of all significant lifts.  It also incorporates the requirements of “Heavy Lifts” and “Dual Lifts”.

Significant Lifts shall be any lift that exceeds a gross weight of 20 tonnes (includes all lifting / rigging gear), a lift that requires two or more cranes, a lift over live operational plant or a lift that exceeds 85% of the cranes rated capacity in that particular configuration.

All significant lifts shall require a formal lift study to be compiled by the Rigging Superintendent / Supervisor and verified by a qualified Engineer.  All lift studies shall require the following information.

• Weight, in accordance with the requirements of section 1.1.1.
• Sufficient detail of the element to be lifted to determine the outline, position of lifting lugs, centre of gravity and dimensions of lifting points.  Vendor drawings preferred.
• Should the above lift be in an obviously clear area, where boom / crane / structure clearances present no problem, a simple scale plan showing the piece, the crane and any structure, at lift and set point with appropriate dimensions and a method statement will be sufficient.  Where boom / crane / structure clearances cannot be shown to be ample “by inspection”, a plan as above, plus a section at any critical point shall be produced to scale.  Should a general scale drawing show that at least 1.0 metre clearance on piece / boom or structure is not available calculations shall be presented to determine the available clearance, and operational conditions described to demonstrate that such clearances are practical and safe.  “Two Block” clearance shall also be indicated.  A check for Underground services shall be carried out by the rigging supervisor and included on the plan where available.
• A sketch to scale, indicating all slings and shackles to be used plus the loads and safety factors in each, bearing in mind the requirements of hardware etc, and inclusive of all details of lugs or other methods of attachment to the piece.
• Calculations determining the approximate ground loads to be shown as point loads and ground pressure for outriggers and track weight, maximum bearing pressure for crawlers and a statement explaining the adequacy (or remedial action to be taken) of the ground, including underground services, shall be supplied.
• Details and positioning of any gear used to stabilise the load.
• Any additional rigging equipment that is required to support, stabilise or secure the load once in position.
• Transportation details of movement of the load on site to the point of lift.
• Access and work platform details for erection personnel.
• General lift data shall be provided in the form of a table as depicted in Exhibit B.
• The completed lift study shall be issued for review to all relevant parties, ie. client representative, vendor, lift crane supplier and heavy haulage contractor.

1.1        Rigging Criteria - General

1.1.1        Weights

Where the estimated lift weight, including rigging / hook, etc, is less than 85% of chart capacity, Vendor supplied information (including shipping documents, etc) may be used to determine piece weight, assuming such a weight appears appropriate.

       Where the estimated lift weight, including rigging / hooks etc is greater than 85% of chart capacity, the vendor shall supply a weight certificate, signed by a Registered Engineer.

       Where the estimated lift weight including rigging / hooks etc. exceed 85% of chart capacity, a certificate plus an independent weight audit or a certified Weighbridge Certificate shall be provided.

       Where the estimated lift weight, including rigging / hooks etc. is greater than 85% of chart capacity, the increase in radius over that planned that causes the lift to exceed 100% of chart capacity shall be calculated and included in the lift data.

1.1.2        Multi Crane Lifts

       In the case of multi crane lifts the following deductions to the cranes’ capacity charts shall apply.

• 2 cranes        20%
• 3 cranes        33%
• more than 3 cranes        50%

       However, should this prove impractical due to crane availability etc proposals that fully quantify all loads and the reactions on each crane, shall be submitted for consideration by the Client (which may require liaison with the Statutory Authority). Such proposals shall quantify the technical and operational controls required to safely execute this lift.

       Tailing operations shall be considered as two crane lifts.  However, effects such as decreasing load on the tailing crane, and the diminishing reaction of the tailing crane on the primary crane shall be taken into consideration.  Once the piece is vertical and the tailing crane removed, the lift shall be considered as a single crane lift.

       Multi Crane Lift Authority / Approval

       All multi crane lift studies shall be submitted to the Client, a minimum of seven (7) days prior to the lift for approval.

On receival of the lift study the Client shall review the submission and when satisfied that the information is correct, forward the lift study to the project Insurance Broker.

On receipt of confirmation that insurance cover is in place the Client shall approve and authorise the lift.

Note:  Under no circumstances shall any multi crane lift proceed without the approval of Symmetrical Group and or the Client Representative.

1.1.3        Slings / Shackles

       All slings shall be used at a maximum of 20% of their minimum breaking load. (Ratio 1:5)

       Any sling “broken” over a shackle, hook or other fitting shall have the appropriate efficiency factor applied before the factor of safety is calculated.

       In cases where “rigid” structures are lifted with four or more slings, a slinging method shall be specified that allows equalisation of loads in the sling parts, or some appropriate allowance made in the sling / lug / shackle capacity.

       Where equalisation cannot be verified by relevant standards it shall be assumed that only two (2) slings carry the load.

       Engineer calculations to verify load sharing in four (4) or more slings may be acceptable, but shall require written approval from the Client.  The approval with all engineer calculations, statutory authority approval and other supporting documentation shall be attached and form part of the lift study.

       Current test certificates shall be provided with each lift study for crane hoist and luffing ropes, slings, chains lifting beams, spreaders and other equipment used to lift or support the load during lifting operations.

1.1.4        Lugs / Hardware

       Any lugs, spreaders or other hardware used between the hook and lifted piece shall be designed to an appropriate standard with suitable impact factors included etc.

       The following standards should be acceptable:

• AS 4100
• AIOSC Eighth Edition

       Suggested impact factors are as follows in line with BS 2573:

• For hook loads up to 75 tonnes        20%
• For hook loads from 75 - 100 tonnes        Graded from 20-5%
• For hook loads over 100 tonnes        5%

Engineer’s calculations and N.D.T. results shall be provided for all lifting attachments (lugs, pad eyes spreaders etc.) irrespective of the weight of the load to be lifted.

Speadsheets and lifting beams shall be marked with their gross weights and safe working loads.

       No lug or lifting hardware shall be fixed to any equipment, eg. welding, bolting without the appropriate approval.

1.1.5        Capacity Charts

       Crane manufacturers approved load capacity charts shall be marked up with boom length, radius, boom angle, and capacity and submitted with each rigging study and shall be verified for that particular series of crane.

1.1.6        Centre of Gravity

       Where non-symmetrical loads are to be lifted a sketch depicting the calculated centre of gravity, and the length, angle and loadings of each sling shall be incorporated into each lift study.

1.1.7        Crane Orientation

       Each lift study shall have depicted the crane orientation in relation to the load to be lifted and the quadrants of operation during all phases of the lift.

1.1.8        Activity Plan

       All significant lifts shall include an activity plan as part of the lift study.  The activity plan shall detail all the steps to be taken prior to and during the actual lift to ensure the safe execution of the lift.

       The attached proforma Attachment A shall be used and shall be signed off by the Contractors or Subcontractors Rigging Superintendent / Supervisor  and passed to the Client for verification as each item is verified.

       The Client may also require control checks ie lifting over or in the vicinity of operational plant and shall utilise the Attachment A proforma where required.

1.2        Job Hazard Analysis

All lift studies shall form part of the Job Hazard Analysis, and shall be discussed with all personnel involved in the lift, i.e. supervisors, riggers, crane operators, transport personnel etc. prior to the commencement of the lift.

1.3        Equipment Inspection

In addition to the quarterly inspection and tagging of all lifting and rigging gear, all lifting and rigging gear shall be inspected by a competent person prior to be being used in any significant lift.

A colour coding of quarterly tags shall be consistent with that established for electrical equipment to ensure uniformity.  An example of colour coding and inspection periods follows:

• Jan-Feb-Mar                Red
• Apr-May-June                Green
• July-Aug-Sept                Blue
• Oct-Nov-Dec                Yellow

1.4        Access And Pre-Erection Inspection

Approved safe access, egress and work platforms shall be provided and maintained for the rigging crew involved in the rigging up, positioning and de-rigging of the lift.  This shall consist of one or a combination of the following:

·        ladders

·        scaffolding

·        temporary work platforms

·        crane hoisted work box

Safety harnesses and static lines / inertia reels may be used as a last resort if other means are not practicable.  This equipment must be used and erected in accordance with statutory safety requirements.

Under no circumstances shall any person be exposed to open steelwork or potential falls.

1.5        Exclusion Zones

Prior to the commencement of any significant lift, the Contractor or Subcontractor shall notify (where applicable) all relevant persons who may be impacted or affected by the lift and advise THE CLIENT of any required closure of roads, access ways, work areas etc.  Exclusion zones shall be agreed with THE CLIENT at least seven (7) days prior to implementation.

Exclusion zones shall be established to ensure non essential personnel are kept clear of the lift area.  Exclusion zones shall be established and recognisable by way of solid barricading, flagging and sign posting, or control personnel.  The Exclusion Zone shall be identified, installed and maintained prior to and throughout the lift.  Once the lift is positioned and is undergoing consolidation and deemed safe the Exclusion Zone will be re-established to the immediate area of the lift and all other affected work areas re-opened.

1.6        Communication

Prior to the commencement of any significant lift a communication system shall be established between the crane operator(s) and rigging crews.  This system shall be by radios with a dedicated channel to ensure no outside interference during the lift.

Communication with the transport operator and other designated parties shall be identified any clearly detailed in the Job Hazard Analysis.

2.0 Referenced Forms

F-S-20- Requirements for Significant Lifts        

Date published: 25/07/2013

* -25/07/2013 12:27:06 PM