Asme b30.10 Hooks

Instructivo Fecha Inicio Vigencia : 14.07.
2008
DLB - DIV LOS BRONCES
Versin: 1.0
IS - SIG ISO-OHSAS PNP.DLBISRAC.0009
RAC - 02 Adm. del Riesgo y de los Pgina 1 de 86
Cambios
LIFTING OPERATIONS
Estado Elaborador Revisor Aprobador
Vigente Wilhelm Carlos -- Asesor Senior AFRS
La impresin o copia de este documento constituye una Copia No Controlada. El usuario debe verificar su vigencia
en Documentum.
LIFTING OPERATIONS
TABLE OF CONTENTS
1. SCOPE....................................................................................
2. OBJECTIVE...............................................................................
3. APPLICATION...........................................................................
4. DEFINITIONS...........................................................................
5. REASON FOR INCLUSION........................................................10
6. REQUIREMENTS.....................................................................10
7.1 PLANT AND EQUIPMENT REQUIREMENTS.................................10
1 ELECTRICAL ISOLATION 11
2 OPERABILITY AND FALL PROTECTION 12
3 PHYSICAL LOCKING SYSTEM 13
4 OVERLOAD PROTECTION 14
5 TEMPERATURE CONTROL 15
6 NO INTERUPTION OF OPERATOR 15
7 SUFFICIENT CONTROLS TO PREVENT CRUSHING 16
8 POSITIVE LOCKING SAFETY CATCH 18
9 SWL TO BE CLEARLY MARKED 18
10 LOAD MONITORING AND INDICATION 20
11 COMPLIANCE WITH STANDARDS 22
12 IDENTIFICATION OF CRANE AND LIFTING EQUIPMENT 23
13 MAXIMUM ENVIRONMENTAL CONDITIONS IDENTIFIED BY COMPETENT
PERSON 25
14 COLOUR CODING FOR MAINTENANCE 27
15 LIFTING ONLY FROM DESIGNATED LIFTING POINT 28
16 ALL LIFTING EQUIPMENT TO BE MAINTAINED 30
7.2 SYSTEM AND PROCEDURAL REQUIREMENTS............................31
17 ACCEPTANCE PROCESS FOR ALL LIFTING EQUIPMENT 31
18 LOAD CHARTS AVAILABLE 35
19 ENSURE OPERATORS CAN UNDERSTAND LOAD CHARTS 38
20 PROCEDURE TO ADDRESS USE OF CRANES 38
21 OPERATORS TO HAVE TIME FOR FAMILIARIZATION 45
22 RISK ASSESSMENT 45
23 SIDE LOADING TO BE PREVENTED 51
24 OUTRIGGERS TO BE USED 51
25 CONTROLS TO PREVENT FALLING OBJECTS 52
26 PERSONNEL TO BE LIFTED IN WORK BASKETS ONLY 53
27 NO WORK IN DROP ZONE OF SUSPENDED LOADS 54
28 MODIFICATIONS SUBJECT TO APPROVAL 55
29 PREVENTATIVE MAINTENANCE SYSTEM 56
30 INSPECTION AND TESTING 58
31 PERIODIC INSPECTIONS 59
32 REGISTER TO BE KEPT 60
7.3 PEOPLE REQUIREMENTS.........................................................60
33 SUITABLY QUALIFIED PEOPLE 60
34 ROLES AND RESPONSIBILITIES TO BE DEFINED 62
35 COMPETENCY BASED TRAINING PROGRAMME 64
36 INSPECTIONS BY COMPETENT INSPECTOR 65
37 COMMUNICATION IN COMMON LANGUAGE AND CORRECT SIGNALS 65
AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

Version 01 -26 June 2008 Printed copies are not controlled
Page 2 of 86
LIFTING OPERATIONS
38 SOLO CRANE OPERATORS TRAINED IN SLINGING 68

39 FIT FOR WORK POLICY 68
40 BEHAVIOUR BASED OBSERVATIONS 69
REFERENCES............................................................................... 69
APPENDICES............................................................................... 70
APPENDIX 1: A GUIDE TO LIFTING HAZARDS AND CONTROLS 70
APPENDIX 2: LIFTING EQUIPMENT MAINTENANCE AND INSPECTION 80
1. SCOPE
This guideline refers to the Group-wide implementation of the Anglo Fatal Risk Standard
Lifting Operations and should be read in conjunction with the respective Standard.
The guidelines contained in this document are considered as "highly recommended" and
deviations are to be documented and justified. Full adherence to these guidelines will not be
a factor in determining compliance with the Standards, since alternative methods can be
available if justified on a risk basis.
In case of conflict with requirements of any other Anglo document or guideline, the following
hierarchy will apply:
1. Anglo Safety Way- ASW

2. Anglo Fatal Risk Standards- AFRS
3. AFRS Guidelines
It is important that when implementing Standards the organisation takes cognizance

of and complies with the relevant legal requirements in the country of application.
2. OBJECTIVE
The purpose of this Guideline is to provide guidance and clarity to assist in implementing the
requirements of the Anglo Fatal Risk Standard Lifting Operations, which is intended to
eliminate or minimise the risk of fatalities and injuries arising from the performance of lifting
operations.
This guideline has been developed to provide more detail and clarification for the
implementation of the requirements of the Standard. This should enable sites to be more
aligned with each other on what the boundaries are with regards to meeting the
requirements.
This guideline is by no means exhaustive and will be updated periodically and supported by
good practice sharing. It is not intended as a template for achieving compliance.

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LIFTING OPERATIONS
3. APPLICATION
This Standard applies wherever lifting operations are undertaken. It includes lifts
involving Anglo American owned, hired or contracted cranes and lifting machines
such as mobile, crawler, tower, derrick, portal and pedestal-type equipment (e.g.
cherry pickers), vehicle loading cranes, electric overhead travelling cranes, hoisting
blocks/tackle and monorail cranes. The Standard also applies to lifting equipment
including slings, chains, wire ropes, shackles, pad-eyes, containers, baskets, tuggers,
winches, man-riding winches, jacks, work-belts, harnesses and transfer baskets for
equipment and personnel.
In addition to the manufacturers standard safety features, local statutory

requirements or, in the absence of these, ISO Standards, the minimum safety features
indicated in this Standard shall or should be included.
This Standard applies to all Anglo American Group managed businesses and
operations, including contractors and visitors when involved in controlled activities.
The AFRS Lifting Operations Standard details the requirements for Anglo owned, hired or
contracted cranes and other mechanical lifting equipment to operate on Anglo owned or
managed sites. It includes the planning, resourcing (equipment), training, competency,
operation, monitoring and auditing requirements and responsibilities. Reference is made to
Appendices providing additional information as needed. The standard requires that a system
of work for the use of cranes and lifting equipment is established and maintained.
This is achieved through:

Ensuring all lifting operations have been adequately assessed with regards to their risk
Ensuring all cranes and lifting equipment utilised on a lift are fit for their intended
purposes
Ensuring all personnel involved in the lift have the necessary skills, experience and
competence to safely perform such lifts
Included are cranes such as mobile, crawler, tower, derrick, portal and pedestal-type, vehicle
loading cranes, electric overhead traveling cranes, and monorail cranes or crawl beams. The
Standard also applies to lifting equipment including slings, chains, wire ropes, shackles, pad-
eyes, containers, baskets, tuggers, winches, man-riding winches, chain blocks, and
workbaskets. Slinging of long or heavy material or equipment below conveyances in vertical
mine shafts, and installation or removal of conveyances, are also included as a lifting
operations, requiring the use of winches and performed by a Rigger.
Mine shaft lifting operations

Slinging is the term used for transporting long or heavy equipment down or up mine shafts.
Slinging must be treated as a lifting operation and the requirements of AFRS No 8 Lifting
Operations shall apply.
Installation and removal of conveyances in mine shafts is required from time to time. This
shall be treated as a lifting operation. The requirements of AFRS No 8 Lifting Operations
shall apply.

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LIFTING OPERATIONS
Installation or removal of cages from mine shafts
Pipes prepared for slinging down mine shaft
These operations occur adjacent to open mine shafts, so the requirements of AFRS No 7
Working at Heights shall also be applied.
This guideline does not cover manual lifting operations. Injuries do occur when lifting using
the wrong posture, or lifting heavy items, but this is excluded from the scope of AFRS No 8.
Application Exclusions
This guideline does not cover manual lifting operations. Injuries do occur when lifting using
the wrong posture, or lifting heavy items, but this is excluded from the scope of AFRS No 8,
so the guideline makes no reference to manual lifting.

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LIFTING OPERATIONS
4. DEFINITIONS
Pertinent section in the standard: This Standard applies to all Anglo American Group
managed businesses and operations, including contractors and visitors when
involved in controlled activities.
Controlled Activities/ sites are those where the Group Company has the authority to
determine how to manage the operation.
It does not include monitored or uncontrolled activities.
Monitored Activities are those where Anglo American can exercise some influence but
cannot set Policies and/or comprehensive Control Standards and/or directly supervise and
enforce their application (i.e. contractor and supplier transporting their goods and/or
personnel to or from controlled sites).
Uncontrolled Activities are those where Anglo American does not set or influence Policies
or Control Standards and does not supervise safety performance. These include services
provided by public Companies, activities performed at supplier or manufacturer shops, etc.
Where there is uncertainty over whether the activity is controlled, monitored or uncontrolled,
the matter should be referred to the Safety function for determination.
Other definitions and abbreviations used in this Standard
Note: There are various different terms used for equipment, competencies, and activities in
different countries in which Anglo operates. The definitions below give the term used in
these guidelines, and where relevant, alternative terms that may be used.
Anti two-block cut out means a cut out to prevent damage or injuries due to two solid
blocks or components being pulled or pushed together. The most commonly applied anti
two-block cut out stops the hoist drum on a crane if the hook block is pulled up too close to
the sheave block. Additional anti two-block cut outs may be applied to cut hydraulic power
on a mobile crane if the boom is retracted too close to stops, or if the boom is elevated or
lowered too close to its stops.
1 Note: in South Africa this would generally be described as an interlocked limit switch or an
interlocked trip switch.

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LIFTING OPERATIONS
2
3 Anti two-block devices
4
Anti two-block
devices
5 Competence (Lifting Operations) refers to a persons ability to execute specific

task/s in accordance to a prescribed method or specification for which he/she was trained by
a certified/reputable institution.
Competent person means a person who has the right training and experience to be
regarded as competent under relevant legislation and/or internal regulations.
6
7 Crane means any powered device intended for raising and lowering a load and
moving it horizontally. Mobile cranes, EOT cranes, fork lifts
8 Note: specific equipment included under the general term cranes includes mobile cranes,
EOT cranes, fork lifts, monorail hoists, etc.
9
10 Crane chart rated capacity means the lifting capacity of the crane at a given boom
length, boom angle, radius, outrigger configuration and boom configuration and orientation
(over rear / over front / over side) as defined in accordance with AS 1418 Pt5 and AS2550
and in accordance with the crane manufacturers recommendations.
11
12 Drop zone means the area below a lift into which the lifted item may fall if something
breaks or goes wrong with the lift.
13
14 Dunnage means soft material (usually timber) placed on the ground or on the
structure to temporarily support a load. Dunnage may be used to ensure the load is kept
above the ground to prevent corrosion or moisture damage, or it may be used to cushion
impact during lifting or placing of the load.
15
16 EOT crane means an electric overhead traveling crane.
Note: Portal cranes have a similar action to EOT cranes, but rather than running on elevated
rails they have legs at each side and run on rails at ground level. Portal cranes may also be
referred to as goliath cranes or gantry cranes. Semi-portal cranes (or semi-gantry cranes or
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LIFTING OPERATIONS
semi-goliath cranes) may also be encountered, and are also included within the intent of this
requirement. A semi-portal crane has one side supported on an elevated rail, as for an
ordinary EOT crane, and the other side supported on a leg with the rail at ground level.
External rated capacity lighting refers to clearly visible green, amber and red lights
mounted externally to the crane: green to indicate safe operating range, amber when
approaching maximum rated capacity and red when maximum rated capacity has been
exceeded.
17 Lifting crew are persons working directly with a crane, or other lifting, operation.
Lifting equipment refers to any device which is used or designed to be used directly or
indirectly to lift a load or connect a load to a crane or shaft conveyance, and which does not
form part of a load (e.g. wire rope slings, chain slings, man-made fibre slings, hooks and
fittings, swivels, shackles, eye bolts, rigging screws, wedge sockets, plate clamps and lifting
beams).
Lifting operations refer to any operation using a crane and lifting equipment that involves
the raising and lowering of a load, including the suspension of a load.
18 Lifting plan means a study which reviews a proposed lift with the specific intent of
providing assurance that the lift can be executed in a safe manner. This will always include
at least: a risk assessment; identification of loads and lifting equipment capacities; ground
condition; and identification of the personnel to be involved
19 Note: this may also be referred to as a rigging study or a significant lifting study.
20 Lift complexity types. Three complexities of lift are defined:

21 A Routine lift is a straightforward lift, having no complications and being well within
the capacity of lifting equipment.
22 A Serious lift is a lift that has additional risks and aspects requiring specific
consideration.
23 A Critical lift is any lift in which there are significant complexities that require specific
consideration by a competent person to ensure safety of the lift.
24 Mobile Crane means a crane mounted on a mobile chassis specifically designed for
that crane.
25 Note: this is sometimes more fully referred to as a mobile truck mounted crane.
26 Pad-eye means a steel plate or bracket with a hole intended for attachment of lifting
tackle to an item to be lifted. It may be bolted or welded to the item to be lifted.
27 Note: this is also referred to as a lifting lug.
28 Register means a record of all important documentation related to each item of lifting
equipment used on the site.
29 Note: this is also referred to as a logbook.

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LIFTING OPERATIONS
30 Rigger is the competent person in charge of lifting operations. The Rigger is a

person empowered to apply slinging techniques, including the selection and inspection of
lifting accessories and directing the Crane Operator in the movement of the load, including
when the load is out of view of the Crane Operator.
31 Note: a rigger may also be known as a banksman or a dogger.
32 Risk analysis is a formal, rational process of giving consideration to all the risks
potentially associated with a particular job or project, and determining what actions are
necessary in order to reduce any risks assessed as being too high.
33 Note: a similar process, frequently done in Australia is a job safety analysis (JSA).
34 Slinging means the process of lowering or raising long material or heavy equipment
in a vertical mineshaft either below a mine shaft conveyance or attached directly to the lower
end of the hoist rope.
35 Spotter means a person appointed to ensure that cranes working in the vicinity of
overhead electric power lines are not in danger of electrical contact
36 Note: may also be referred to as a signaller.
37 SWL means the Safe Working Load for a crane or other lifting equipment
38 Note: three equivalent terms used in some countries are WLL working load limit or MRC
maximum rated capacity or MML maximum mass load.
39 Tag line means a line attached to a load during lifting for the purpose of steadying the
load against swinging or rotating
40 Note: this may also be referred to as a guide line.
41 Tugger means a mechanical lever device, usually attached to a steel wire rope,
which can be used to exert a high pulling load on the rope
42 Note: this may also be referred to as a tirfor.
43 VLC means a crane that is mounted on a vehicle and is used to load and unload and
do other tasks within the operating parameters of that crane. A Vehicle Loading Crane must
not be confused with a Mobile Truck Mounted Crane which refers to Mobile Cranes.
44 Note: this may also be referred to as a vehicle mounted crane.
45 Wind Vane Mode means the method of parking a crane to ensure it will have
minimum resistance to weather conditions prevalent during the period the crane is parked
and unattended. This refers predominantly to tower cranes and port cranes that are able to
slew. When parked, these cranes should not be locked in a fixed parking position, so that
under high wind conditions they can swing into the position that minimizes the total wind load
on the crane.
46 Work basket refers to a personnel carrying device designed to be suspended from a

crane or other lifting machine.

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47 Note: this may also be referred to as a work box, a man cage, a boatswains chair or a
personal transfer basket.
5. REASON FOR INCLUSION
A significant proportion of our fatal and significant incidents have occurred in the
course of lifting and crane operations. Identified causes and contributing factors
include:
(a) lack of job planning and hazard assessment

It is frequently found that lifting studies contain inadequate risk assessments. Risk
assessments presented tend to only cover the actual lifting equipment, but not the
ground conditions, weather conditions, or other factors.
(b) incorrect selection of cranes and lifting equipment for the task
A common error is use of incorrect anchor points when tuggers, chain blocks or
winches are used for lifting operations.
(c) inadequate knowledge of lifting operations by personnel involved
(d) inadequate inspection, maintenance, tagging and storage of cranes and lifting
equipment
(e) lack of training in correct use of lifting equipment
(f) lack of competence in lifting operations
(g) incorrect use of cranes and lifting equipment, including poor practices such as
out-of-vertical loading and over-loading
(h) poor recognition of unsafe conditions, including environmental conditions
(i) operation of cranes and lifting equipment with safety and warning devices
overridden, inoperable or illegible
(j) incorrect design of cranes and lifting equipment
It is commonly found that mine workers have made up a tripod, A frame, or other
makeshift structure for the purpose of lifting some equipment. Often this makeshift
lifting equipment has inadequate strength for the lifting operation being performed.
6. REQUIREMENTS
This section is structured using exactly the same numbering sequence as the Anglo Fatal
Risk Standard document. Each requirement is repeated in bold font, followed by a statement
of intent. This is followed by discussion and clarification of that particular requirement with
reference to other related requirements, Appendices, Communities of Practice, and other
relevant documents. Appendices are used to reduce the size of this document, and allow
more efficient continuous improvement.
Detail has been added to some, but not all requirements, as some sections were deemed self
explanatory. Links to associated reference material has been given throughout this document.
The main source of reference material and examples of leading practice can be found on the
Anglo Fatal Risk Standard Quickplace.

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7.1 PLANT AND EQUIPMENT REQUIREMENTS
ELECTRICAL ISOLATION
All electrical cranes shall have power supply isolation points capable of being
positively locked out and isolated.
Intent: All energy sources for all cranes and other powered lifting equipment (e.g. air hoists)
must have positive isolation capability to prevent inadvertent operation of the crane or lifting
systems or components (inclusive of mobile cranes and vehicle mounted cranes). The intent
is also to comply to Standard 2: Surface Mobile Equipment and Standard 6: Isolation
(where applicable). Other energy sources such as braking of hoist drums and wheels, air
winches, etc. must be considered.
Note: Although this requirement is aimed primarily at electrical cranes, some mobile cranes
have multiple isolation points to enable the isolation of any potential energy such as the
power unit, hydraulics, freefall mechanism levers and compressed air.
Common Hazard: Although there are many examples of lockable isolation points for
electrical cranes, the intent is that power is removed and access is controlled.
Where the removal of power does not guarantee the total immobilisation of the crane,
alternative measures must be implemented to ensure the safety of the person/s that intend to
work on the unit. Movement of the whole crane or components of the crane may result from
gravity, wind, or other causes.
Typical electrical switch boxes for cranes
Leading Practice:
Ensure that all access to monorail cranes, electric overhead traveling cranes or any
other type of cranes accessible by a ladder system, is locked out and controlled.
Ensure that all access to walkways along overhead crane rail gantries is locked out
and controlled, unless the walkway is separated from the path of the cranes by
adequate guardrails (see Anglo Fatal Risk Standard No 7, Working at Heights for
information on adequate guardrails).

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LIFTING OPERATIONS
Warning and lock out on access to overhead cranes
Fit air drain valve to cranes and air powered lifting equipment to allow potential
compressed air to be isolated.
Lower hooks to the ground prior to working on the winch brake system to eliminate
the potential energy risk.
1
OPERABILITY AND FALL PROTECTION
Cranes shall have their operability assessed against site conditions and workforce
(e.g. language for the controls) and have fall protection systems provided for people
in charge of their operation, maintenance and inspection.
Intent: The operators and/or maintainers of the crane must have:
Unrestricted and safe access to the seating position

Comfortable seating for prolonged periods of operation
Clear and unrestricted visibility for the vision field of normal and expected operation
Comfortable reach to controls
Safe and practical access to perform pre-start checks, lubrication checks
maintenance checks and any other routine and non-routine work that may be
required in the normal operation of the machine.
Safe access and egress in terms of working at heights, slips trips and falls.
Note:
Refer to Standard 2: Surface Mobile Equipment and Standard 7: Working at

Heights for additional requirements and guidelines for access to machine and
inspection points and where working above 2 meters from a safe working level or
ground level is required.
Working decks that are below 2 meters should be assessed to identify the risk to
persons working at that level.
Common Hazard: When safe access is not fixed and persons are required to make use of
other means of temporary access, the risk is that at night or away from the workshop,
persons will take a shortcut due to unavailability of these temporary means resulting in injury
or fatality exposure.

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LIFTING OPERATIONS
Access ladder extended Access ladder retracted
Leading Practice:
Provide safe means of access to Operators cabin or platform.

Provide fall protection to all other raised work areas where practical.
Guardrails on mobile crane Anchor point for harness on EOH crane
PHYSICAL LOCKING SYSTEM
Cranes shall not be used without a physical locking system that disables and isolates
their free-fall capability.
Intent: Cranes equipped with freefall devices require the ability for these devices to be
positively isolated to stop inadvertent free fall of the hook blocks. This isolation shall be in
place unless a particular task may require the use of free fall, in which case a risk
assessment is required and appropriate site authorisation obtained prior to removal of the
locking mechanism to enable the device to operate as intended.
Common Hazard: On some cranes these levers are in an exposed position where
accidental activation is possible.

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LIFTING OPERATIONS
Isolation of free fall levers
OVERLOAD PROTECTION
Electric overhead traveling and portal cranes should have overload protection.
Intent: Overload protection is intended to prevent a crane from lifting a load more than the
SWL thus placing a mechanical, electrical or other risk to equipment, load and personnel.
The overload protection should stop the lifting of the load yet allow the safe removal of the
load. Whilst this requirement refers specifically to electrical overhead cranes and portal
cranes, any other types of cranes and lifting devices where practical, should not be excluded.
In the case of manual winches such as chain blocks, a portable load cell may be required to
confirm the load being applied.
Some types of overload protection
TEMPERATURE CONTROL

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LIFTING OPERATIONS
Crane cabins should be air-conditioned or heated in accordance with environmental

conditions.
Intent: The intent is to enable cabins to be closed at all times.
The reason for this inclusion is to stem the effects of fatigue in both hot and cold climates. Be
aware of placement of air conditioning units to allow for safe access.
This requirement is also to ensure a positive cabin pressure with filtered air to prevent
ingress of atmospheric contaminants. Air conditioning and heating allows the cabin to remain
closed which will also have positive effect on reducing operator exposure to unacceptable
noise levels.
Note: Be aware of potential fogging issues, particular in underground situations, which may
affect operator visibility.
Common Hazard: The exposure time of the operator to heat or cold is an important factor in
the risk assessment to determine the need for air conditioners or heaters. Even non extreme
environmental factors could have a huge effect on the judgment of the operator when
executing lifting operations. Positioning of the air conditioning units must be carefully planned
to ensure that a working at heights risk is not present when servicing this unit.
Safe access to air-

Air-conditioning unit
conditioning unit
on cab
Crane cabin with air conditioning unit
NO INTERUPTION OF OPERATOR
All crane cabins shall have signs to warn against interruption of the operator.
Intent: To prevent distractions and loss of concentration of the crane or lifting equipment
Operator.
This requirement shall also be applied whilst slinging operations in mine shafts are being
undertaken. The Winder Driver shall not be interrupted.
Note: Ensure that the signage is sized and placed correctly as to enable persons from all
possible approach angles to see.

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Leading Practice:
Where cranes are controlled via a pennant or radio transmitter, it is Leading Practice to
have positive identification of the operator by wearing a high visibility jacket containing
the words Do not interfere with me while I am busy with a lift This method will also
aid easy identification of the person operating the crane in particularly busy areas.
When complex lifts, or slinging operations in mine shafts, are being performed, a Person
In Charge (PIC) should be appointed who should be clearly identifiable via a special
jacket or insignia. The PIC should be a competent Rigger.
SUFFICIENT CONTROLS TO PREVENT CRUSHING
Vehicle loading cranes shall have sufficient engineering controls to prevent the
operator from being crushed during lifting operations.
Intent: To prevent the operator from being crushed between the jib and the operator station.
Where these units are equipped with multiple controls, interlocks should be considered to
ensure that the unit is operated from the safe side at all times if operated manually.
Positioning of personnel involved in a lifting operation is a key issue for all crane operations.
Common Hazard: Do not rely on operators and their experience or on procedures to work
safely with these types of cranes. Fatalities world wide involved highly experienced operators
with access to good procedures.
Leading Practice:
It is possible to use remote controls as an alternative to ensure the Operator is

separated from the danger zone. There is a risk however of the Operator placing
himself in other danger situations if not careful due to the possibility of being in any
position when operating with this remote control unit.
A procedure should be in place to train personnel to avoid these hazards as a remote

control is not a guarantee that lifting will be executed safely.

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LIFTING OPERATIONS
POSITIVE LOCKING SAFETY CATCH
All crane hooks shall be fitted with a positive locking safety catch.
Intent: The safety catch or safety clip is designed and positioned in such a way as to
prevent the unintentional dislodgement of the suspended load from the hook. These units are
exposed to severe punishment in the normal line of duty due to the hooks being bumped and
dragged in normal operations thus sustaining heavy wear and tear. Maintenance of these
units should be scheduled to ensure that they are always in good working order.
Note: Should the sling attached to the hook be exposed to a rolling or twisting action, it is
possible for detachment (roll out) to occur and particular attention should be given to this
danger when lifting using this type of attachment.
Leading Practice: A large shackle should be used to connect the sling to the hook. This
shackle should be of adequate diameter to physically stop the safety catch from opening and
causing roll out.
Typical hooks with safety catches
SWL TO BE CLEARLY MARKED
The safe working load (SWL) shall be clearly identified and marked on all cranes and
relevant lifting equipment and shall not be exceeded.
Intent: To ensure all personnel involved in lifting operations are aware of the Safe Working
Load of a particular lifting device. This is to prevent equipment being overloaded and for use
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in planning of lifting tasks. The mass of all components suspended from a hook, when added
together, must not exceed the SWL. This includes shackles, slings, lifting beams, and the
item being lifted. The mass of all components must be known prior to commencing any lift.
Note: The only time when the SWL is exceeded on purpose, is when statutory load testing is
undertaken by an appropriately qualified person/s undertaking such testing.
Note: It is important to note that SWL is known by different terms in different countries, and
may be noted differently on equipment supplied from different countries. The terms WLL
(working load limit) and MRC (maximum rated capacity) are equivalent terms to SWL. The
most common term used in various countries is listed below:
Country Short term Long term Standards

Australia (since 2002) MRC Maximum Rated Capacity AS 1418
Australia (before 2002) WLL Working load Limit
South Africa SWL Safe Working Load
UK SWL Safe Working Load
USA WLL Working Load Limit
Common Hazard: SWL not known. This is particularly often the case on monorail hoist
beams which have been repainted, and on tripods and A frames made up by mine
personnel. Safe working load of equipment and tackle being used must be known and used
in the calculation for a safe lift. These limits may never be exceeded
The SWL of all hoisting equipment and rigging hardware are based on almost ideal
conditions seldom achieved in the field. It is therefore important to recognise the factors such
as wear, improper sling angle, point loading and centre of gravity that can affect the rated
safe working loads of equipment and hardware.
EOT cranes with SWL and Equipment Numbers
Mobile crane with SWL clearly marked EOT crane with MRC and serial no.

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LIFTING OPERATIONS
4000 kg SWL rope block Crawl beam with SWL 5000 kg clearly marked
LOAD MONITORING AND INDICATION
For cranes, the following should be made available:

(a) load cells
(b) load moment indicators
(c) external rated capacity lighting
(d) stability monitoring devices (to prevent overturning)
Intent: To enable all persons involved in or affected by a lifting operation to ascertain that a
crane does not operate outside of its safe working capacity.
The table below gives the requirements as shall (i.e. compulsory), should (i.e. to be applied
wherever practicable see section Requirements above) or not applicable.
Load Moment External Rated Anti two-block

Crane Type Load Cell
Indicator Capacity Lighting cut out
All Mobile Slew Cranes Shall Shall Shall Shall

Pedestal and Tower Shall Shall Should Shall
Electric Overhead Traveling Not Applicable Should Should Shall
Mobile Pick & Carry Should Should Should Should

Vehicle Loading Crane Should Should Should Shall
Portal Not Applicable Should Should Shall
(Note: the anti two-block cut out referred here is to prevent the hook block being pulled up against the
sheave block, possibly resulting in rope break. Anti two-block cut outs on retraction and luffing of the
boom should be used where relevant and practicable.)

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Total load lifted

EOT Crane equipped with load cells for all hoisting mechanisms
Typical load cell arrangement on an overhead crane
Note: External Rated Capacity Lighting should be installed as follows:

A set of green, amber and red lights is installed in a visible place on the crane so as
to be highly visible to persons involved or affected by lifting operations.
The lights indicate green (<90% of crane chart rated capacity), amber (90% 100%
of crane chart rated capacity) and red (>100% crane chart rated capacity) and are
suggested to be of a robust digital LED type.
A red light shall also be activated when the cranes moment indicator over-ride switch
is activated or disabled or the crane is put in rigging mode to pack the crane up and
place the boom in its cradle.
The green and amber units should be of the continuous type lighting, not flashing or
rotating. The red light shall be of a flashing type and is activated when the cranes
moment indicator over-ride switch is activated or disabled or the crane is put in
rigging mode to pack the crane up and place the boom in its cradle.

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Green 00% to 90% (Safe) Amber 90% to 100% (Caution)
Red crane chart rated capacity

exceeded (Danger)
Examples of external rated capacity lighting
Leading Practice is to also have an audible alarm that activates to alert the crane Operator
and Crew when the crane chart rated capacity is exceeded. The audible alarm is activated
when the cranes moment indicator over-ride switch is activated or disabled but will not be
activated when the crane is put in rigging mode to pack the crane up and place the boom in
its cradle.
Note: There is evidence that continuous exposure at close range to flashing or rotating lights
can create unsafe working conditions.
LED digital type lights are favoured for this type of application because they have proven to
be more robust than bulb type lights. This could reduce potential crane downtime.
COMPLIANCE WITH STANDARDS
All cranes and lifting equipment shall comply with the requirements of the relevant
approved design standard. The minimum acceptable design standard shall be the
relevant ISO Standard. In countries where the requirements of the relevant national
standard exceed the requirements of the ISO Standard, the national standard shall
apply.
Intent: To ensure that all equipment used in lifting operations is fit for purpose. Due to the
many standards of design and differences in interpretation, it is very important that a
recognised relevant and approved design standard is followed. Where these standards are
not present, the relevant ISO standard shall apply.
Leading Practice:
1. Ensure that procurement of lifting tackle is very clearly specified and preferred
Suppliers and products established via a technical specification.
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LIFTING OPERATIONS
2. Ensure that manufacturing of lifting tackle is done under proper quality control. The
more stringent of AA STD 100 shall apply.
1 Poor Quality Hook

2
IDENTIFICATION OF CRANE AND LIFTING EQUIPMENT
All cranes and lifting equipment shall be identifiable with a unique identity code and
its rated capacity should be visibly displayed.
Intent: For all equipment involved in lifting operations to be issued with an identify number
and documented on a register to facilitate the inspection program and monitoring
compliance. To ensure that users know the safe strength of all equipment, and that it is
structurally sound and fit for purpose.
Note: In the past, colour coding has been used on some sites in South Africa and various
other countries to designate the SWL of slings and other lifting tackle. This practice must
no longer be used, and all personnel must be trained accordingly. The actual SWL shall
be clearly marked, either by being painted on or hard-stamped on a tag.
Cranes
Cranes should be clearly marked with their identity number and their SWL.
Clear and reasonable size
Typical marking of Crane

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LIFTING OPERATIONS
Mine Shaft conveyances

Mine shaft conveyances shall be
clearly and permanently marked with
their serial number and the maximum
slinging load permitted.
Typical marking of Mine Shaft

Conveyance
Slings
Slings shall be marked with an identification number and their SWL. This marking should be
on a flat ferrule or permanent attached ring.
Typical marking of Sling
In some cases the SWL for use of the sling at an angle of 45

degrees is also marked, but this is not specifically required.
However, ensure that everyone using slings is aware that their
capacity is reduced when used at an angle, and knows how to
evaluate this reduced capacity.
The reduced capacity of slings can be evaluated using the

formula:
SWL at angle SWL vertical SIN( )
Remote Control Units

Cranes may be operated from a cabin, using a pendant or using a remote control unit. The
use of remote control units has unique hazards associated with it, because the remote
control units are not physically linked to the crane. Crane remote control units generally
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LIFTING OPERATIONS
utilize unlicensed frequencies, with frequency hopping and encryption to ensure that there is
no interference from other radio signals.
Each site shall ensure that a procedure is in place covering storage and use of the remote
control units.
Leading practice: Remote control units must be clearly marked with the identification
number of the crane they control, and they must be kept in a locked cabinet, for which only
the designated Operator has a key.
MAXIMUM ENVIRONMENTAL CONDITIONS IDENTIFIED BY COMPETENT PERSON
A competent person shall determine the maximum environmental conditions under

which cranes and lifting equipment can be used safely. Except in the event of an
emergency, cranes and lifting equipment shall not be put into service if the maximum
environmental conditions are exceeded. Risks shall be assessed in emergency
situations.
Intent: To ensure that personnel involved or affected by lifting operations are not placed at
risk from operating cranes in adverse weather conditions such as high winds, rough seas,
lightening, heavy rains, poor ground conditions, etc.
Note:
The environmental hazards described here are indicative. They should not be regarded as a
comprehensive list. There may be additional environmental conditions specific to a particular
site that must be considered.
Common Environmental Hazards include:
1. Wind
Never carry out any hoisting or rigging operations when winds create hazards for workers,
the general public, or property. A swinging load cause additional hazards, increases the size
of the drop zone, and makes accurate placement very difficult.
Assess load size and shape to determine whether high winds may cause problems. In
particular, avoid handling loads that present large wind resistance surfaces. Even though the
weight of the load is within the normal capacity of the equipment, height or gusting winds
may prevent proper control during the lift.
Wind loading can be critical to how the load is rigged, lifted and landed with consequences
for the safety of everyone involved.
Wind noise must be considered when using radio communication. All movement must stop
when communication is lost or not clear.

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LIFTING OPERATIONS
Centred
crane boom
m Load swinging
well downwind of
centred boom
Large drop zone
Load pushed off centre in a wind that is beyond the recommended speed. There is a danger
that accurate placing cannot be done, and the drop zone is significantly larger
Note: Cranes should be fitted with an anemometer for wind speed detection. (Australian
Standard for maximum wind speed during lifting operations is 10 m/s or 36 km/hr).
Typical wind speed measurement unit on mobile crane
2. Visibility
When the visibility of crane Operators, Riggers and Crew is impaired by snow, fog, rain, poor
light, dust or any other factor, strict supervision must be enforced and the operations must be
stopped if the risk is increased.
3. Temperature
At sub-freezing temperatures steel components may become brittle. Supervision must
ensure that no part of the hoisting device or tackle is shock loaded or impacted upon, since
catastrophic brittle fracture of the steel may result.
Electronic equipment may malfunction at very low temperature, or very high temperature.
Load indicators, anti two-block cut out devices and communications equipment shall all be
rated for the temperature ranges typically encountered on the particular site.
At high ambient temperature hydraulic oil pressure, motor performance and braking
efficiency may be adversely affected. These all need to be considered in the lifting plan
calculations.
4. Lightning
Cranes, with their tall steel booms or towers are prone to lightning strikes during electrical
storms, which could cause injury or fatalities to personnel and/or damage to the crane.
It is considered best practice to earth cranes as an additional control against electrical

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hazards.
5. Waterlogged, Muddy or Sandy Ground

Following prolonged rain, or on poorly drained sites, ground may become waterlogged, or
muddy. Ground may also be dry and sandy. Where any doubt exists in regard to the ability
of the ground to resist the bearing pressure below crane outriggers, a registered Professional
Engineer or other competent person must approve the use of the ground for the lift.
COLOUR CODING FOR MAINTENANCE
Items of lifting equipment that are subject to wear and frequent replacement (e.g.
slings, shackles, pad-eyes, shipping and handling baskets) or are used to transport
equipment to and from sites shall be colour-coded to confirm compliance with
inspection requirements.
Intent: Colour coding allows quick visual identification to confirm that lifting equipment
covered under this requirement has undergone specific periodic inspections as per the colour
code for the present period.
Leading Practice is to include the year of inspection on the colour coding tag to ensure that
the potential is eliminated where equipment might have not been inspected for twelve
months.
Pad-eye colour coded as per current Typical colour coding information board and tags
lifting equipment standard per site

Colour coding on fibre slings shall not be used due to
Detrimental chemical effect of paint on fibre strength
Notes:
(i) South African Sites
Many sites in South Africa (and some other countries) have in the past
used colour coding to identify the SWL of slings and other lifting tackle.
With the introduction of this Standard, this practice must be discontinued.
It is very important that as a matter of urgency, sites in South Africa (and
elsewhere) where colour coding has in the past been used for identifying

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the SWL of slings and other lifting tackle, must plan and implement a programme to ensure:
(a)
Re-training of personnel in accordance with this new practice.
(b)
Removing the old colour coding, and replacing it with the new maintenance
schedule colour coding. To avoid confusion, and ensure a safe transition, it may be
worthwhile to consider complete removal of all colour coding for a period of a few
years, and rely solely on serial numbers and the logbook for compliance with the
necessary maintenance schedule.
This programme requires careful risk assessment and implementation to ensure a safe,
simple, trouble-free transition to the new system.
(ii) The colour coding system does not authorize unlicensed users to use the equipment,
nor does it negate the requirement for an inspection prior to use. It merely confirms
that the device is registered and was fit for purpose at the last periodic inspection.
LIFTING ONLY FROM DESIGNATED LIFTING POINT
Lifting by the use of a block and tackle, for example, shall only be done from
designated lifting points or be authorized by a competent person.
Intent: When lifting heavy loads it is imperative that lifting equipment is properly anchored, to
sufficiently strong structural supports. The intent of this requirement is to ensure that no
injuries or fatalities occur as a result of the failure or collapse of structural supports to which
lifting tackle is attached.
Leading Practice:
(i) All designated lifting points should be marked with the SWL. Alternatively, the SWL of
designated lifting points should be clearly shown on drawings.
(ii) Designated lifting points should be provided directly above equipment that may need
to be removed for maintenance, or directly above the lifting position.
(iii) Designated lifting points should be maintained in good condition.
Common Errors:
(i) Lifting tackle is attached to inadequate structural members. Light roof trusses,
bracing members, light posts, walkway grating and guardrails are not adequate
attachment points for lifting tackle.
Grating damaged
by slings
Walkway grating may present

a convenient place to attach
slings, but it is not strong
enough.

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LIFTING OPERATIONS
(ii) Lifting tackle is attached to lifting points that are not above the lifting point. This leads
to the load swinging sideways as soon as it is lifted off its supports. This can result in
injury to personnel, or damage to equipment.
(iii) A frames are made up on site, without proper design or approval by registered
Professional Engineers. The most common error is that A frames do not have
adequate bracing, allowing them to sway sideways resulting in collapse.

A frame made up on site. A frame has leaned
against the wall, but if it had leaned the other way it
would have fallen over.
A frame properly
No SWLdesigned. A frame
noted because supports
lifting
load safely. added by site. Lifting from angle
bracing has damaged bracing.
hangers
(iv) SWL is not indicated at the lifting point. This may occur because the lifting point has
not been properly designed for a particular SWL. It may occur because repainting of
the steelwork has obliterated it. It may occur because there is only one item that may
need to be lifted, so that it does not seem necessary to note it.
(v) Lifting lugs are welded to structural steelwork on site, without design or approval by
registered Professional Engineer. This is commonly done when no provision has
been made for lifting of equipment such as pipes, electrical motors, pumps, liner
plates, and when the constraints of the location prevent the use of mobile cranes or
forklifts.
(vi) Lifting beams have no end stops, allowing hoists or trolleys to fall off the end during
lifting operations.

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LIFTING OPERATIONS
This beam has no end

stop. A lifting trolley
will come off the end
DO:

(i) Check that the load to be lifted is within the SWL of the designated lifting
point to be used. If no SWL is shown, find out what the SWL is before proceeding.
(ii) Inspect the designated lifting point for signs of deterioration, such as
corrosion, cracks, wear, or damage.
(iii) Ensure that the lifting tackle cannot slip off the designated lifting point.
DONT:
(iv) Weld, or attach lifting equipment to any structural steelwork just because it
happens to be convenient.
(v) Use any designated lifting point if it has deteriorated or been damaged.
TO BE DONE:
(vi) All locations at which lifting is required, but cannot be done with cranes,
must be identified.
(vii) Where no designated lifting points exist at identified locations, a
competent person must be appointed to specify the work required to install designated
lifting points. The designated lifting points must then be installed.
ALL LIFTING EQUIPMENT TO BE MAINTAINED
All lifting equipment shall be maintained in good condition with inspection

maintenance log books. Proof-loading shall be undertaken as appropriate.
Intent: To ensure that all lifting equipment, including cranes and other lifting devices, as well
lifting tackle including shackles, slings, etc, remains in good condition, so that it is at all times
adequate to carry the loads it is certified to carry.
The following inspections shall be done:

Daily
Inspections shall be carried out by the Operator cranes or the user of other
equipment.
Inspections of cranes shall be recorded in an equipment logbook.
Periodically
Inspections shall be carried out by a competent person.
Inspections shall be carried out at intervals as specified by legislation, or by the
equipment Manufacturer. These inspections are usually required at intervals of 3
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LIFTING OPERATIONS
months to 6 months, or after a specified number of hours of machine operation.

Inspections of cranes shall be recorded in an equipment logbook.
Annually
Inspections shall be carried out by a testing and inspection authority.
Load testing of cranes is generally required annually.
Load test certificates shall be kept with the crane records.
Special
Inspections shall be carried out by a competent person.
Structural components of cranes are generally required to be comprehensively
inspected at intervals of about 5 to 10 years, or after 5 000 to 10 000 hours of
operation.
Following any accident, overloading event, or other suspected damage lifting
equipment shall be inspected, and tested if necessary.
More detailed information about the inspection requirements for the various items of lifting
equipment is provided in Appendix 2.
DO:
(i) Daily inspect all lifting equipment.
(ii) Check that all equipment used has been properly inspected and tested.
(iii) Discard damaged equipment until it has been properly repaired and certified by a
competent person to be fit for use.
DONT:
(iv) Use damaged equipment.
TO BE DONE:
(v) Make an inventory of all lifting equipment, and ensure that the inspection and
testing requirements are clearly indicated in the inventory.
(vi) Ensure that all relevant lifting equipment has a logbook, and that all inspection
and testing requirements are entered in the logbook.
7.2 SYSTEM AND PROCEDURAL REQUIREMENTS
ACCEPTANCE PROCESS FOR ALL LIFTING EQUIPMENT
A formal selection and acceptance process based on risk assessment shall be in

place for all new (to site) and modified lifting equipment, taking into account the
cranes various safety features and cabin ergonomics, prior to commencement of
work.
Intent: This is to ensure that all new or modified lifting equipment is fit for purpose, meets the
appropriate design standards and that any modifications are approved by the original
equipment manufacturer or equivalent, as well as all the requirements of the lifting operations
Standard.

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LIFTING OPERATIONS
Identifying the different crane types
1
2 Mobile Rough Terrain Cranes (Mobile Slew Cranes)

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LIFTING OPERATIONS
1 Mobile Truck Mounted Cranes (Mobile Slew Cranes)

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LIFTING OPERATIONS
1 Crawler Cranes (Mobile Slew Cranes)
1 Pedestal or Tower Cranes

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LIFTING OPERATIONS
Vehicle Mounted (or Vehicle Loading) Cranes
LOAD CHARTS AVAILABLE
Manufacturers crane and lifting equipment operating instructions and load charts
shall be available to the crane and lifting equipment operator. These should be in the
language of the country in which the lifting equipment is being used.
Intent: This is to ensure that crane and lifting equipment Operators have access to legible
operations manuals and load charts that the Operator can understand, to facilitate safe
operation and use of lifting equipment.
Note: Always only use the load charts provided for the specific crane or other lifting
equipment being used.

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LIFTING OPERATIONS
Typical Mobile Crane Radius Chart

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LIFTING OPERATIONS
Typical Mobile Crane Load Chart

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LIFTING OPERATIONS
ENSURE OPERATORS CAN UNDERSTAND LOAD CHARTS
Where crane and lifting equipment operators are not conversant with the language of
the country, provisions shall be made to ensure that the operators can understand the
operating manuals and load charts.
Intent: This is to ensure that crane and lifting equipment Operators can understand load
charts and manuals to facilitate safe operation and use of lifting equipment.
Reason: Some of the Anglo American Group operations are located in countries where the
main language is other than English. In other countries where the Anglo American Group
has operations, although English may be considered to be the main language of business, it
is not the home language of all the people (see the chart giving the language breakdown of
South Africa). This is relevant for permanent Operators as well as contractor Operators.
PROCEDURE TO ADDRESS USE OF CRANES
A procedure shall be in place to address:
(a) that the load and reach do not exceed the capacity of the lifting equipment
(b) lifting operations when the arcs of operation of two or more cranes can
overlap*
(c) stationary multiple crane lifting operations*
(d) that pickup and carry operations using multiple mobile cranes is prevented
(e) the danger to lifting operations when adverse weather conditions are present
or imminent (e.g. electrical storm, high winds and sea state)
(f) the safety of personnel when cranes and lifting equipment are operating in
the proximity of live electrical conductors*
(g) lifting operations when lifting near or over unprotected plant, equipment or
services, including live process or hydrocarbon processes*
(h) the effective hand-over, from one operator to another, of cranes with complex
boom, jib or tower configurations
(i) availability and use of check-lists for pre- and post-operational inspections
* Detailed lifting plans are required for these procedures and shall be approved by
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LIFTING OPERATIONS
a competent supervisor. Co-ordination meetings shall be held prior to such lifts to

ensure all personnel understand how they are to be executed.
Note: Detailed lifting plans are required for points above marked * and shall be
approved by a competent supervisor. Safety meetings shall be held prior to such lifts to
ensure all personnel understand how it is to be executed.
Each of items (a) to (i) is dealt with individually below.
(a) The procedure shall address that the load and reach do not exceed the capacity
of the lifting equipment
Intent: To ensure that lifting equipment is used within its capabilities.
The mass of items to be lifted shall be known and the maximum radius of the lift shall be
known. These can be established by calculation or measurement, as appropriate.
(b) The procedure shall address lifting operations when the arcs of operation of
two or more cranes can overlap*
Intent: To ensure that procedures are in place and followed where the potential exist of
conflicting arcs of different cranes. Measurements must be done and controls put in
place to ensure that the cranes can safely work within overlapping work space.
Note: This is also applicable to areas where two or more cranes (typically EOT cranes)
have potential to conflicting with other types of cranes such as service cranes.
Overlapping of arcs of various cranes must be well managed
(c) The procedure shall address stationary multiple crane lifting operations*
Intent: To ensure that a lifting plan is developed that takes into account all the risks
when two or more cranes are involved in a common lift.

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LIFTING OPERATIONS
Multiple crane lifts must be well managed
(d) The procedure shall address that pickup and carry operations using multiple
mobile cranes is prevented
Intent: To ensure that the lifting plan does not, at any time allow loads to be carried by
more than one crane. Where attempts are made to carry loads using two or more
cranes, the distribution of loads becomes uncertain and uncontrollable due to
unevenness of the ground, movement of the cranes without outriggers, etc. This
makes any carrying of loads with multiple cranes a dangerous operation, which must
thus not be contemplated.
If loads need to be moved, but cannot be safely moved by a single crane, they shall be
loaded onto a trailer or low-bed transporter to be moved.
(Note: Carry here means that the cranes are moving in order to move the load to a new
location. This does not prevent Lifting and luffing or slewing to move the load while the
cranes are stationary).
(e) The procedure shall address the danger to lifting operations when adverse
weather conditions are present or imminent (e.g. electrical storm, high winds and sea
state)
Intent: To ensure that the lifting plan includes all facets of weather interference and the
negative effect and risks on lifting operations at that time. The plan should specifically
define the course of action to be taken in the event of adverse or extreme weather.
Typically the greatest risk will be to supply boat to oilrig transfers due to rough seas
causing uncontrolled movement of the supply boat. The course of action may be to
abort the delivery and return to shore, it may be to wait for improved sea conditions, or
there may be other options.

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LIFTING OPERATIONS
Supply boat movement on rough seas
There are also risks to all crane lifting operations associated with rain, dust or wind.
The course of action may be to lower the load to the ground, it may be to return the
load to its transporter, or some other action.
(f) The procedure shall address the safety of personnel when cranes and lifting
equipment are operating in the proximity of live electrical conductors*
Intent: To ensure that personnel and equipment are not harmed by electrocution or
electrical current, when working in the vicinity of live electrical conductors or overhead
power lines.
Example 1
The following extract from a guideline compiled by the Construction Safety Association
of Ontario, is a good example of best practice to deal with the risk associated with
working in close proximity to live electrical conductors.
Electrical Contract. One of the most frequent killers of riggers is electrocution caused
by the contact of a hoisting device, load line, or load with power lines. When working
with or around cranes that are within a booms length of any powerline, ensure that a
competent spotter is stationed at all times within view of the Operator to warn when any
part of the machine or its load approaches the minimum distances specified in the
Regulations for Construction Projects.
Voltage Rating of Powerline Minimum distance

750 to 150 000 volts 3 metres (10)
150 001 to 250 000 volts 4,5 metres (15)
Over 250 000 volts 6 metres (20)
Be especially careful when working near overhead lines that have long spans. These
lines tens to swing laterally in the wind and can cause unexpected contact. For a
summary of requirements, see the illustrations below.
Example 2
The West Australia OSH Guidelines define the Danger Zone around overhead power
lines as:
Voltage Rating of Powerline Danger Zone distance

Insulated line 1 000 volts 0,5 m
Uninsulated line 1 000 volts 1,0 m
> 1 000 volts and 33 000 volts 3,0 m
> 33 000 volts 6,0 m

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LIFTING OPERATIONS
A recommended process for ensuring safety is summarized in the diagram on the next
page.

Page 42 of 86
LIFTING OPERATIONS
Working in the Contact Supply authority Determine Can the work process Safe working
vicinity of to establish voltage and the result in employees, plant procedures to
overhead insulation of overhead danger or materials entering the be
power lines power lines zone danger zone? No established
Yes
Contact Supply authority to Can overhead power Safe working

determine if overhead power lines be adequately procedures to
lines can be effectively insulated and effectively be
insulated and cordoned off cordoned off? Yes established
No
Contact Supply Comply with

authority for Supply
approval authority
requirements requirements
ed
Recommended process for ensuring safety
Marking of power lines: All overhead electrical conductors or power lines on

construction sites and mine sites where cranes are used, shall be clearly marked with
warning signs showing the voltage and the height above the roadway surface.
Marking of overhead powerline height
What to look out for:

The voltage of overhead power lines has been established. Written confirmation of
this should be kept on site.
All personnel, equipment and loads must stay outside the danger area.
Where necessary, a properly positioned spotter has been assigned, and is in
communication with the crane Operator.
Where work within the danger zone cannot be avoided, permission has been
obtained, risk assessments have been completed, and all necessary precautions
have been taken.
Laydown areas, site access routes, and other site layout arrangements have
minimized the need to work in proximity to overhead power lines.
Special precautions may need to be taken when Operators or other persons who are
Page 43 of 86
LIFTING OPERATIONS
unfamiliar with the site are working in the proximity to overhead power lines. For
example, when deliveries are made, Drivers may not be aware of the positions of
overhead power lines. When cranes are moved from one location on a site, to
another location, the Operators may not be aware of overhead power lines to be
passed.
(g) The procedure shall address lifting operations when lifting near or over
unprotected plant, equipment or services, including live process or hydrocarbon
processes*
Intent: To ensure that the lifting plan considers the content of the process and any
protective measures to deal with the type of hazard. For example, toxic gas might
need 44inimizes44e breathing apparatus at hand when the task is in progress. Plant
handling harmful substances may need an Operator on standby to shut off the flow in
case of an accident.
Load being swung over unprotected plant
(h) The procedure shall address the effective hand-over, from one operator to
another, of cranes with complex boom, jib or tower configurations
Intent: To ensure that the lifting plan considers the implications of a new shift Operator
taking over a crane which is rigged or loaded in a complex or unusual way. It is
imperative that the new Operator is fully aware of the current state of all components of
the crane, and any specific information that might have a bearing on the safety of the
lift. This is particularly important when visibility is impaired for some reason, such as in
poor lighting conditions or when adjacent buildings obstruct the Operators view.
Crane with unusual and extremely long boom configuration

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LIFTING OPERATIONS
(i) The procedure shall address availability and use of check-lists for pre- and
post-operational inspections
Intent: To ensure that inspection points and procedures are not left out and to ensure
that deficiencies are logged for maintenance and shift handover purposes. To ensure
that any risks associated with lifting operations are identified, assessed and controls put
in place to ensure that safe working conditions are maintained.
OPERATORS TO HAVE TIME FOR FAMILIARIZATION
Cranes shall not be used for lifting operations until crane operators have been given
sufficient time to 45inimizes45e themselves with relevant aspects of the crane.
Intent: Crane operators should not only have the required formal qualification, but they must
also be assessed to be competent by a site authorized assessor to operate the particular
crane being used.
Cranes may be extremely complex pieces of equipment
RISK ASSESSMENT
Risks associated with all lifting, crane maintenance, assembly activities and
environmental conditions shall be assessed as part of the planning process.
Barricading, warning signs or other means of ensuring personnel protection shall be
in place during lifting operations and for those cranes left unattended in wind vane
mode.
Intent: The intent of a risk assessment considering personnel protection, prior to lifting taking
place, is to ensure all elements and risks are taken into consideration to ensure a safe zone
is established and no inadvertent access into the danger zone takes place.
Notes:
Wind vane mode allows certain types of cranes to slew down wind thus offering least
resistance to the wind force when unattended. When cranes are left in this mode, it is
possible to get 360 degree rotation on some cranes and therefore a risk assessment
should be performed taking the different parking standards into consideration to
ensure that the area is free from obstructions.
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LIFTING OPERATIONS
Some EOT cranes move on outside gantries and are therefore exposed to the
elements. These cranes should have storm lock facilities to prevent uncontrolled
movement by wind pressure. Part of the risk assessment procedure should consider
how the storm lock is applied. There have been cases where workers have been
exposed to additional risks (such as lightning) in order to apply the storm lock.
Crane blown off gantry during a wind storm
RISK ANALYSIS AND LIFTING PLAN
The following procedures shall be implemented for the different types of lifts.
(a) Routine Lift

Lifting Crews shall complete a Routine Lift Checklist, such as that shown below. If
any questions in this checklist are answered by no, the lift should be treated as a
Serious Lift.
Standard site procedures for safe lifts may be used. Where there are no standard site
procedures, a risk assessment shall be conducted, and a procedure developed.
(b) Serious Lift

Lifting Crews shall do a risk assessment and prepare a lift procedure. The Supervisor
shall approve the risk assessment and lift procedure before proceeding with the lift.
The Supervisor may provide guidance or additional expertise to the Lifting Crew and
the task can then be reassessed using the Routine Lift Checklist. If any answers are
still no, the lift should be treated as a Critical lift.
The lift shall be authorized by the Supervisor.
(c) Critical Lift

A lifting plan shall be prepared for the lift.
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The lifting plan should include at least the following:

A site plan, showing routing of services, pipes and conveyors, as well as all
surrounding structures or buildings
The site plan shall indicate the location of all major lifting equipment with lift
radius and load path, transport routes, and lift and placement positions
A site hazard and obstruction assessment
An environmental risk assessment
A risk assessment for the lift
Drawings showing the items to be lifted, with total calculated mass, centre of
gravity, lifting lugs and all dimensions
Drawings showing the crane and sling configuration, including boom and sling
angles and calculated forces, as well as ground pressure under outriggers
Full list of all lifting equipment and accessories to be used, with serial numbers,
SWL and current inspection certificates
A list of Crane Operators and Lifting Crew to be used, with competence
certificates
The lifting plan shall be reviewed and approved by an independent competent person
with experience in lifting prior to the lift taking place.
Note: when performing critical lifts on a routine basis as part of a regular production
process (i.e. transporting molten metal ladles in a smelter), the lifting plan should be
prepared at the commissioning phase and then updated whenever substantive
changes are made. Substantive changes include changes such as introduction of
modified ladles, extension of the smelter building, the addition of a new crane, any
modification of the smelter building that impacts the ladle crane bay, etc. The lifting
plan should be reviewed every three years, even if no substantive changes have been
made to the lifting procedure.
A guide to likely lifting hazards and possible controls can be found in Appendix A: A Guide
to Lifting Hazards and Controls. This guide may be used for risk analyses and the
preparation of lifting plans.
All parties (i.e. site Supervisor or Rigger, Contractor, Rigging Specialist, Project Manager and
the Design Engineer where appropriate) involved in a lift shall be represented in the risk
assessment and in preparation of the lifting procedure or the lifting plan as required. All
parties shall approve and sign-off the risk assessment and the lifting procedure or lifting plan.
The lift complexity types can be determined using the information in the table below.
Lift complexity type determination

Item Routine Lift Serious Lift Critical Lift
Cranes and crane interactions
Number of cranes used 1 1 2 or more
Interaction with other cranes or No Yes, but not in Yes
mobile equipment the same lift
Load lifted
Ratio of crane chart rated capacity 0 to 70 % 70 to 90 % Over 90 %
Total mass of load if lifted by EOT < 10 tons 10 to 50 tons Over 50 tons
crane
Total mass of load if lifted by < 5 tons 5 to 20 tons Over 20 tons
mobile crane
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Persons lifted No No Yes
Lift of hazardous material No No Yes
Proportion of liquids in lift mass None < 20 % > 20 %
Centre of gravity position Well known Well known Difficult to
determine
Centre of gravity near centre of Yes No No
load
Centre of gravity below sling Yes Yes No
attachments
Very large or flexible load No No Yes
Strategically important, fragile or No Yes Yes
expensive load
Proximity of obstructions
Proximity of overhead powerlines Well clear of any Lift does not go Lift does go over
powerlines over or between or between
powerlines powerlines
Proximity of fixed obstructions Well clear to Crane boom or Crane boom or
sides, above and load can reach load can reach
below obstructions obstructions
Limited headroom for EOT crane No Tight clearance, Yes, requiring
lifts but no tilting or rotation
manipulation of of load
load
Slewing over plant, pipelines, No Yes Yes
conveyors or tanks that do not
contain any dangerous
substances, hazardous chemicals
or gases
Slewing over plant, pipelines, No No Yes
conveyors or tanks that do contain
dangerous substances, hazardous
chemicals or gases
Visibility to Crane Operator Entire lift Part or none of Part or none of
lift lift
Number of Spotters required None 1 2 or more
Outriggers and ground conditions
Ground soft or muddy No No Yes
Outriggers fully extended Yes Yes No
Outriggers close to steep No No Yes
embankment, large drains or other
holes
General
Straightforward lift with no Yes No No
complexities
Ease of slinging load No difficulty Difficult Difficult
Effect of weather None Small Significant
Access for lifting at lifting or Straightforward Straightforward Awkward
placement positions
Use of lifting beams or frames No Single beam Yes
only
Specific unusual risks identified No No Yes

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Any persons are required to be in No No Yes
the drop zone
Crane supported on structure on No No Yes
which it is not normally supported
MINE AREA
PROJECT
ROUTINE LIFT CHECKLIST Yes No N/A
THE LOAD
Do you know the weight? Have you included all the items to be lifted i.e. all items on or below the
boom head?
If you are using lifting lugs have they been properly designed? Are the lugs aligned with the slings
so they are not bent?
If you are not using lifting lugs is the load attachment simple and clear?
Is the load free of loose unsecured items and is it ready to lift, e.g. restraints removed?
Will the lifting hook be directly over the centre of gravity of the load at pick up and placement?
THE LIFTING EQUIPMENT
Have the SWL of the slings, shackles, etc been checked for the load to be applied?
Have the sling angles and rigging method been considered in checking the capacity?
Has all equipment been checked for correct capacity and up to date inspection and test certificates?
Has the lifting equipment been inspected for defects and damage?
Are the slings protected from any sharp edges?
Is the lift within the specific limits of the relevant crane load charts for the configuration and radius?
Have the pre and post start operational checks been completed?
Are all the crane safety devices functioning correctly?
If the crane is more than 10 tonne capacity, is the external rated capacity lighting functioning
correctly?
Have the ground conditions or structure been determined to be adequate?
Is the crane set up with outriggers fully deployed and supported on the correct crane mats?
Is there adequate ancillary equipment, e.g. boom lifts, scissor lifts, fork lifts?
THE LIFT
Have you determined the lift complexity type?
Is there a routine procedure, or have you done a risk assessment or prepared a lifting plan as
appropriate?
Does the lifting procedure include bringing equipment and loads to site, setting up equipment, lifting,
moving and placing the load, and removal of equipment from site?
Are you using the procedure or lifting plan?
Is there adequate guidance in the defined behaviours and rules for your site for this lift?
Is the area of the lift free of operating plant, piping, live electrical lines and underground services? If
not, have the risks associated with these been properly considered?
Has the radius been checked with a tape measure or surveyed using Engineering plans, etc?
Has the area of the lifting operation been protected using barricades, tape and/ or spotters?
If people are working at height, has a risk assessment been done and correct PPE sourced?
Are environmental conditions safe for the lift e.g., not too windy, storms approaching?
If there any chance of the load impacting the boom, or the crane body or boom impacting obstacles
has a rigging study been done?
THE CREW
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Does the Rigger have the appropriate statutory certification and certification by the site as being
competent for a lift of this nature?
If the load is heavier or more complex than the Rigger normally handles does the Rigger have the
Supervisors permission to lift?
Do the Operators of ancillary equipment have appropriate statutory certification? Have the
Operators been assessed by the site as being competent to operate the equipment as per the site
standards?
Has the Controller of the lift been identified and is he/she wearing an appropriately coloured
reflective vest?
Has the Crane Operator the appropriate statutory certification and been assessed by the site as
being competent to operate this crane/ lifting equipment for this type of lift?
Have all members of the Lifting Crew been assessed as being medically fit for their tasks?
Date: ____________ Signed Crane Operator: _______________ Signed Rigger: _________________
Note: The approval of a Supervisor is required before proceeding with the lift if any question is answered No.
SIDE LOADING TO BE PREVENTED
Side loading of crane booms should be prevented according to the manufacturers

specifications.
Intent: To ensure that cranes are not used outside of their specifications for safe operation
as designated by the OEM. This also includes horizontal pushing or pulling of loads with the
boom. On EOT cranes and hoists load should only be applied in the vertical plane and no
dragging of the load is permitted.
Note:
This must be reinforced as part of the crane operators and dogger/rigger induction to
all sites
This also needs to be included as part of the pass out package for crane operators
The consequences of side loading crane booms also need to be explained e.g.
o Tipping the crane over
o Bending of the crane boom
o Breaking or the damaging of head sheaves
o Damaging of hoist ropes
o Load swinging out of control
OUTRIGGERS TO BE USED
With the exception of pick and carry operations, no lifting shall be carried out without
outriggers being deployed and locked.
Intent: To ensure that outriggers are fully deployed in such a way as to prevent the crane
from overbalancing. This requirement is applicable only to those cranes to which outriggers
are fitted.
Note: A good practice is to use packers under the outriggers, the dimensions of which should
be determined by the stability of the ground.

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Typical outrigger packing Possible outcomes when ground is too soft or outriggers are not
used
Common Hazards:
(a) Pick and carry operations should only be permitted where it is not practical to transfer
the load to a more suitable means of transport. In most cases pick and carry
operations are only required for a few meters to enable the crane to reach an area
where alternative transport can be safely made available. Pick and carry operations
using two or more cranes are not ever allowed.
All pick and carry operations should only be attempted by competent crane operators
and spotters must be used to ensure no risk is created during these operations. All
persons must be aware that the drop zone is enlarged during pick and carry operations
because the load is moving and swinging.
All pick and carry operations should be in line with the manufacturers
recommendations, particularly for tyre pressure and slope of the ground. This is
normally indicated on the machines load chart. These recommendations should be
considered as part of the risk assessment process.
(b) Insufficient care is given to ground conditions. Soft or muddy ground, sub-surface
services such as storm water pipes, or close proximity to excavations may lead to
collapse of the ground supporting the outriggers.
CONTROLS TO PREVENT FALLING OBJECTS
Controls shall be in place to prevent the falling of objects from lifting equipment and
suspended loads.
Intent: To prevent personnel being injured, or equipment being damaged, by objects falling
from the slung load or crane. Examples of objects that may fall are scaffold tubes and tube
clamps falling from carry frames, loose material falling from transfer chutes, or components
such as filters or even gearboxes falling from lifted motors.

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LIFTING OPERATIONS
The chart below shows the consequences resulting from a range of reported events involving
dropped objects. Although this chart should not be taken as definitive because of the many
variables involved, it does give some idea of the possible consequences when objects of
different weights drop from different heights. This chart thus assists in understanding the risk
of loose items dropping from heights during a lift.
Examples of suggested controls to ensure minimum risk to others, include:
Barricading or demarcating of work area to restrict and control access
Some demarcating styles and methods

Caution tape Danger tape
Some barricading styles and methods
Netting tape Solid units
1
Use of lifting cages for small heavy items

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Clear understanding of what has to be lifted and where it has to be positioned.
Use of good slinging practices and securing loads.
PERSONNEL TO BE LIFTED IN WORK BASKETS ONLY
The lifting of personnel with cranes shall be carried out only with the use of approved
workbaskets or cages. Cranes used for this purpose shall be approved as suitable for
man-lifting operations. A recovery plan should be in place before personnel are lifted.
Intent: These controls should be in place and used to ensure that the risks associated with
the use of man cages are reduced to low as reasonably practicable. Any additional controls
as required after risk assessment per site should be included.
Requirements for using work baskets:
Work baskets shall comply with local legislation. (If none exists, the Australian
Standard 1418.17 may be used as a good guideline.)
As a minimum requirement, work baskets shall be designed by a competent person,

and an approved drawing of the wok basket should be kept in the register.
Have a relevant work basket permit approved.
Cranes used for lifting personnel require as a minimum the following:

Be fitted with a safety hook.
Be equipped with power lowering.
Be equipped with controls that return to the neutral position when released and cause
the motion to stop.
Be equipped with a lockout control to prevent free fall of the work basket and its
contents.
Be fitted with an up limit switch on the hoist motion.
Be fitted with a down limit switch, if the work basket is to be lowered below the crane
supporting surface.
Secondary sling, large shackle to physically prevent the safety latch from opening or
secondary method for securing the safety latch to prevent roll out.
Total under hook load (which should be taken as not less than 750 kg) multiplied by a
factor of 2, should not exceed the crane chart rated capacity.

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Note: the use of the work basket shall be limited to those situations where it is necessary to
elevate personnel to carry out work where it is not possible to use any other appropriate
method and should only be allowed where no other method is available for safely elevating
personnel.
Common Hazard: In most incidents investigated, recovery plans were not present. Recovery
plans may need to be developed on a task by task basis. Personnel involved in the
formulation and/or carrying out of recovery plans must be competent in the skills required to
safely perform the rescue task.
NO WORK IN DROP ZONE OF SUSPENDED LOADS
The elimination of the need to work under or in the drop zone of suspended loads
shall be pursued. Where working under suspended loads is unavoidable, controls
shall be in place to eliminate or 54inimize the risks to personnel.
Intent: That working under suspended loads is the absolute last resort. In the unlikely
circumstance that working under a suspended load is required a comprehensive risk
assessment is required and shall be authorized by the senior site manager. It is vital to
ensure that all the controls that were identified in the risk assessment are implemented.
Note: Counterweights are deemed to be suspended loads. Counterweight suspension

chains are deemed to be lifting chains. Leading practice is that counterweights should be
suspended within screened off or barricaded areas. Alternatively, counterweights should be
adequately controlled by the use of support beams placed beneath and above the
counterweight.
Common Hazard: In the highly unlikely event where personnel are required to work under a
suspended load they should adopt the work basket rule as follows:
Double the require capacity i.e. if the load is 10 tonnes then the crane would have to
be capable of lifting 20 tonnes at the given radius and lifting equipment must be rated
at 20 tonnes.
Where people may be in danger of being under a load that swings or rotates, the load
should be kept under control by using one or more taglines.

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Use of tag lines
MODIFICATIONS SUBJECT TO APPROVAL
Any modification to cranes and lifting equipment shall be subjected to the original
equipment manufacturers approval and to a rigorous change management process.
Intent: To ensure that any modifications made to lifting equipment do not have a negative
impact on performance specifications. If situations exist where the OEM is no longer in
existence an approved equivalent will assess any modifications.
Note: The relevant site change management procedure must be used in conjunction with the
OEM approval.
This process should be followed irrespective of how small the proposed modification is
considered to be. For example, tack welding a small bracket or plate to the boom of a crane
may very quickly lead to fatigue cracking of the boom, and thus an unsafe situation.
PREVENTATIVE MAINTENANCE SYSTEM
A preventative maintenance system should be in place to ensure that all cranes and
lifting equipment are maintained and in a serviceable condition, with appropriate
records being kept.
Intent: To ensure that all equipment 55inimize in any lifting operation is maintained in a safe
operating condition. Preventative maintenance activities need to be in compliance to local
legislation, the manufacturers specifications, and to any relevant regional standards.
Monitoring of preventative maintenance activities needs to be completed to ensure that they
are being completed as per the schedule.
Note: The rated safe working loads apply only to equipment and hardware in a good
serviceable condition. Any equipment damaged in service should be taken out of service and
repaired or destroyed.
See Appendix 2 for additional information relating to caring for, inspecting and maintenance
of cranes and lifting equipment.
Leading Practice: Personnel performing any maintenance on equipment involved in lifting

operations should have had adequate training by the manufacturer, or authorized agent, to
perform the required tasks. This ensures that maintenance is performed correctly and
55inimizes the risk of future failure.

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LIFTING OPERATIONS
Common Hazards:
Unsafe equipment No one with reasonable cause to believe that equipment is unsafe or
unsuitable, shall use such equipment until the defect/s has been reported to a responsible
person, and appropriate action has been taken. The responsible person shall have such
equipment inspected and either declared safe or removed from use.
Slings After the hoist rope, the sling is the most commonly used piece of rigging equipment.
Observe the following precautions with slings.
Never use damaged slings. Inspect slings prior to use to ensure their safety. Check
wire slings for kinking, wear, abrasion, broken wires, worn or cracked fittings, loose
seizings and splices, crushing, flattening, rust or corrosion. Pay special attention to

the areas around thimbles and other fittings

Avoid sharp bends, pinching and crushing. Use loops and thimbles at all times.
Corner pads that prevent the sling from being sharply bent or cut can be made from
split sections of large diameter pipe, corner saddles, padding or blocking.
Never allow wire rope slings or any wire rope to lie on the ground for extended
periods of time or on damp or wet surfaces, rusty steel or near corrosive substances.
Avoid dragging slings from underneath loads.
Keep wire rope slings away from flame cutting and electric arc welding.
Never make slings up from discarded hoist rope.
Avoid using single leg wire rope slings with hand spliced eyes where possible. The
load can spin, causing the rope to unlay and the splice to pull out. Use slings with
Flemish Spliced Eyes.
Never wrap a wire rope completely around a hook. The sharp radius will damage the
sling.

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Avoid bending the eye section of wire rope slings around corners. The bend will
weaken the splice or swaging. There must be no bending near any attached fittings.
Ensure the sling angle is always greater than 45 degrees. When the horizontal
distance between the attachment points (S in figure below) on the load is less than
the length of the shortest sling leg (L in the figure below), then the angle is greater
than 60 degrees and generally safe.
Notes:
(a) When using slings in this configuration, ensure that they cannot pull inwards,
allowing the load to tilt and fall out of the slings.
(b) When using slings in this configuration, always calculate the actual load on the
slings (see item 12 above)

Do not assume that multi-leg slings will safely lift a load equal to the SWL of one leg
multiplied by the number of legs, although the rated SWL of the multi-leg slings will be
based on this assumption. There is no way of knowing that each leg is carrying its
fair share of the load. With slings having more than two legs and connected to a rigid
load, it is possible for some of the legs to take practically the full load while the others
merely play a balancing role. It should always be assumed that any two legs may
carry the entire weight of the lifted load.
INSPECTION AND TESTING
All cranes and lifting equipment shall be inspected and tested to ensure all safety
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devices are working (including non-destructive testing as required by the relevant

standard) prior to being operated or put into service. After any repair and/or
modification, cranes and lifting equipment shall be inspected (and non-destructively
tested as required by the relevant standard) prior to being returned to service.
Intent: To ensure that all lifting equipment and cranes are fit, and remain fit, for their intended
use.
Leading Practice: The following inspections are considered Leading Practice:
Proof testing and certification of all new and modified equipment.

Annual proof testing and certification of in use lifting equipment
3 monthly visual inspections by a competent person.
Pre-start inspection by the person using the equipment.
2 yearly random audit of lifting equipment conducted by a third party, who must be a
competent person.
The following items require proof testing:

Chain slings
Web/flat fiber slings
Round fiber slings
Pad eyes and lifting eyes.
This list is not exhaustive
The following items do not require proof testing:

Wire rope slings
Shackles
Note: Proof testing should be completed by a nationally approved certifying body to ensure
impartiality of results.
PERIODIC INSPECTIONS
A system of periodic inspection shall be in place for all cranes and lifting equipment.
Lifting equipment shall be inspected visually and confirmed fit for purpose prior to
being put into service. Visual inspection of lifting equipment by an approved
competent person shall be performed on a regular basis (e.g. six monthly) unless
regulations in the local area require examination more frequently.
Intent: To ensure that lifting equipment is in safe working condition and preventative
maintenance regimes are in compliance to statutory regulations
Examples of inspection times:

Equipment : Prior to every lift
Equipment used regularly: 3 monthly and tagged.
Mobile cranes: Daily pre-start, 12 monthly, and every 10 years.
Fixed Hoists and EOT cranes: 12 monthly, 10 year and 25 year.
Common Hazards: Defects are sometimes difficult to see if very close detailed inspections
are not done. Defective components Examine all hardware, equipment, tackle and slings
before use. Destroy and de-register any defective components. Equipment merely discarded
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LIFTING OPERATIONS
may be picked up and used by someone unaware of its defects.
Cracked EOT crane rail could lead to serious incident if not detected and repaired.
REGISTER TO BE KEPT
A register of all lifting equipment (including slings) should be maintained. This should
include:
(a) equipments unique identification number

(b) documentary evidence of all inspections
(c) certifications
(d) maintenance
(e) modifications and tests.
Equipments unique identification number

Documentary evidence of all inspections
Certifications
Maintenance
Modifications and tests
Intent: To allow all lifting equipment to be monitored and tracked in terms of inspections,
repairs made, modifications or removal from service.
Each site should maintain a register of all lifting equipment owned by them.
When a Contractors equipment is used for lifting operations on a site, the Contractor should
maintain a register of the equipment on site. This register, or a copy of this register, should
be available on site at all times.
7.3 PEOPLE REQUIREMENTS
SUITABLY QUALIFIED PEOPLE
Suitably qualified, certified and competent person/s shall be involved in the planning,
supervision and implementation of the lifting operations.
Intent: To ensure that all personnel involved in lifting operations have the required
qualifications, certification, authorisation and competencies required to operate and utilise
lifting equipment in a safe manner. These qualifications will be to the relative national
standard.

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Note: The single most important precaution in lifting operations is to determine load weight
before attempting any lift.
COMPETENCY ASSESSMENT
This guideline provides minimum competencies for rigger and crane operators as defined in
the Anglo Fatal Risk Standard for Lifting operations. It is acknowledged that different
countries may use different terms to describe the jobs of the persons defined below.
RIGGER: A person in charge of lifting operations. A person empowered to apply slinging

techniques, including the selection and inspection of lifting accessories and directing the
Crane Operator in the movement of the load, including when the load is out of view of the
operator, and must demonstrate:
Compliance with behaviours in observations conducted against the site behavioural

observation sheets. At least 5 lifts are observed and compliance with required
behaviours on 5 consecutive observations is necessary for the person to be judged to
be competent.
Competence in signalling all crane motions using hands, whistles and radio protocols.
Competence in selecting and inspecting the correct sling type including the use of
chain shortening devices.
Competence in the correct use of the various sling types.
Correct application of rule of thumb calculations for the capacity of slings.
Correct interpretation of various forms of SWL Rigging Cards to determine Lifting
Accessory size selection.
Correct interpretation of when to prepare a risk analysis or lifting plan.
Compliance with site standards for the preparation of a risk analysis.
Knowledge of:
o Effects of angles on slings and lifting accessories.
o Effects of load moments on cranes.
o Estimation of approximate weights of loads composed of different materials.
o Slinging loads including awkward loads and positioning loads in restricted areas.
o Selection of crane and set up and crane rated capacity calculations.
o Attachment of hooks to lifting lugs and eye bolts.
o Procedures when working at heights.
o Procedures when thunder is heard or lightning is observed.
o Procedures in windy conditions.
o Procedures for working in the vicinity of or when coming into contact with live
electrical conductors.
Note: Riggers need to demonstrate additional competencies to the above for activities such
as:
Lateral shifting of loads which may involve the use of chain blocks, tirfors, sheaves,
winches etc, sometimes in conjunction with cranes.
Knowledge of crane selection and set up and crane chart rated capacity calculation
for multi-crane lifts.
Competence in steel erection.
Competence in directing lifts involving personnel in work baskets.
Competence in demolition rigging.
Specialist rigging applications.

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LIFTING OPERATIONS
CRANE OPERATOR
In addition to the competencies for the Rigger, the Crane Operator must demonstrate
knowledge of:
Interpretation of operator manuals.

Interpretation of load charts.
Interpretation of crane configuration requirements for the crane being operated.
Daily maintenance requirements as detailed in the Operating Manual for the crane
being operated.
Emergency response strategies for loss of power during lifting operations.
In addition the Crane Operator must operate the crane and demonstrate the ability to:
Conduct a pre-start check of the crane and document the results.

Set the crane up correctly for operation
Correctly enter the crane configuration into the onboard computer, if applicable.
Check the operation of crane limit switches and safety devices.
Boom up and down and hold a load 1 meter above the ground.
With an unloaded chain set on the hook, slew the crane to cause a pendulum effect
and then control (catch) the resulting swing bringing it to a standstill.
With an unloaded chain set on the hook, raise and lower the boom to cause a
pendulum effect and then control (catch) the resulting swing bringing it to a standstill.
Float a load in a boom down and hoist up scenario and vice versa.
The competent person as referred to in requirement 13 is required with his lifting crew to
under take the planning and implementation of lifting operations and supervise the lifting
operations as required.
ROLES AND RESPONSIBILITIES TO BE DEFINED
The roles and responsibilities of personnel engaged in lifting operations shall be

defined clearly.
Intent: To ensure that all persons involved in lifting operations clearly understand their roles
and responsibilities.
Common responsibilities of personnel involved in Lifting Operations:
All personnel involved in a lifting operation are empowered to stop a lift when it is
unsafe due to miscalculations of the lifting plan or other reasons that result in unsafe
conditions. A competent person must review the lifting plan following a stoppage and
a meeting with the Lifting Crew must be held before lifting resumes.
The Crane Operator and the Rigger must be jointly responsible for determining the
load weight and placement of the crane so that it is set up within the radius selected.
The maximum radius of the lift shall be measured by tape if the load is 70% or more
of the crane chart rated capacity of the crane.
The Crane Operator is responsible for setting up the crane and programming its
safety features where applicable and operating the crane within its safe working
limits.
The Rigger is responsible for directing a lift and positioning the load.

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Only one person must be directing the crane operator at any one time. The directing
Rigger must be known to all in the Lifting Crew and must be the only one to give
signals.
If a person in charge is utilised for a particular lifting operation, they need to be able
to be identified as such.
In situations when more than one person is required to give signals (e.g. when control
passes from a person at ground level to a person on or in a structure) an assessment
of risk must be done detailing where directing of the Crane Operator must be handed
over.
Individual Responsibilities
The Equipment Owner must ensure that:
Safe, suitable equipment is provided to meet the requirements of the task at hand
Operators are capable and aware of their responsibilities
Maintenance, repair, transport, assembly and other personnel are trained and
experienced to handle their specific jobs
Training and upgrading is provided for all personnel
Responsibilities and authorities are clearly designated for each member of the lifting
crew
A thorough equipment maintenance and inspection program is in operation, including
keeping an up to date equipment register and other required documentation
Client and site supervision are capable and aware of their respective responsibilities
Equipment is maintained and inspected in accordance with the manufacturers
requirement and applicable regulations
The Equipment Operator is generally responsible for the safety of the crane operation as
soon as the load is lifted. Operators must know:
The particular model of crane they operate, its characteristics, functions and
limitations
The information in the cranes operating manual
The cranes load chart, including all notes and warnings and how to calculate or
determine the cranes actual net capacity in every possible configuration
Proper inspection and maintenance procedures to be followed in accordance with the
guidelines of the owner and manufacturer
Any site conditions that may effect crane operation, including the presence of
overhead power lines
Basic load rigging procedures
In addition the Equipment Operator must:
Refuse to operate the equipment if there are any problems that may affect its safe
use. Inform the owner in writing of these problems with the equipment, preferably in
the machines logbook. Only recommence use of the equipment once repairs have
been completed, appropriate inspections and tests have been completed, and a
competent person has certified the equipment safe for use.
Record in the register all inspections, maintenance and work done on the crane in the
field.
Check that the site is properly prepared for crane operation.
Review plans and requirements with site supervision.
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Find out the load and rigging weight and where the load is to be placed. Although
operators are NOT responsible for determining load weights, they become
responsible if they do so or if they lift the load without checking the weight with site
supervision.
Determine the number of parts of hoist line required.
Check the load chart to ensure that the crane has enough net capacity for each
planned lift.
Select the best boom, jib and crane configuration to suit load, site and lift conditions.
Assume responsibility for assembling, setting up and rigging the crane properly.
Follow the manufacturers operating instructions in accordance with the load chart.
Consider all factors that may reduce crane capacity and adjust the load weight
accordingly.
Maintain communication with Spotters.
Operate in a smooth, controlled and safe manner.
Shut down and secure the machine properly when leaving it unattended.
The Site Supervisor (Site Foreman, Rigger Foreman, Lead of the Trade involved etc.) has
overall responsibility as Person In Charge (PIC) of the lift and must therefore plan all phases
of the operation. Specifically the PIC must:
Supervise all work involving the crane.

Determine the correct load weight and radius and inform the Crane Operator.
Ensure that the lifting crew is experienced and capable of establishing weight, judging
distances, heights and clearances, selecting correct tackle and lifting equipment
suitable for the load, rigging the load safely and securely.
Supervise the lifting crew.
Ensure that the load is properly rigged.
Ensure the Spotters are capable of directing the crane and load, including use of
international hand signals where other forms of communication are not possible.
Designate Spotters and identify them to the Crane Operator.
Ensure the safety of the rigging crew and other personnel that could be affected by
the crane operations.
Keep the public and non essential personnel clear of the crane during operations.
Control the movement of all personnel in the area affected by the lift.
Ensure all required precautions when the lift is near power lines.
Ensure that all personnel involved in the lift understand their respective roles and
responsibilities and their roles in the overall safety of each lift.
Important: The lifting plan must specify all responsibilities. These must not be assumed.
This is particularly important when there are several parties involved. For example, a
construction site may have a steel erection crew on site, which includes a competent Rigger.
For a particular heavy lift, a specialist rigging company may have been appointed, with their
own Rigger. If responsibilities are not clearly defined, it may be unclear which Rigger is in
charge of a particular lift.
COMPETENCY BASED TRAINING PROGRAMME
A competency-based training programme for contractors, employees and supervisors

shall be in place. An approved examiner should assess the competence of trainers
performing such training.

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LIFTING OPERATIONS
Intent: To ensure that all personnel are appropriately qualified and competent to perform
required lifting operation tasks in a safe manner.
Having personnel with the appropriate teaching/training qualifications to the

appropriate regional standard.
Implementing a pass out system so that the operators have a clear understanding of
their role and are comfortable that they, within reason are able to perform any task
that is required.
Documented experience of operators.
Having a clear understanding of the experience and limitation of operators.
Ongoing and refresher training.
Knowledge of the relevant Mines Act and Regulations and other local statutory
requirements.
Knowledge of the relevant regional Standards.
Persons are required to be reassessed for competency on a frequency of 2 years
INSPECTIONS BY COMPETENT INSPECTOR
A competent inspector shall perform inspections of cranes, lifting machines and lifting
equipment. An approved examiner shall assess the competence of the lifting and
handling equipment inspector.
Intent: To ensure that persons inspecting lifting equipment have the knowledge and skills to
be able to identify items that are not fit for purpose. The examiner should be appropriately
qualified to perform the assessments as per regional standards.
COMMUNICATION IN COMMON LANGUAGE AND CORRECT SIGNALS
Crane operators and crew shall be able to communicate in a common language and to
use the correct crane signals.
Intent: To ensure a common communication system is used among Crane Operators,

Riggers, and others on the Lifting Crew to avoid confusion.
Many countries have different signal standards. Local requirements should be followed and
where these do not exist, the chart below should be used.

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LIFTING OPERATIONS
Typical hand signals for pendant control

cranes

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LIFTING OPERATIONS
Typical hand signals for mobile cranes

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LIFTING OPERATIONS
SOLO CRANE OPERATORS TRAINED IN SLINGING
Solo crane operators shall be trained in slinging practices.
Intent: To ensure that crane drivers operating in a solo capacity, such as Vehicle Mounted
Cranes or pendant control cranes, are able to sling loads in a safe manner. Also to ensure
that Crane Operators are able to identify poor slinging practices applied by others in the
Lifting Crew before the load is lifted.
Leading Practice: It is considered leading practice to use a Rigger for every lift. In some
cases more than one person may be required to safely supervise and control a load. This
needs to be considered when performing the risk assessment.

Not a good technique as the slings are not spread
wide enough, no one is controlling the load, the Operator is
in the danger zone and he is not protected from falling from
heights.
FIT FOR WORK POLICY
A fit-for-work policy shall be in place, incorporating the clearly defined maximum

levels of drugs (including prescribed medication) and alcohol allowed in the system of
drivers/operators, and a system shall be in place for fatigue management.
Intent: To avoid injury and fatality due to lifting accidents caused by engaging or selecting
Crane Operators who are not fit for the task.
The intent is to avoid accidents and injuries such as:
Falls from equipment during accessing and working on equipment due to a lack of
mobility, strength, agility, etc.
Impacts or aggravation to existing health issues from the risks of equipment vibration,
dust, noise etc.
Collisions due to issues such as vision, depth perception, reaction speed,
coordination, hearing, sleep disorders, epilepsy, alcohol or impacting drug
dependency, etc.

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LIFTING OPERATIONS
BEHAVIOUR BASED OBSERVATIONS
Behaviour-based observations shall be performed and any need for additional specific
training shall incorporate the results of these observations.
Intent: The intent is to avoid serious injury/fatality from lifting operations where unsafe
behaviour could result in selection of inappropriate equipment and methods. It is vital that a
no blame no shame concept is incorporated during observations.
Common Hazards: The safe working loads of most rigging and hoisting equipment is
determined from the static loads and appropriate safety factors is applied to account for
dynamic motions of the load and equipment. To ensure that safety is not compromised due to
behaviour, allow for other dynamic forces created by the normal operational movement of the
machine and its load. Always avoid the sudden snatching, swinging and stopping of
suspended loads. Rapid acceleration and deceleration can only increase the stresses on
both machine and tackle and thus increase risk of failure.
REFERENCES
Anglo Documents
Anglo Fatal Risk Standards (Issue 2).
AA STD 100 Quality Requirements for Critical Products and Services.
Australian Standards
AS 1418
AS 2550-1 Cranes, Hoists and Winches Safe Use. Part 1 General Requirements
ISO Standards for cranes:
2374 Lifting appliances -- Range of maximum capacities for basic models
4301, 4302, 4304, 4305, 4306, 4310, 7296, 7363, 7752, 8087, 8431, 8566, 8686, 9373,
9374, 9926, 9927, 9928, 9942, 10245, 10571
10972-1 Cranes -- Requirements for mechanisms -- Part 1: General

10972-3 Cranes -- Requirements for mechanisms -- Part 3: Tower cranes
10972-4 Cranes -- Requirements for mechanisms -- Part 4: Jib cranes
10972-5 Cranes -- Requirements for mechanisms -- Part 5: Bridge and gantry cranes
10973, 11629, 11630, 11660, 11661, 11662, 11994, 12210, 12478, 12480, 12482, 12485,
12488, 12603, 13200, 13202, 14518, 15442, 15513, 15696, 16880, 16881, 19961, 21669,
23853, 25599.
ISO Standards for hoists:
3154, 3155, 3156, 5614, 6984, 13534, 13535.
ISO Standards for lifting equipment:

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LIFTING OPERATIONS
1834, 1835, 1837, 2262, 2308, 2415, 3056, 3075, 3076, 3266, 3874, 4308, 4309, 4344,
4347, 4558, 4779, 4878 (withdrawn?), 7531, 7592, 7593, 7597, 8383, 8539, 8611, 8792,
8793, 8794, 10425, 16798,
CSAO (Construction Safety Association of Ontario) Hoisting and Rigging Safety
APPENDICES
APPENDIX 1: A GUIDE TO LIFTING HAZARDS AND CONTROLS
The following provides a guide to likely lifting hazards and possible controls. Whilst this is
detailed, it does not cover all aspects and scenarios. Individual lifts need to be assessed
within their own particular context and specific hazards relating to the lift identified.
Note: If in doubt, do a lifting plan.
The following format of Possible Hazard and Possible Controls can facilitate the
preparation of risk assessments, or the Job Safety Analysis with or without pre- and post-risk
scores.

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LIFTING OPERATIONS
STEP/ITEM POSSIBLE HAZARD POSSIBLE CONTROLS
ISOLATION CONSIDERATIONS
Electrical Lifting is carried out without properly Necessary Electrical Isolations must be enacted
Isolations electrically isolating the associated as per site procedures e.g.:
equipment Restricted Operation
Out of Service
Danger Tagging
People operating ancillary equipment/ No personnel operating ancillary equipment/
erecting scaffold within the operating area erecting scaffold etc must work within the
of an EOT crane without the EOT crane operating area of an EOT crane unless it is
being de-energised isolated.
Please note that in incidents with EOT cranes
Isolation is a major factor, so give it particular
attention.
Mechanical, Lifting is carried out without properly Necessary Mechanical Isolations must be
Hydraulic and mechanically or hydraulically isolating the enacted as per site procedures.
Pneumatic associated equipment
Isolations
Lifting activities cause an item of In the case of conveyors, procedures must take
mechanical equipment to be moved by an into account that whilst the electrical energy
energy source which is not its own and source is isolated, the belt may still be capable
others working on the equipment are of movement as a result of lifting operations.
unaware of the lifting activity
Unexpected mechanical movement occurs A procedure must be in place to protect people

while performing maintenance or the like working using isolation procedures from
on an electrically isolated EOT crane, e.g. unexpected mechanical belt movements
due to wind, being bumped resulting from lifting or mechanical operations
(e.g. bag tag procedures).
Check that brakes are functioning correctly to
guard against unexpected movement.
PEOPLE
Inexperienced Person/ persons in Lifting Crew are not Ensure personnel have relevant local Statutory
Crew/ competent to carry out the lift certification where applicable.
Unfamiliar with Ensure personnel have been assessed by the
Lifting Task site and have been judged to be competent
Use a competent person to support the lifting
personnel until people are competent.
A new person is added to the crew part Go through the job with the new member and
way through the task ensure they are made aware of the details of the
JSA/ procedures relevant to task with full crew
participation. Have new person sign off JSA if
applicable.
Inexperienced Person/ persons operating support Ensure personnel have relevant local Statutory
Operator of equipment (e.g. boom lift) are not certification.
support competent to operate the equipment Ensure personnel have been assessed by the
equipment site and have been judged to be competent.
Use a competent person to support the lifting
personnel until people are competent.

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LIFTING OPERATIONS

Crane Crane operator is unfamiliar with crane to Allow time for Crane Operator to practice and
Operator be used become familiar with the operation of the crane.
Unfamiliar with Supported unfamiliar person with an
Crane experienced operator.
Allow sufficient time for the operator to study the
crane operating manual and load chart (if
applicable) before requiring him to lift (can take
a minimum of half a day).
Use a competent operator for support until the
unfamiliar operator is competent.
Crane Hazard depends on ailment. Ailment Ensure up to date medical certificate of fitness
Operator or impairs ability of Crane Operator or Crew
Crew to operate crane safely
medically unfit
Resourcing Insufficient / inadequate resources as Assess the risk, plan the job and select and list
the Lift follows to carry out the task: resources required.
people Check that resources are on site before
PPE, fall protection equipment etc conducting the lift/ lifts.
support equipment (boom lifts etc)
the correct Crane
certified lifting accessories
water, UV protection and the like
chocks and dunnage
approved outrigger packing
Communication Crane Operator receives signals from more Nominate the person controlling the lift in the
than one person pre lift planning process.
Have person/ persons controlling the lift wear
unique coloured high visibility vests.
Crane Operator is confused about who is Identify when control will be passes from one
controlling the lift when control passes from person to another and detail in JSA.
one Rigger to another
The person controlling the lift during Ensure the person controlling lift can see
placement is unable to see the personnel personnel placing the load during placement.
placing the load
Communication between Rigger and Crane Ensure an intrinsically safe radio channel is
Operator on radio channel is being available when using radios for control
interrupted by other traffic signalling.
Hand signal by Rigger is misinterpreted by Rigger and Crane Operator are both competent
Crane Operator with site hand signalling protocol.
Crane Operator is confused by terminology Rigger and Crane Operator are familiar with
being used by Rigger on the radio radio protocols.
Rigger and Crane Operator work together as a
regular crew.
Mobile phone ringing during lift distracts Pre job briefing reminds personnel involved in
personnel from their task the lift that all mobile and other phones will be
switched off until completion of the lifting
sequence.

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LIFTING OPERATIONS

Responsibility Weight of item being lifted is Require Rigger and Crane Operator to be jointly
underestimated responsible for determining the weight. Seek
Supervisors support if unsure.
Radius of lift is underestimated Require Rigger and Crane Operator to measure

the radius with a tape if the lift is over 70% of
the Rated Capacity of the Crane for the
configuration and radius.
Crane inappropriately set up for the lift Make Crane Operator responsible for setting up
the crane, programming the computer with the
correct configuration and operating within the
Rated Capacity of the crane.
People believe they are not empowered to Make clear in job briefing that in case of
stop the lift when they believe it is unsafe emergency, ANYONE may stop the lift.
to proceed Make clear to the signalling Rigger that he/she
is empowered to stop the lift whenever the lift
varies from the plan.
Make clear to the Crane Operator that he/she
can stop the lift whenever he believes it is
unsafe to continue.
Minimising Manual handling of heavy rigging Planning allows for maximum use of Crane
Manual accessories causes injury to Rigger or auxiliary hoist where applicable or other
Handling Assistants mechanical devices to minimise manual
handling.
LOAD
The Weight Weight of the item to be lifted Weight to be obtained from Engineering or
underestimated Vendor drawings or data sheets. Rigger and
Crane Operator may perform independent
calculation from first principles.
Weight of Container underestimated. Take a trial pick and confirm weight on crane
Load Cell (cant do on demolition work).
Weight of all items on and below boom Take a trial pick and confirm weight on crane
head not allowed for Load Cell.
Know the weights of rope fall, block etc and
keep in crane cabin.
Require use of Lift Calculation Sheet to ensure
rigour
Lifting Lugs Use of improperly designed lifting lugs Ensure a competent person designs or
approves the design, of the lugs
Use of poor quality lugs Visually check lug welds for proper weld quality.
Confirm with NDT if unsure.
Improperly slinging load in weak direction Check drawings and engineering records
of the lug Align sling in strong direction of the lug.
Strength of Load collapses during lift (this may be Strength of load to be checked by Designer of
load expected on long or slender loads, such as equipment.
roof trusses or conveyor gantries) Load only to be lifted at designated lifting points.

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LIFTING OPERATIONS

Awkward The load awkward to lift and place Use certified and competent riggers. Obtain
Loads Engineering input if necessary.
It is difficult to attach slings to the load Use certified and competent riggers. Obtain
Engineering input if necessary.
The load contains liquids Use certified and competent riggers. Obtain
Engineering input if necessary.
Wind can apply significant loadings to the Use certified and competent riggers. Check
lifted load (e.g. shutters) weather forecasts before lifting if load is to be
suspended for an extended period of time.
The load has sharp edges which may Protect slings from damage using packers/
damage the slings protection. Rig correctly to avoid any chance of
slings slipping (use spreader beams?).
Load tilts and slides out of slings Ensure slings are attached above load centre of
gravity
Ensure slings are well spread towards the ends
or corners of the load
Have stability checked by a competent person if
spreader beam or lifting frame is used
Load has Pieces may be loose or loosen during lift Ensure all pieces are properly secured prior to
separate lift commencing
pieces
CRANE
Crane access Crane cannot be set up in correct location Prior to lift, check site plan or drawing,
to site considering headroom, road width and turning
circle requirements.
Crane is damaged or damages services Prior to lift, check site plan or drawing,
along access road considering headroom, road width and turning
circle requirements. Check bridges and culverts
for load carrying capacity.
Lifting On Crane lifting load in stationary lift without NOT PERMITTED.
Rubber deploying outriggers
Lifting with Lifting with outriggers not fully extended Only lifts without outriggers fully extended if the
outriggers not Crane Chart permits it and a risk assessment or
fully extended lifting plan has been done.
Require approval from the relevant Manager of
the lifting operation.

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LIFTING OPERATIONS

Preparing Crane lifts with safety devices not Post start checks include checks that limit
crane to lift functioning devices and brakes are functioning correctly and
are done in the morning and/ or prior to lifting
sequences commencing.
Lifts outside of Rated Lifting Capacity of Install Rated Capacity Indicator Lighting and
the crane alarms on cranes so that all are aware when this
situation occurs.
Lift within the specific limits of the crane load
charts for the configuration and radius
Crane configuration checked for consistency
with risk assessment or lifting plan. If a pin jib,
ensure that the boom and/or fly sections are
configured as per the operating manual.
Ensure that the correct counterweight is fitted for
the planned configuration of the crane.
Crane Operator cannot see out of and Ensure that crane cabin windows and mirrors
around crane due to dirty glass are clean in pre start routines.
Crane Operator is drowsy and Ensure crane cabin air conditioning is

concentration effected by a hot, stuffy or functioning correctly and allows circulation of
cold cabin. fresh air.
Lifts in an area where static and other Ensure insulation of mobile crane from the floor
electric sources are present without proper level is correct before lifting.
insulation of crane
Lifting with Side loading to crane booms/ carriages. Plan lifts to avoid producing out of vertical lifting
hoist rope ropes.
out of vertical
Load is likely to slide sideways as weight is Plan lifts to avoid producing out of vertical lifting
transferred from ground or floor onto crane ropes.
When this is necessary because of load

transfer, keep any pulling forces in line with the
boom and use certified and competent riggers.
Welding a Hoist ropes and crane electronics Planning allows for isolation of crane hook from
suspended damaged by earth leakage induced by load, e.g. using soft slings or approved isolating
load welding suspended loads device.
Longer period of time taken to weld Check out weather forecasts before proceeding
suspended load increases risk of lift being with the lift. Ensure item being welded is
effected by wind or bad weather correctly earthed.
LIFTING ACCESSORIES
Sling or chain Soft slings chosen when they may be Dont use soft slings without considering the
selection damaged by bumping against objects potential for damage.
Chains used when they may damage the Protect the load or choose an alternative type of
load. Load has sharp edges and may cut or sling. Protect the sling from the load and choose
damage the sling appropriate sling type.
Use of heavy sets of slings or chains Use auxiliary hoist to help lift slings or use other
causes back injuries etc to Rigger ancillary equipment to assist.
Use of slings or chains with inadequate Use lifting plan, or Rigger to calculate actual
SWL. This is particularly likely when slings loads in slings before selection. Obtain
are angled with lifting beams engineering input if necessary.
Ensure that slings are not inadequately
specified because of uneven sharing of tension
from load between multiple slings.
Shackle Use of shackles with inadequate SWL. Use lifting plan, or Rigger to calculate actual
selection This is particularly likely when shackles are loads on shackles before selection. Obtain
used with slings that are angled with lifting engineering input if necessary
beams
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LIFTING OPERATIONS

Sling, chain Wrong slings, chains or shackles used All slings, chains and shackles to be tagged with
and shackle because not properly identified serial number, SWL and next inspection date
identification
Sling, chain Slings, chains or shackles break because All slings, chains and shackles to be tagged with
and shackle of deterioration or damage serial number, SWL, current certification and
maintenance next inspection date
All slings, chains and shackles to be thoroughly
visually inspected by competent Rigger prior to
use
Lifting beams Use of beams with inadequate SWL Use lifting plan, or Rigger to calculate actual
loads on beams before selection. Obtain
engineering input if necessary
Tuggers Tugger breaks because of inadequate SWL Only use properly identified tugger.
Ensure that maximum tension in tugger is
known. Specifically, consider the effect of over-
tightening the tugger so that load is not
unevenly spread between slings.
Tugger breaks because of damage
Only use tugger with up to date inspection
certificate.
Perform pre-start inspection.
Work basket Injury to personnel due to collapse of work Only use work basket which has been properly
basket designed by a competent person, and which has
been constructed to proper specifications.
Only use work basket with up to date inspection
record, and with no visible damage.
Collapse of work basket due to overloading Ensure work baskets are properly tagged with
clear statement of people and equipment loads
that can be carried.
Injury to person due to falling from work Use proper Working at Heights procedures
basket and equipment (see AFRS No 7)
Lifting Load falls due to failure of lifting bracket Lifting brackets must be designed and approved
brackets for use by competent person.
THE AREA WHERE THE LIFT IS TO BE PERFORMED

Ground/ Ground unable to bear weight of load Inspect ground before lifting. Look for filled or
Structure soft ground, evidence of old trenches. If in
Capacity to doubt, get engineering input
Support
Weight of Structure unable to bear weight of load Get engineering input to confirm adequacy of
Load. structure to support load
Ground/ Ground unable to bear weight of load, Inspect ground before lifting. Look for filled or
Structure crane and accessories imparted through soft ground, evidence of old trenches. If in
Capacity to outriggers or tracks e.g. wharf doubt, get engineering input. Use packing and/
Support or mats under outriggers/ tracks
Weight
transferred Structure unable to bear weight of load, Get engineering input to confirm adequacy of
through crane and accessories imparted through structure to support load
Tracks/ outriggers or tracks e.g. wharf or Use packing under outriggers/ tracks to transfer
Outriggers. suspended slab weight correctly to structure
Uneven Ground is uneven where crane is to be set Assess whether able to be compensated for by
Ground up using safe amount of outrigger packing
Level the crane set up area by installing a crane
pad

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LIFTING OPERATIONS

Underground Loads imposed by lifting activity damages Check Plans and get Engineering advice
and Aerial underground plant / services
Services
Trenches for underground services, sumps, Check Plans and get Engineering advice
or large storm water pipes, weaken bearing
area
Crane contacts overhead power lines Inspect for aerial Services. Apply site
procedures if aerial conductors are in the vicinity
Soft ground Filled ground not properly compacted Competent person to approve ground for
outrigger pressure
Site of demolition of old structures may All old material to be removed, holes filled,
have holes, loose blocks of ground made good
concrete/steel/masonry
Trip Hazards Personnel injured by trips and falls Remove significant trip hazards from work
environment
Ensure people are aware of hazard
Emergency Cranes or other lifting equipment blocks Lifting plan to consider alternative routes
vehicle access roads so that emergency vehicles cannot
access other parts of plant
Adjacent to Vehicles using road strike crane Lifting plan to specify closure of road or
public road, barricading to protect crane from impact
site road or Use of signage to warn road users
haul road
Vehicles strike Rigger or other lifting Crew Lifting plan to specify closure of road or
members barricading to protect persons from impact
Use of signage to warn road users
Use spotter to warn Rigger and Crew about
approaching vehicles
RIGGING THE LOAD

Rigging the Load incorrectly rigged or slung Use certified and competent riggers
Load
Slinging arrangement unstable Use certified and competent riggers
Lifting plan to be approved by competent person
Lifting tackle Incorrect lifting tackle used Lifting plan to specify tackle to be used.
used Identification of tackle to be checked prior to lift
LIFTING AND SLEWING

Complex The lift is part of a complex sequence Ensure that the sequence is adequately detailed
Sequences in the risk assessment and lifting plan
Ready for Improvising to place load when dunnage Place dunnage and have chocks ready before
lifting and chocks are not in place ready to load is lifted.
accept the load
People under Person under a slung load with no crushing Consider other options and choose method
slung load protection provided based on risk
Rigger under a slung load in an attempt to Use tag lines for control or pre sling with tag
control it lines and use hooks
Plan job to keep Rigger away from under
Slew load over Load dropped on or impacts plant Ensure that appropriate masks, showers, or
live plant containing dangerous or toxic gases or other measures are available in case of
chemicals accidental contamination
Ensure measures available to prevent
environmental contamination
Lifting plan with risk assessment to be approved

Damage to plant under load leads to by Plant Supervisor
hazards elsewhere (e.g. load dropped on Follow site isolation procedure, permit systems
conveyor belt breaks belt, releasing stored and lifting over live plant procedure
energy in belt tension; load dropped on
pipe breaks pipe releasing pressure; etc)

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LIFTING OPERATIONS

Clearances of Crane component strikes adjacent Check clearance of Counterweight, A Frame,
crane and load structure during lift Masts and Gantries to Obstacles.
to objects
during the lift Load impacts boom during lift (boom Check clearance of Boom to Obstacles.
bound) Check clearance of load to Boom.
Load being lifted by EOT crane strikes Check clearance of load to crane beam and
crane beams / carriage carriages.
Load being lifted by EOT crane strikes Identify pinch points and crush areas.
structures, other objects Prepare scale drawings and Rigging Studies if
clearances are tight.
Limited High sling or chain loads due to shallow Use different lift arrangement.
headroom for sling angle
booms or
loads
Barricading or Person impacted by counterweight during Identify tail swing area and barricade, tape or
taping and swing motion place warning markers.
restricting
access to Load drops on person below load Area below lift barricaded or taped with
Lifting Areas information tags, restricted entry tags, and / or
protected with spotters as per site procedures.
Person walks into area below lifted load Barricade, tape off area or control access to all
and load drops on the person the areas affected by the lift with spotter.
Working at Person in Lifting Crew falls from height Plan job to eliminate or minimise working at
Heights heights if practicable (use of accessible lifting
lugs, etc).
(See AFRS No Provide safe access for lifting tasks with ladders,
7 Working at scaffold, boom lifts etc.
Heights) Identify appropriate anchor points for fall
protection equipment.
Identify appropriate type of lanyard, inertia reel
and harness to be used.
Apply relevant site procedures.
Tool used by person at height falls and Barricade, tape off area below.
strikes a person Use tool lanyards
Hand and Foot Hands caught in slip/ nip areas when Keep hands clear of slip / nip areas when chains
Injuries chains or slings are being put under or slings are being put under tension.
tension
Bundled load shifts against itself and Never touch bundled loads with hands, use tag
injures Riggers hand lines.
Feet crushed when taking weight/ placing Keep feet out of crush areas.
loads
PLACING THE LOAD AND SHUTTING DOWN

Placing Loads Insufficient personnel and/ or support Plan adequately and identify personnel and
equipment to safely place the load equipment (e.g. boom lifts) required in the risk
assessment or lifting plan
Personnel are in crush areas as load is Body positioning discussed in pre job planning if
placed. confined areas are involved
Releasing Boom impacts structure above as weight is Confirm adequate headroom exists before
Loads released (due to boom deflection) lifting. Do a scaled drawing if necessary
Slightly lower boom to release weight ensuring
there is no contact with the obstruction above
Rigging accessories catch on structure Rigger directs till rigging gear in sight of Crane
during removal Operator

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LIFTING OPERATIONS

Load is placed in incorrect position on a Planning allows for truck driver to be involved in
truck discussions about orientation and placement of
the load on the truck
Load is placed along grain of dunnage Place load correctly on dunnage and packing,
use steel plate if required
PICK AND CARRY AND TRAVELLING

Pick and Carry Crew embark on pick and carry task and Crane operator and rigger walk and inspect the
improvise as obstacles are encountered route to be used
Route with: Choose to use a truck to carry the load

bumpy uneven ground, soft ground.
grades including side slopes
power lines overhead or close to route
Rough terrain type crane used for pick and Only use Rough Terrain cranes for pick and
carry when ground is uneven carry over the front in accordance with the
manufacturers recommendations and only on
firm level ground
Improper tyre pressure causes load swing Crane Operator checks that tyre pressures are
during operation correct in pre start routine
Picks and Carries over a long distance and Choose to use a truck to carry the load
travels fast causing dynamic loading of
slings
Wheel hits a pot hole or bump causing Operator engages Axle Locks if applicable and
dynamic loading of the sling uses low range.
Load swings and strikes surrounding Use rigger with tag line to control the load or tie
objects or crane the load to the crane using appropriate
accessories.
Load strikes other people in congested Use a spotter in congested areas.

area
Slings swinging on unloaded hook strike Stow gear after releasing the load.
others or surrounding objects
Load drops on the Rigger and/or Assistants Rigger uses tag line, Load is carried low and
Rigger and Assistants are never under the load.
Travelling Travels crane with boom in raised position Chooses to stow boom before travelling. If it is
necessary to travel with the boom up, ensure
load charts are used for planning the travelling
and that only a very short distance is travelled.
Engage necessary locks
Apply the pick and carry checklist and controls
above.
INTERACTIONS WITH OTHER CRANES

Interactions One crane operates while passing its boom Plan work and separate and mark Arcs of
with other over or under the boom of another crane. Operation for each crane and do a risk
cranes assessment of lifting plan for passing one crane
boom over or under another crane boom.
Two EOT cranes carry out a tandem lift Consider risks involved in disabling anti collision
devices and in loadings on supporting
structures. Do a lifting plan.
SPECIAL LIFTING SITUATIONS

Lifting with Lifting is carried out with a floating crane Specialist procedures for the particular type of
floating Crane lifting will be developed and used.

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LIFTING OPERATIONS

Sub Sea Lifts Lifting is carried out in a sub sea situation Specialist procedures for the particular type of
lifting will be developed and used.
Lifting Lifting personnel when other methods are Consider options and choose method based on
Personnel available to do the work risk.
Lifting personnel with a crane in other than NOT ALLOWED.

a certified man cage/ basket
Lifting personnel in a certified man basket The requirements detailed in the site procedure
for lifting personnel shall be applied.
EMERGENCY SITUATIONS
Lightning, Load is to be suspended for an extended Check out weather forecasts before proceeding
Storms and period of time, exposing the lift to changes with the lift.
High Winds in the weather Ensure Crew knows routine if it storms. If it
storms, Crew is to stop lifting and the boom is to
be retracted/ lowered if practical to do so. The
crew must understand that they are not to touch
rigging accessories while lightning is about.
If using an EOT crane, lower the load to the
ground. If unloaded, lift the hook to maximum
height. Check whether the crane beam needs to
be tied to the main girders.
Power Lines Crane contacts energised power lines Lift maintaining minimum clearances to lines
and structures/use spotter as per local
regulations and site procedures.
Remind Crane Operator and lifting Crew of
practices to be applied in case of contact before
undertaking the lift.
ENVIRONMENTAL CONSIDERATIONS
Spills Oil spills from crane impact environment Crane carries oil spill kit.
Oil spill from load (e.g. gearbox) impact Crane carries oil spill kit.
environment
Other Other environmental impact? Address other environmental impact.
APPENDIX 2: LIFTING EQUIPMENT MAINTENANCE AND INSPECTION

All equipment used for lifting operations shall be properly maintained, including relevant
inspections and load tests. The specific requirements, inspection intervals and discard
criteria vary in different countries, and should be obtained from applicable legislation or from
the Manufacturers.
a. Cranes
Operator Daily Inspections:
See typical Daily Crane Operation Log Book on the next page.

Page 79 of 86
LIFTING OPERATIONS

Page 80 of 86
LIFTING OPERATIONS
Periodic Inspections and Testing:

A competent person shall inspect all components of the crane at
intervals not exceeding one year, but preferably every three months.
Cranes should be load tested up to 110 % of their SWL, or the crane
chart rated capacity, over the full range of operating conditions at
intervals not exceeding one year.
It is considered leading practice for cranes to be checked every two to
three years by an independent competent person.
Major Inspection and NDT:

A major inspection shall be conducted as specified by applicable
legislation, by the Manufacturer, or by a competent person. The crane
or lifting equipment shall be stripped down to allow access to all parts
requiring tests or inspection. Inspection methods may require visual
inspection, NDT, or other means. The aim of the major inspection is to
ensure continued safe operation of the equipment.
After 10 years, or 10 000 operational hours all cranes and lifting
equipment shall be subjected to a major inspection.
All cranes and lifting equipment that are to be modified or upgraded
shall be subjected to a major inspection.
Any cranes or lifting equipment that has been involved in an accident,
or has been overloaded shall be subjected to a major inspection.
Care of Cranes and Lifting Equipment:

Never make any modifications, however small, without written approval
from the Manufacturer or competent person. The written approval
shall be kept in the register.
Never attach any brackets for any purpose whatsoever to cranes or
lifting equipment. Drilling, or tack welding, for attachment of brackets
can substantially weaken the lifting equipment.
Register to be Kept:
A register shall be kept on site for all cranes used on site.
The register shall contain at least:
The unique serial number of the crane.
The purchase or commissioning date.
The number of hours of operation of the crane.
A record of inspections.
A record of load tests.
1 b. Slings and Chains

User Inspections:
Inspect nylon slings on a daily basis or before each use for frayed
threads, cuts, tears, loose connections or other damage.
Inspect wire slings on a daily basis or before each use for broken
strands, kinks, corrosion, or other damage.
Check for distortion or corrosion of hooks and eyes.
Look for burn holes or damage from welding or other heat sources.
Check that slings and chains have the proper tag showing the
necessary information.
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LIFTING OPERATIONS
If the slings or chains are damaged or worn, do not use them.
Competent Person Inspections:

A competent person other than the user should inspect all slings and
chains periodically, preferably every three months, but at least once a
year.
Care, Marking and Inventory:

Store slings and chains in a dry, and safe environment; ideally in a
locked storage area.
Maintain a register indicating the date of entry into service, and the
nature of the work performed or other relevant details.
Ensure that tags remain firmly attached to slings and chains.
Periodic Inspections:
All slings and chains shall be load tested at intervals not exceeding
one year.
Tag in place, showing

all necessary
information.

Chains stored badly,
allowing onset of
corrosion.
A test certificate shall be obtained from the test authority.

All test certificates shall be kept in the register.
1
2 c. Shackles
User Inspections:
Shackles should be checked on a regular basis and before each use.
If sprung latches are not closing properly, they should be cleaned and
lubricated carefully, and discarded if the problem cannot be resolved.
Check for damage, deformities, or excessive wear.
Damaged shackles shall be tagged and removed from service and the
inventory list.
Care, Marking, Use and Inventory:

Dirty shackles shall be cleaned with kerosene, WD-40, or similar
solvent and immersed in boiling water for 30 seconds to remove
cleaning agent
Dry with a soft cloth to ensure that the gate and gatekeeper operate
properly.

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LIFTING OPERATIONS
Shackles shall not be loaded along the gate side.
Discard the shackle:

After it has been damaged.
Discard shackles and all integral components if any discoloration,
deformation, cracks, or abrasions are detected.
If it has sustained any fall.
If the spring brake and latch are bent, or not closing properly even after
cleaning.
If the gatekeeper no longer engages the slot cleanly.
If it shows excessive wear, chemical damage, burn damage, and/or
ultraviolet deterioration.
After 5 years of use.

Page 83 of 86
LIFTING OPERATIONS
APPENDIX 3: LIFT PLANNING GUIDE

This flowchart is intended as a quick reference for the use Project Managers or Engineering
Managers who are in control of sites where lifts must be performed.
The flowchart makes reference to other sections of this guideline document, and is intended
for use together with this guideline. It is not intended as a stand-alone document.

Page 84 of 86
LIFTING OPERATIONS
LIFT PLANNING GUIDE

Identify lift parameters including:
Lift mass
Area of lift Including site plan
Ground conditions
Environmental factors IF ANY INFORMATION IS UNKNOWN DO NOT LIFT
Identify Lifting Crew including: For a heavy or complex lift, this may be done by a
Rigger Specialist Rigging Contractor, but it must be done.
Crane Operator
Others IF ANY PERSON HAS NOT BEEN FOUND
Check competence and medical fitness COMPETENT DO NOT LIFT
Identify or design lifting equipment including: For a heavy or complex lift, this may be done by a
Cranes, winches Specialist Rigging Contractor, but it must be done.
Lifting tackle, slings, shackles, tuggers
Brackets, lugs, lifting beams, anchors
Check all inspection and test certificates. IF ANY EQUIPMENT IS NOT FIT FOR USE OR SWL
Check SWL and crane chart rated capacity. IS INADEQUATE DO NOT LIFT
Use lift complexity type determination in section 22 Risk Assessment section to determine lift complexity
type
Routine Serious Critical
Identify appropriate standard Perform risk assessment and Perform risk assessment.
procedure plan lift procedure. Prepare comprehensive lifting
OR plan.
Perform risk assessment and
plan lift procedure.
Obtain Supervisor approval for
lift. Obtain Independent Competent
Person approval for lift.
Perform pre-start inspection of
equipment.
Perform pre-start inspection of
Check that everybody
equipment. Perform pre-start inspection of
understands their responsibilities.
Check that everybody equipment.
understands their responsibilities. Check that everybody
Check Contractor inductions understands their responsibilities.
Set up lifting equipment and where appropriate. Check Contractor inductions
demarcate or barricade work where appropriate.
area, including drop zone.
Set up lifting equipment and

demarcate or barricade work Set up lifting equipment and
PERFORM LIFT SAFELY demarcate or barricade work
PERFORM LIFT SAFELY

PERFORM LIFT SAFELY

Page 85 of 86
LIFTING OPERATIONS

Page 86 of 86

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Instructivo Fecha Inicio Vigencia : 14.07.

Estado Elaborador Revisor Aprobador

Vigente Wilhelm Carlos -- Asesor Senior AFRS

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

38 SOLO CRANE OPERATORS TRAINED IN SLINGING 68

1. Anglo Safety Way- ASW

It is important that when implementing Standards the organisation takes cognizance

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

In addition to the manufacturers standard safety features, local statutory

This is achieved through:

Mine shaft lifting operations

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

Installation or removal of cages from mine shafts

Pipes prepared for slinging down mine shaft

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

It does not include monitored or uncontrolled activities.

Other definitions and abbreviations used in this Standard

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

5 Competence (Lifting Operations) refers to a persons ability to execute specific

20 Lift complexity types. Three complexities of lift are defined:

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

30 Rigger is the competent person in charge of lifting operations. The Rigger is a

46 Work basket refers to a personnel carrying device designed to be suspended from a

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

5. REASON FOR INCLUSION

(a) lack of job planning and hazard assessment

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

7.1 PLANT AND EQUIPMENT REQUIREMENTS

Typical electrical switch boxes for cranes

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

Warning and lock out on access to overhead cranes

Intent: The operators and/or maintainers of the crane must have:

Unrestricted and safe access to the seating position

Refer to Standard 2: Surface Mobile Equipment and Standard 7: Working at

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

Access ladder extended Access ladder retracted

Provide safe means of access to Operators cabin or platform.

Guardrails on mobile crane Anchor point for harness on EOH crane

PHYSICAL LOCKING SYSTEM

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

Isolation of free fall levers

Some types of overload protection

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

Crane cabins should be air-conditioned or heated in accordance with environmental

Intent: The intent is to enable cabins to be closed at all times.

Safe access to air-

Crane cabin with air conditioning unit

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

SUFFICIENT CONTROLS TO PREVENT CRUSHING

It is possible to use remote controls as an alternative to ensure the Operator is

A procedure should be in place to train personnel to avoid these hazards as a remote

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

POSITIVE LOCKING SAFETY CATCH

Typical hooks with safety catches

SWL TO BE CLEARLY MARKED

Country Short term Long term Standards

EOT cranes with SWL and Equipment Numbers

AFRS Guideline N 8 Lifting Operations CONTROLLED DOCUMENT

LOAD MONITORING AND INDICATION

For cranes, the following should be made available:

Load Moment External Rated Anti two-block

All Mobile Slew Cranes Shall Shall Shall Shall

Electric Overhead Traveling Not Applicable Should Should Shall