HEALTH AND SAFETY MANUAL

DHI-EHS-HSM-011

LIFTING OPERATIONS

Copyright This document is the property of Doosan Heavy Industries and Construction and all rights are
reserved in respect of it. This document may not be reproduced or disclosed in any manner what so ever, in
whole or in part, without the prior written consent of Doosan.

Doosan expressly disclaims any responsibility for or liability arising from the use
of this document by any third party. Copies printed are UNCONTROLLED.

Revision Details Next Review: January 2015

Rev. Date Revision Status Checked Approved

00 31/03/2014 Draft Yonghyun Kim Seungmin Park

DHI-EHS-HSM-011 (March 2014), Page 1 of 12

PURPOSE AND SCOPE

To outline the minimum requirements for the use, operation and maintenance of cranes. Define the
competencies required and responsibilities for the Safe operation of this type of industrial equipment. Additional
control measures may be required depending on project and country requirements.

DEFINITION
Competent Person: An individual who has immediate knowledge of the subject, either by years
of experience in the specific field, formal education, or specialised training
pertaining to:

 Job activity being performed;

 Operation and use of specific equipment;

 Potential hazards associated with specific jobs;

 Applicable Environment, Health and Safety standards; and

 Project EHS procedure pertaining to the tasks being undertaken

Vehicle Mounted Crane mounted on a vehicle / Crane Trucks for the principal purpose of
Cranes/Crane Trucks: loading and unloading such a vehicle.

Rigging: Work involving the use of mechanical load shifting equipment and
associated gear to move, place or secure a load including plant, equipment
or members of a building or structure and to ensure the stability of those
members and for the setting up and dismantling of cranes and hoists. The
definition does not include work performed by operators or drivers of
mechanical load shifting equipment, unless the work is part of the process
of setting up or dismantling cranes and hoists.
Banking/Dogging (Rigging- The application of slinging techniques including the selection and / or
Rigger): inspection of lifting gear, or the directing of a crane / hoist operator in the
movement of a load when the load is out of the operator’s view.

Slinging Techniques: The exercising of judgement in relation to the suitability and condition of
lifting gear, and the method of slinging, but consideration of the nature of
the load, its mass and its centre of gravity.

Certificate of Competency: A certificate issued in accordance with the national standard, and includes
evidence of a satisfactory assessment.

PROCEDURE
1.0 General
 No person will use or operate any crane unless they have the required certificates of competency
and have valid authority to operate issued by the Site Manager in accordance with project
requirements.

DHI-EHS-HSM-011 (March 2014), Page 2 of 12

  Site Managers or nominee shall ensure all cranes are registered and certified and that all crane
operators hold a valid certificate to operate that particular crane. Copies of current crane
certification and crane operator certificates shall be held by the Site Manager or his nominee.
 Site Manager shall ensure that all cranes used on the Project meet the Country’s Legislative
Requirements and are inspected to ensure that this procedure standard is met.
 Accidents and dangerous occurrences where cranes and other lifting appliances are involved are
mostly caused by abuse, misuse or neglect of the equipment.
 All wire ropes shall be in good condition and free of bird caging, crushing, kinking, broken strands
or excessive wear. Wire rope certificates shall be provided to the company for all hoist, luffing and
pendant ropes.
 All pin jib crane boom jibs, flys and masts shall be free of major defects. All damaged, deformed,
bent or kinked lacings shall be replaced prior to operation. No crane will be permitted to
commence work until all defects identified by the company’s inspection are rectified.
 All cranes should be provided with a Daily Maintenance Logbook. These log books are to be
placed in every crane working on the site. They are to be filled out by the operator and signed as
noting the remedial work required on a daily basis. Logs are to be kept in the crane cab and
copies are to be provided to the EHS department weekly.
 Site Manager shall ensure that at all times whilst any crane is working on site that a copy of the
crane’s operators manual is present in the operator’s cabin on the crane and Load Charts.
 All cranes shall be fitted with anti two block and load indication equipment to both main and
auxiliary hoist lines. Site Manager shall ensure all such equipment is regularly maintained and
calibrated quarterly so as to ensure its effective operation and accuracy.
 Records of quarterly calibrations shall be provided to EHS Coordinator upon request.
 No crane shall operate closer than three (3) metres to power (33kv) lines unless such lines have
been isolated or insulated by the proper authority
 Where cranes are to be left unattended for some time or at the end of each shift, they shall be
parked in a Safe condition in accordance with the manufacturer’s recommendations. Where the
manufacturer’s recommendations are not practicable, the following minimum requirements shall
be carried out:
 All crane booms shall be orientated so that the boom does not lie in the direction of operating
plant

1.1 Hydraulic cranes (already on outriggers)

 Boom fully retracted and position between 55 and 65 degrees;
 Lifting gear removed from hooks;
 Hooks raised to within 2 metres of anti two block device;
 Crane level, with outriggers lowered with tyres as close to ground as practical;
 Upper deck slewed to facilitate access to engine for pre-start checks (Safe access/egress for
operator must be provided);
 Crane must not be left in known or possible water run-off or collection areas.

DHI-EHS-HSM-011 (March 2014), Page 3 of 12

1.2 Hydraulic Crane (in travel mode)
 Boom fully retracted and positioned as per operators manual for travel;
 Hooks tied back to carrier;
 All parking brakes applied;
 Crane to be left on level ground (use wheel chocks if ground not level);
 Crane must not be left in known or possible water run-off or collection areas.

1.3 Crawler Cranes

 Lifting gear removed from hooks;
 Hooks raised to within 2 metres of anti two block device;
 Boom positioned at 55 to 65 degrees;
 Upper deck slewed in line with tracks and positive pin lock applied;
 Crane must be left on firm level ground;
 Crane must not be left in known or possible water run-off or collection areas.

When the possibility of lifting a load over other personnel working in the direct area exists, the foreman
in charge of the lift shall:

 Notify foreman/supervisor in the area of the nature of the lift and the area the load and
boom shall be slewed over;
 Prior to commencing the lift, the lifting Erection Contractor’s foreman must have
confirmation from his own and other Erection Contractor’s foremen who have personnel in the lift
area that those personnel have been advised of the lift and are clear of the direct path of the load
and boom travel radius.
 A foreman who if notified of a pending lift shall immediately:
 Assess the impact of the lift on his crew’s work area;
 Notify the crew of the appropriate action;
 Advise the lifting foreman / supervisor that a) and b) have been complied with.

Site Manager shall ensure that concrete filled drums are not lifted by reinforcing rod loop cast into the
concrete. Personnel involved in the lifting and moving of these drums must ensure that only approved
lifting gear is used when work of this nature is being carried out.

Drums shall not be used for lifting tools, fittings etc unless fitted into an approved drum lifter.

Site Manager and Contractors shall provide to the EHS Coordinator copies of crane manufacturers
manuals.

All cranes shall be fitted with operational anti free fall devices (auto troll or similar) and air conditioned
operator cabins.

DHI-EHS-HSM-011 (March 2014), Page 4 of 12

 The lifting of multiple loads (Christmas trees) by a crane is prohibited.

Cranes shall not pick and carry loads on a fly or with a fly in the un-stowed position.

Safe access and egress to operator cabins for drivers and for maintenance personnel to other parts of
the crane shall be provided.

Where cranes are being moved around site the following is mandatory:

 Chains/slings shall be removed or secured to the crane body;

 Hook blocks shall be secured to prevent swinging and damage to boom sections. Where it is
impractical to secure hook blocks, the hook blocks may be held fast against the boom head.
 Doggers and riggers shall guide the crane during movement on site;
 Tag lines shall be used on loads when in ‘pick and carry’ operation;
 Under no circumstances shall a rigger or dogger remain in the crane cab or on the crane when
walking loads;
 Personnel shall not be carried on cranes unless manufacturer approved seating is provided.
Where seat belts are fitted these shall be used.

The free falling of loads is prohibited on site. All loads are to be lowered by means of power lowering or
positively engaged drive down system.

Cranes shall not lift on two hooks at the same time unless a risk assessment has been undertaken and
there is written confirmation from the manufacturer that the lifting method is within the design criteria of
the crane and does not compromise and Safety or integrity of the crane.

Under no circumstances can independent loads be lifted on two hooks at the same time.

All inspection, maintenance and repair records for cranes working on site shall be available for
inspection upon request.

2.0 Communication
Communication between crane operator and dogman/rigger shall be of such a type that will not interfere
with the operation of other equipment in the immediate or adjacent areas. If radio communication is to be
used, radios must first be approved by the Company and shall be fitted with an effective Safety lock-out
system that will prevent other persons from operating the same channel.

3.0 Training
The Site Manager is responsible for ensuring that the operators who are to operate any crane are
adequately trained and conversant in the following:

 The Safe operation of the machine;

 Location and operation of all safety backup systems;
 Reading and understanding of the load charts;
 Capabilities of the machine in any unusual circumstances;
 Any peculiarities pertaining to the machine.

DHI-EHS-HSM-011 (March 2014), Page 5 of 12

4.0 Competency Verification
Site Manager shall record details of operator training and competency assessment for each crane that
the person is qualified to operate.

The verification of the competency of a person to operate a particular crane shall consist of:

 National Certificate of Competency for the size and type of crane to be operated or specific
country competency.
 A statement of medical suitability of the person to operate the crane including, eyesight, hearing,
depth perception etc;
 An ability to read, write and understand the load charts for the crane(s) to be operated;
 Having satisfactorily completed (prior to mobilisation) a competency assessment for the crane(s)
to be operated consisting of a combination of written and verbal test of the load charts, set-up
requirements, operating requirements, pre and post inspection and maintenance requirements
and operators EHS responsibilities;
 Having satisfactorily completed an operating test demonstration in the operation of the crane and
set-up and erection of booms, jibs and flys.

5.0 Lifting Operations

Lifts shall be classified in three categories and the following shall apply:
CLASSIFICATION CRITERIA ACTION

Standard Lift Load less than 50 tonnes Daily Lift Log

Load less than 75% of chart capacity

Is not a non-standard or critical lift

Non-Standard Lift Load less than 50 tonnes Lift Evaluation

Load greater than 75% but less than 85% of

chart capacity

Is not a critical lift

Load is supported or balanced using chain

blocks

Load lifted over or near operating plant or

overhead power lines

Critical Lift More than one crane is utilised Critical Lift Plan

Special lifting equipment or non-standard

crane configuration used

Gross load greater than 50 tonnes

Load greater than 85% of chart capacity

DHI-EHS-HSM-011 (March 2014), Page 6 of 12

 The Site Manager or nominee shall review and approve all lift evaluations for non-standard lifts. These
evaluations shall be filed and made available upon request.

Critical Lift Plans shall be approved by the Site Manager after review by a suitably qualified competent
person (Engineer etc).

6.0 Crane Setup on Outrigger

All cranes set up on outriggers, except on concrete pavement, shall have, as a minimum, timber mats
placed under each outrigger that are a minimum 75mm in thickness. The pads shall extend a minimum
of 200 mm past each edge of the outrigger.

The Site Manager shall ensure in all instances that the mats provided under outriggers are of an
appropriate size to ensure the stability of the crane in all lifting operations and are suitable and adequate
for the prevailing ground conditions.

7.0 Planning the Job

Potential hazards associated with the use of cranes and other load moving equipment are to be
identified, and measures to eliminate or control these hazards put in place prior to any lift commencing.

Relevant site information shall be obtained and potential hazards are to be identified, such as:

 overhead power lines;

 trees;
 overhead service lines such as; steam, gas, water, telephone;
 underground services;
 uneven and / or unstable ground;
 allowable ground loading;
 other Contractors workers or persons in the area;
 surrounding buildings / vessels / structures / equipment;
 hazardous materials;
 corrosive substances;
 barricades;
 inadequate lighting;
 radio interference;
Optimum prevention / control measures are selected.

Approved site access and egress is identified.

Coordination requirements with other site personnel are determined.

Determine or confirm appropriate mass and dimensions of load.

Appropriate load shifting equipment is identified including:

 slings;
 ropes;

DHI-EHS-HSM-011 (March 2014), Page 7 of 12

  shackles;
 eye bolts;
 spreader beams.
Check for appropriate approvals for work and the appropriate competent persons.

The job method and sequence is developed to include hazard prevention control measures and safety
procedures.

The job feasibility and schedule are checked with other persons as necessary.

The job plan is developed to include hazard prevention / control measures and to applicable Standards,
codes of practice and equipment manufacturer’s specifications.

8.0 Operational Responsibilities - Cranes

The Crane Operator shall be responsible for:

 Daily pre-operational equipment checks are carried out in accordance with the checklist provided
for the crane and in accordance with the manufacturer’s recommendations;
 The service log book for the crane is checked to ensure all service requirements have been met
and action taken as required;
 Prior to operations, equipment and site area are visually checked for any evidence of interference,
and any faults reported to a supervisor for corrective action.

9.0 Crane Operations in Windy Conditions

In the absence of specific information from the crane manufacturer or agent, personnel shall not operate
a crane in wind speeds in excess of 10 metres/second.

10.0 Controls and Lifting Gear

The crane is to be started in accordance with equipment procedures and check made for any abnormal
noise or movement. Any abnormal operation is reported to the supervisor for corrective action.

The operating and emergency controls and safety devices are located and identified and their correct
operation tested in accordance with prescribed procedures.

All communication equipment, lighting and alarm systems are checked for correct operation.

A Permit approved by the Site Manager is required for the use of crane hoisted work boxes.

The Permit shall only be valid for the specific task and where the task is in excess of one (1) working
day. The Permit shall be revalidated by the rigging supervisor ensuring that the relevant crane checks
are conducted prior to revalidation.

Defective controls, communication equipment, safety devices, lighting, or alarms are reported to
supervision for corrective action and the defects entered into the crane’s service log book.

The operating radii of the crane for planned operations is / are verified and measured taking into account
the estimated increase in radius due to boom deflection. The boom is slewed at the planned radii to
check that there are no unanticipated complications or obstructions.

DHI-EHS-HSM-011 (March 2014), Page 8 of 12

 Slings and lifting gear shall be checked prior to the commencement of lifting tasks. Defective slings or
lifting gear are identified and segregated and reported to the supervisor for disposal, repair and / or
replacement. The inspection is completed by a competent person and recorded on the form Appendix A
- Lifting Operations Risk Checklist. Refer to Personnel Competency for approval requirements.

The lifting gear must be tagged with the corresponding colour tag in accordance with in ‘DHI-EHS-HSM-
032 Inspection and Tagging’.

11.0 Shutting Down Crane

Crane hoisted workboxes / man basket shall only be used where there is no other practicable alternative
means to safely carry out the work.

Supervisors / Superintendents shall provide a comprehensive risk assessment to the EHS Coordinator
for review, a minimum of 1 working day prior to the use of any crane hoisted workbox / man basket and
submit the completed permit application to the Site Manager for approval Appendix B - Crane Inspection
Checklist.

All cranes used to lift workboxes / man basket shall be fitted with a double acting or positively locking
safety catch on the crane hook, drive up and down controls for hoisting and luffing motions, be equipped
with controls that return to the neutral position when released and this action caused the motion to stop.

Personnel in the workbox / man basket shall be issued with, trained and instructed to wear a safety
harness that is attached to an approved anchorage at all times.

Access and egress from a workbox / man basket is prohibited except where approved by the Site
Manager following discussions with the EHS Manager.

A certificated rigger must be in the workbox / man basket at all times when elevated.

Radio communication on a dedicated individual crane channel shall be used at all times when using a
workbox / man basket. A minimum of 2 radios shall be used, in case of battery failure.

Gas cylinders or material other than essential tools etc and objects protruding outside the confines of the
workbox / man basket is not permitted.

Travelling the crane with personnel in the cage is prohibited.

The counterweight swing radius of the crane shall be barricaded and clear of obstructions.

12.0 Use of Crane Hoisted Workboxes/Man Basket

Crane hoisted workboxes / man basket shall only be used where there is no other practicable
alternative means to safely carry out the work.

Supervisors shall provide a comprehensive risk assessment to the EHS Coordinator for review, a
minimum of 1 working day prior to the use of any crane hoisted workbox / man basket and submit the
completed permit application to the Site Manager for approval.

All cranes used to lift workboxes / man basket shall be fitted with a double acting or positively locking
Safety catch on the crane hook, drive up and down controls for hoisting and slewing motions, be
equipped with controls that return to the neutral position when released and this action caused the
motion to stop.

Personnel in the workbox / man basket shall be issued with, trained and instructed to wear a Safety
harness that is attached to an approved anchorage at all times.

DHI-EHS-HSM-011 (March 2014), Page 9 of 12

 Access and egress from a workbox / man basket is prohibited except where approved by the Site
Manager following discussions with the EHS Manager.

A certificated rigger must be in the workbox / man basket at all times when elevated.

Radio communication on a dedicated individual crane channel shall be used at all times when using a
workbox / man basket. A minimum of 2 radios shall be used, in case of battery failure.

Gas cylinders or material other than essential tools etc and objects protruding outside the confines of
the workbox / man basket is not permitted.

Travelling the crane with personnel in the cage is prohibited.

The counterweight swing radius of the crane shall be barricaded and clear of obstructions.

13.0 References
 DHI-EHS-HSM-032 Inspection and Tagging

14.0 Appendix
 Appendix A - Lifting Operations Risk Checklist
 Appendix B - Crane Inspection Checklist

DHI-EHS-HSM-011 (March 2014), Page 10 of 12

Appendix A - Lifting Operations Risk Checklist

LIFTING OPERATIONS - RISK CHECKLIST

NAME OF
DATE:            
CONTRACTOR:
P.M.A NO. /
DAY:            
EXPIRY DATE:
OPERATOR’S
LOCATION:            
LICENCE CLASS:
TYPE OF EQUIPMENT:      

REMA
NO. DESCRIPTION CHECKED BY
RKS

1 Use of untrained or inexperienced personnel. YES NO            

2 Overloading and overturning of crane. YES NO            
3 Failure or equipment. YES NO            
4 Incorrect slingings of loads. YES NO            
5 Misuse of equipment. YES NO            
6 Incorrect selection of equipment. YES NO            
7 Falls of materials. YES NO            
8 Striking structures. YES NO            
9 Unsafe access/egress. YES NO            
10 Contact with overhead services. YES NO            
SCAFFOLD CRANE
11 Suitability of equipment. YES NO            
Adequate support for crane/ equipment and checking of
12 YES NO            
anchoring devices.
13 Use of untrained or inexperienced personnel. YES NO            
14 Falls of materials. YES NO            
LIFTING EQUIPMENT, SLINGS AND GEAR
15 Use of damaged or defective equipment. YES NO            
16 Overloading equipment. YES NO            
17 Misuse of equipment. YES NO            
Remarks if any:
     
     

Checked By:       Approved By:

DHI-EHS-HSM-011 (March 2014), Page 11 of 12

Appendix B - Crane Inspection Checklist

Crane Inspection Checklist

PROJECT:      
DATE:       NAME OF CONTRACTOR:      
DAY:       P.M.A NO. / EXPIRY DATE:      
LOCATION:       OPERATOR’S LICENCE CLASS:      
TYPE OF EQUIPMENT:       CERT / BADGE NO.:      
NO. DESCRIPTION REMARKS CHECKED BY
PRE-LIFTING CHECKS
1 Lifting procedure/prepared/planned YES NO            
2 Main crane inspected/Jibs good condition YES NO            
3 Secondary crane inspected YES NO            
4 Work area in safe-condition YES NO            
5 Lifting calculation completed/Load Test/Charts YES NO            
6 Height clearance calculation completed YES NO            
7 Shackles inspected YES NO            
8 Slings inspected with certificates YES NO            
9 Spreader bar inspected YES NO            
10 Dimension of equipment & resting area checked for installation YES NO            
11 Reverse alarm & lights functioning YES NO            
12 Doors & windscreen good condition YES NO            
13 Main brake system functioning YES NO            
14 Winch brake system functioning YES NO            
15 Wire cables good condition YES NO            
16 Radius charts YES NO            
TRANSPORTATION CHECKS
17 Ground stability of route YES NO            
18 Compaction of route YES NO            
19 Steel plates (where required) YES NO            
FINAL LIFTING CHECKS
20 Main crane outriggers fully extended YES NO            
21 Stability of main crane outriggers YES NO            
22 Compaction of main crane outriggers footing YES NO            
23 Any obstruction to existing equipments/vehicles YES NO            
24 Dedicated signalman (one person only) with vest YES NO            
25 Working platforms/staging secured/safe condition YES NO            
26 Tag lines in place YES NO            
27 Weather in good condition YES NO            
28 Warning sign and barricaded YES NO            
29 Area supervisor/safety personnel supervision YES NO            
30 Fire extinguisher in place YES NO            
Remarks if any:
     
     

Checked By:       Approved For Lifting By:

DHI-EHS-HSM-011 (March 2014), Page 12 of 12