Crane Safety Precautions

Purpose
 This procedure and practice is provided as a guide to
Contractor, its subcontractors their staff, and
specifically the rigging staff and rigging coordinators
to execute all crane lifts safely. This procedure shall be
implemented by Contractor and enforced by Owner
on the Project.

2
SCOPE
This procedure provides the following:
Establishes the requirement for organizing a Contractor Crane and
Rigging Group, lists personnel and defines their role in the successful
execution of this practice, identifies the responsibilities of key
personnel for this practice.
Identifies the requirements for design and review of lifting lugs.
Categorizes rigging lifts for and establishes responsibility for the
design, engineering and approval of the transportation and rigging of
all equipment and modules. This practice covers all crawler cranes,
truck cranes, carry deck cranes, monorails, boom trucks, etc.
Establishes guidelines that must be adhered to when requiring a
variance from this procedure.

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Crane Operator
A qualified person who is licensed, trained, certified
and experienced in the use, the capabilities, and all of
the functions of a specific machine, mechanical system,
or tool. All Crane Operators must meet the following
requirements:
An up-to-date shall be on file with Contractor, detailing
specific experience in crane operation.

4
Signalman
 A designated person who is trained and experience in hand signals
used and understood by crane operators.

 One designated signalman will be responsible for the control and

coordination of any particular lift or Heavy Rigging Activity and shall
wear a green reflective vest.

 Under certain conditions, such as multiple crane lifts, or lifting "in the
blind", it may be deemed necessary for additional signalmen to
participate in a lift or Heavy Rigging Activity. One signalman will be
designated as the “Lead Signalman”.

5
Responsibilities
 Responsible Personnel - The crane operator, and the
qualified field rigger, are jointly responsible for
determination of the load weight and placement of the
crane so that it is set up within the operating radius
selected. The rigging supervisor has final
responsibility for all operations.

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Contents

• Cranes Instructions & Standards

• Cranes Components & Stability
• Operations Responsibility
• Maintenance or Construction Responsibility
• Critical Lifts
• Precautions
• Incidents
If YOU THINK SAFE…
I THINK
SAFETY
..and YOU ACT SAFE IIFOLLOW THE
I ACT SAFE- YOU’LL
KNOW THE BE
SAFE RULES
RULES
SAFE
 Most of crane incidents within the
company are due to ‘loss of stability’

Let’s take a look at, and understand ‘Stability’

 STABILITY
1.1 Outrigger spans
1.2 Outrigger set-up
1.3 Counterweight options
1.4 Center-of-gravity
1.5 Tipping axis
OUTRIGGER SPANS
IT IS NOT ALLOWED TO Full extension
MIX SPANS-

ONLY ALL FULL SPANS

MAY BE USED
OR
ONLY ALL PARTIAL
SPANS MAY BE USED

Partial extension
OUTRIGGER
SPAN 1

 ALL MAXIMUM
SPAN
OUTRIGGER
SPAN 2

 ALL PARTIAL
SPAN
INCORRECT
OUTRIGGER SPAN 1

PARTIAL
SPAN

X FULL
SPAN
 INCORRECT
OUTRIGGER SPAN 2

PARTIAL FULL
SPAN SPAN

X
SPAN OPERATION
THE BEAMS TRANSFER LOAD TO THE CARRIER AT THE CORRECT
POSITIONS WHEN CARRIER WHEELS CLEAR THE GROUND.

CRANE (AND LOAD) WEIGHT

 
INCORRECT SPAN -
OPERATOR ERROR
THIS BEAM TRANSFERS LOAD TO THE CARRIER AT AN
INCORRECT POSITION WHEN CARRIER RAISES.

X
THIS AREA IS
NOT STRONG
This accident is due to an
OPERATOR ERROR
Operator Error.
He used an Incorrect
Outrigger Span……..!

No extension
beams used
OUTRIGGER SECURITY

X
FOR ROAD
TRAVEL, THESE
LOCKING


DEVICES MUST
BE USED
 TIPPING AXIS
EXPLANATION 1
‘outriggers
nearest to
the load’

TO RIGHT SIDE
TIPPING AXIS
EXPLANATION 2

STILL TO RIGHT SIDE

ABOUT THE TIPPING
AXIS

CRANE WEIGHT

‘outriggers
nearest to
the load’

LOAD WEIGHT

Y X

TIPPING AXIS
OPERATOR ERROR
Crane was on
tires only.
No outriggers
in use

This accident is due to an Operator Error.

He moved the crane Center-of-Gravity
outside the crane Tipping Axis.
LIFT CONFIGURATION
Boom

Lift
Operating Code Lift Configuration
Configuration  Outrig
gers

Parts-of-Line Counterweight
OPERATOR ERROR

INCORRECT CONFIGURATION
 CRANE INSPECTION
I must ensure If it is to Even for a
this machine be used run-up,
is safe to use If it is to be for craning an inspection
used for is needed
traveling
 Operation Responsibility
• Crane, Crane Operator, Rigger Certificate.
• Maintain daily checklist
• An approved lift plan provided.
• Heavy lifts must be noted on the Work Permit.
• If load critical or man basket required operation foreman should
issue the work permit.
• Crane location and positioning.
• Critical Wind Speed.
• Stop the work
 Maint. / Construction Responsibility

1. Obtaining a work permits from the operating Unit

Foreman before bringing the crane inside the
operating area.
2. Ensure that the crane is in good operating condition.
3. Strictly adhere to the procedures and precautions
mentioned in WP.
4. Immediately stop work if unsafe conditions or crane
incident and immediately report.
5. Ensuring that an approved Lift Plan is utilized if the
lift has been determined to be a “Critical Lift"..
 Critical Lift
Critical lifts are defined as high risk lifts where there
is a potential for serious injury, major property loss,
or disruption of programs or projects. The following
are examples of the critical lifts:
1. Around energized electrical lines.
2. Near or over hydrocarbon loading piers.
3. On barges, vessels and hydrocarbon loading piers.
4. Around and over populated/traffic areas.
5. Tandem, multiple or tailing lifts.
6. On rubber or pick and carry lifts.
7. Personnel Platforms (man lifts)
8. High level or long reach lifts.
SAFETY PRECAUTIONS
 Crane & accessories shall be kept in good condition.
 The crane shall have a sticker updated every three
months
 Crane operated in the vicinity of spills or leaks, special
precautions must be undertaken.
 The weight of the crane shall be stenciled on the crane.
 Repair work, maintenance or refueling inside the Unit
battery limits.
 Moving of a crane into or out of an operating unit.
 The traveling of cranes with suspended loads is not
allowed in Rabigh Refinery
X

Poor flat
support
 X

X
 Load is
too
Telescoping out close
and increasing from the
Too much load
The load radius crane

RESULT
Stability Tripping Strength
failure structure
failure
Incidents
Crane Incident

This accident is due to an

Operator Error. The operator
programmed the incorrect
code into the R.C.L. or it was
by-passed and then he
moved the crane Center-of-
Gravity outside the crane
Tipping Axis.
 Crane Incident

Stabilizers are
retracted

10.5t
Counterweights
 Crane Incident
Note the
trench here

The crane was on

tires with wheels in
the trench.
If the operator had
knowledge of drive
modes, this
accident would not
have occurred
 Crane Incident
...TIPPING (OR
OVERTURNING) OCCURS
It’s as simple as that!!!

This accident is due to an Operator Error. The

operator programmed the incorrect code into the
R.C.L. or it was by-passed and then he moved the
crane Center-of-Gravity outside the crane Tipping
Axis. (Rigger was not attend)
Rigging
All manufactured rigging equipment including, but not limited to: slings
(nylon and wire),
chokers, wirerope lashing, come-alongs, chain falls, etc.
Contractor shall ensure all rigging equipment shall be free from defects,
in good operating
condition and maintained in a safe condition and shall bear the serial
number of the
manufacturer and the Safe Working (SWL) Load capacity marked on it.
All rigging equipment
will also be accompanied by the manufacturer’s certificate indicating the
serial number and
capacity.
Safe Work Practices
1. Rigging and lashing should be protected from damage by softeners or other active
means while in place.
2. Nylon, rope, or other slings subject to damage by sharp edges shall be protected during
the lift.
3. The chains or ropes of a come-along or chain fall shall not be used as chokers.
4. Lifting bays used to make lifts will be barricaded at ground level to protect employees
from walking under loads.
5. Buckets, barrels, tubs, etc. used to lift smaller objects shall be effectively covered and
secured during lifting to prevent accidental spillage of their contents.
6. Sheet metal, boiler siding, insulation or other objects of a sheet nature will not be lifted
by sheet dogs without the prior approval of the Project Manager.
7. Rigging equipment will not remain in the elements longer than necessary to do the
work, protected from mud, dirt and chemical exposures.
8. No hand spliced slings are allowed on the project.
9. Nylon slings are not allowed for hoisting structural steel.
10. Single sling lifts are not allowed.
11. Only inspected rigging equipment bearing the colour coding for the month and that
have the SWL indicated on it and with the manufacturer’s certification shall be allowed
to be used.
Inspection
Inspection
All rigging will be inspected on a monthly basis. The inspection will be conducted and
documented. Inspection reports are to turned in to the Project Safety Office, by the fifth
(5th) day of that month. The Rigging Supervisor, or his designee will conduct this
inspection.
Contractor shall make the inspection records and manufacture’s certifications and
specifications of the rigging equipment available to OWNER upon request. The Rigging
Supervisor or designee will insure that any item found to be defective is removed from
service immediately. These items, if found to be unacceptable, will be tagged out of
service, "DO NOT USE," and returned to the tool room/warehouse.
All rigging equipment found to be in good condition when inspected shall be color
coded for the monthly period, and valid for that period only.
Color Coding
The color coding scheme and placement of color coding
for rigging equipment on this project
will be as follows:-
Yellow Blue Orange Green Red White
January February March April May June
July August September October November December
NOTE!!! Colour coded tie-wraps may be substituted
for tape.
EQUIPMENT REQUIREMENTS
All motorized equipment must have a reverse signal alarm audible at
30 meter distance above the surrounding noise level. In addition while
the equipment is being operated shall have a flagman wearing a yellow
reflective vest and equipped with a red flag and a green flag.
All cracked and broken glass shall be replaced before bringing vehicles
on the jobsite. If glass is broken or damaged on jobsite and if damage
is severe enough to cause a potential safety problem, the machine shall
be stopped until such damage has been repaired.

Vehicles used to transport employees shall have seats firmly secured

and adequate for the number of employees to be carried and all
passengers should be properly seated. Standing on the back of moving
vehicles is prohibited. It is not allowed to transport employees in the
back of pick-up trucks or any open vehicle.
 EQUIPMENT REQUIREMENTS

Owner shall review and approve locations for storage of all fuels, lubricants, starting fluids
prior to use by Contractor for storage.
Contractor shall equip all vehicles and fuel driven construction equipment with a fire
extinguisher, red triangles, flashlight and a first aid kit.

Safety Devices

Contractor shall equip all vehicles and fuel driven construction equipment with a fire
extinguisher, red triangles, flashlight and a first aid kit.

All rubber tired, self propelled scrapers, rubber tired, front-end loaders, rubber tired dozers,
wheel type agricultural and industrial tractors, crawler tractors, crawler type loaders and
motor graders shall be equipped with rollover protective structures and seat belts.

Inspection of these devices will be included as part of the operators' daily pre-operational
inspection, as well in the formal monthly inspection.

No equipment shall be operated with defective or missing safety devices.

Engineered Lifts
Engineered lifts are categorized “A” , “B” and “C” lifts.
“A” Lifts
Lifts up to one hundred (100) tons per the following requirements:
Vessels Vertical 30 tons and over
Vertical 2.4 meters (8 feet) diameter and over
Horizontal 60 tons and over
All other equipment and structures sixty (60) tons and over.
Equipment or vessels over twenty (20) tons that are inside structures, in
inaccessible locations, over operating processes or in hazardous areas as
determined by the site manager or rigging engineer. Also included is
equipment and vessels constructed of nonferrous materials, or are otherwise
prone to damage during handling.

All multiple crane lifts (exclusive of a tailing crane) in which the load could be
transferred from one crane to another during the lift.

All lifts over eighty (80) percent of the capacity chart of the crane for the boom
length and operating radius being used, or over ninety (90) percent if the crane
has an operational load indication device with an overload cut-off.

Transportation - All plant equipment over sixty (60) tons.

“B” Lifts

Lifts 100 to 600 tons.

Responsible personnel for a Type “B” engineered lift must be:
“C” Lifts

Lifts six hundred (600) tons and above.

Prior to awarding a rigging contract and approving a rigging plan,
the manager of the project along with the site manager and rigging
manager shall review the rigging plan, risk analysis, and/or
contractor bid evaluation to ensure that risk/liabilities are
understood and mitigated to the maximum extent possible.
SUMMARY

This specification describes the requirements for

furnishing all engineering, supervision, labor,
equipment, tools, materials, services, and supplies
necessary to provide transportation, erection, and
material handling services to satisfy the particular
requirements of the project/site. This specification
provides these requirements for services performed by
Contractor.