Cranes & Hoists Program
Cranes & Hoists Program
Cranes & Hoists Program
Distribution List
Sr. No/ Designation Issue Date Distributed by
Management
01 QHSE Manager 1st Oct 2017
Representative
Management Management
02 1st Oct 2017
Representative Representative
03 Management
CEO 1st Oct 2017
Representative
04 Management
Chairman 1st Oct 2017
Representative
Revision
Document Issue Revision Original Document Document Document
Issue
Number Number Number Issue Date Prepared By Reviewed by Approved By
Date
QHSE MR / CEO Chairman
AJB-CHP-PR- Manager
1.1 01 01-09-17 01-10-17
02
Copyright
This document contains confidential information. It may be copied in full or in parts only by Al-Jaber
International Company and only for the purpose of Al-Jaber International Company related activities.
Disclosure of any information contained within this procedure to any person (s) outside the employee of Al-
Jaber International Company without written permission of the Top Management is strictly prohibited.
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Al-Jaber International Company
System for Cranes & Hoists Program
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Contents
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1.Purpose
2.POLICY
a) The AJIC Crane Safety Program has been developed to provide our employees and
contractors with safe methods for working with cranes and related equipment (e.g.,
rigging).
b) AJIC employees may be required to operate AJIC cranes (see Appendix A for list of
cranes) and related equipment as part of their job duties. To minimize risks to people
and property AJIC restricts the operation of all cranes to those persons who have been
properly trained, authorized, or certified to operate cranes.
c) The Crane Safety Program applies to all AJIC employees as well as contractors
conducting crane work while on any AJIC property. The intent of this program is to
control crane hazards by ensuring the following:
3. DEFINITIONS
Boom: A structural member attached to the revolving superstructure used for guiding and
acting as a support for a hook or other end attachment for securing load.
Bridge: Principal horizontal beam(s) of the overhead crane which supports the trolley.
Counterweight: Weights used for balancing loads and the weight of the crane in providing
stability for lifting.
Chart (Load): The manufacturer’s minimum and maximum lifting limitations for any
particular crane.
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Designated Signal Person: An individual who is assigned to give recognized hand signals to the
crane operator during any crane lifting operation.
Drum: The spool or cylindrical unit around which wire rope is wound to raise and lower loads.
Groundworker: An individual who performs a variety of duties to support crane lift operations
including unskilled physical labor and specialized equipment operation.
Hoist (Boom): A hoist drum and rope reeving system used to raise and lower the boom.
Hold-Harmless Agreement: A contract under which the one party agrees to indemnify,
defend and hold harmless a second party, from and against all claims arising out of use of
equipment.
Lift Supervisor: Supervisor responsible for direct oversight of a crane lift operation, and
ensuring the operation meets OCSD and regulatory requirements for inspection, personal
qualification, and site preparations.
Load Chart: The manufacturer’s absolute limitations of a crane based on structural strength
and stability of the crane.
Mechanic: Performs technical duties and responsibilities in the maintenance, repair, service,
and troubleshooting of cranes and other mobile equipment.
Outriggers: Support members attached to the crane’s carrier frame which is used to raise the
crane off the rubber wheels for increased capacity and stability.
Overhead Crane: Any hoisting device where the hook-and-line mechanism runs along a
horizontal beam that runs along two rails, or the hook-and-line mechanism runs along a
cantilevered (jib) boom arm.
Pendant Control: Suspended push button controls from crane to floor for operator control of
functions.
Qualified Person: A person designated by the employer who by reason of training, has
demonstrated the ability to safely perform all assigned duties and, when required, is properly
licensed.
Qualified Rigger: A person who is trained to handle and move loads during a crane lift
operation.
Rated Capacity: The maximum load values shown on a load chart for a particular crane
configuration.
Reeving: Refers to a rope system in which the rope travels around drums and sheaves.
Procedure
Risk Manager: Manages, supervises, and coordinates activities and operations within
the Risk Management Division at AJIC.
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Rope: For all hoisting operations any reference to rope will mean wire rope.
Spotter: A safety observer whose sole task is observing and warning against the
unsafe approach to hazards, such as overhead powerlines.
Trolley: Carries drum and hoist mechanism and travels on the bridge rail.
4. RESPONSIBILITIES:
a) Lift Supervisors shall:
1) Make sure operators are properly trained and qualified (See Appendix B).
d) Mechanics shall:
1) Be qualified to make adjustments and repairs.
2) Ensure all maintenance, inspections and testing conducted is based on
manufacturer’s recommendations, and specific site conditions.
3) Seek approval of crane manufacturer for any modifications of the crane that
will change the structural or lift characteristics of the equipment.
4) Ensure all maintenance related inspections occur at frequency specified by
the manufacturer, or Cal/OSHA (see Section 8).
5. PROCEDURE
a) All Cranes
1) All crane load charts are to be clearly legible and in clear view from the
operator’s position.
2) The rated load of a crane must be clearly marked on each side of a crane.
3) Equipment must not be operated in excess of rated capacity.
4) Cranes shall have all required signage and decals on the crane body.
5) No one is permitted to ride on loads, hooks, or slings of any hoist or crane.
6) The empty hook, headache ball, or block should not swing freely.
7) Cranes shall be equipped with the applicable safety devices (see Appendix
1) When working near powerlines, cranes shall comply with the following safe
work practices:
Assume all overhead lines are energized and potentially dangerous.
Stay at least 10 feet away, if the overhead powerline is 50kV or less.
Stay at least 15 feet away, if powerline is over 50kV to 200kV.
2) A fire extinguisher of not less than 10-ABC rating shall be kept in serviceable
condition and readily accessible to the operator.
3) A crane must not be operated when its wheels or tracks are off the ground
unless it is properly supported on outriggers.
4) Crawler and wheel mounted cranes must not be operated without the full
amount of any counterweight in place unless specified by the manufacturer.
5) During a tilt-up or tilt-down operation no employee shall be directly under the
load.
6) The boom or other parts of the equipment must not contact any obstruction.
7) The equipment must not be used to drag or pull loads sideways.
8) The operator must test the brakes each time a load that is 90% or more of the
maximum line pull is handled by lifting the load a few inches and applying the
brakes.
9) No less than two full wraps of rope must remain on their drums at all times,
unless otherwise specified by the manufacturer.
10) If a crane is to travel with a lifted load, the employer must ensure that a
Critical Lift Plan is submitted to Risk Management for approval.
11) Rotational speed of load must not hinder ability to control load. A tag or
restraint line must be used as needed to control rotation of the load.
12) In travel the boom shall be carried in line with the direction of motion and the
superstructure shall be secured against rotation.
d) Tower Cranes
1) Manufacturer’s specification regarding design, erection, operation, and safety
must be available onsite.
2) A Cal/OSHA permit is required before a tower crane is erected, climbed, or
dismantled.
e) Slings, ropes, and attachments
1) Damaged or defective slings shall be taken out of service.
2) Selection and installation of equipment on cranes must meet
recommendations of the rope manufacturer, crane manufacturer, or a
qualified person.
3) Fiber core ropes must not be used for boom hoist reeving.
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4) Rotational resistant ropes may be used at the discretion and under the
guidance of a qualified person. Chain or wire rope slings shall not be
shortened with knots, bolts, or other makeshift devices.
5) Slings shall not be kinked, knotted, loaded in excess of their rated capacities,
or be pulled from under a load when the load is resting on the sling and
damage to the sling may result.
6) Slings shall be set to avoid slippage, be padded or protected from the sharp
edges of their loads, and slings used in a basket hitch shall have the loads
balanced to prevent slippage.
7) Suspended loads shall be kept clear of all obstructions.
8) Hands or fingers shall not be placed between the sling and its load while the
sling is being tightened around the load.
9) Shock loading is prohibited.
10) Only use slings with permanent affixed identification markings that show the
maximum load for each sling.
8. INSPECTION
Inspections should be performed at the recommended intervals, and conducted or
coordinated by the responsible party listed in Table 1, and records shall be maintained by
the responsible parties.
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9. MAINTENANC
AJIC mobile crane maintenance, and AJIC overhead and gantry crane inspections shall be
coordinated by Facilities Engineering. All maintenance must be conducted in accordance
with the manufacturer’s recommended procedures. All guards removed during
maintenance shall be reinstalled, and all safety devices reactivated after maintenance is
performed. The equipment shall be tested for proper operation before being returned to
service after maintenance is performed.
10. TRAINING
Operators shall be trained and written documentation (e.g., certificate) of training shall be
available. Operators of mobile cranes above 7.5 tons lifting capacity or 25 feet of boom
must carry certification during crane operation. In cases where other personnel (e.g.,
contractors) will be using these devices, they shall be similarly trained. See Appendix B for
additional guidance.
In addition, each AJIC employee (i.e., rigger, signal person, and spotter) involved in crane
operations must be trained in the hazards associated with crane hoist/lifting operations.
Training should include overhead powerline awareness, crush/pinch points prevention,
Fall Protection, and Lockout/Tagout procedures. Each employee must be evaluated (e.g.,
tested) on the training topic to ensure the training provided is understood.
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APPENDIX A
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APPENDIX B
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APPENDIX C
Signaling Requirements
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Figure C-1
Recommended Hand Signals for Controlling Crane Operations
Figure C-2
Recommended Hand Signals For Boom Equipment Operations
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Figure C-3
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APPENDIX D
Fall Protection Requirements
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APPENDIX E
The following safety devices and operational aids are required on all cranes
covered by this policy, except gantry and overhead cranes, and cranes with less
than 1 ton lift capacity. In addition, boom hoist limiting devices are not required for
mobile cranes with a rated capacity of 3 tons or less
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APPENDIX F
Critical Lift Planning
Crane lifts are classified into two categories: critical lifts and general lifts. Critical
lifts shall have the following additional planning requirements:
A qualified person shall prepare the Critical Lift Plan (see Appendix F-1 for
sample plan). The qualified person preparing the plan may be the crane
operator, lift supervisor, or designated rigger, and shall include the other
qualified individuals in the lift plan.
The plan shall be reviewed by, and signed by, all personnel involved with
critical lift.
The Critical Lift Plan shall be used when any of the following characteristics or
conditions exist::
o Anytime a load will be lifted over an occupied building.
o Any lift which meets or exceeds 75% of the crane’s capacity at the given
radius as posted in the load chart for the specific crane and its configuration.
o Any lift that requires two or more cranes.
o Any lift of 100,000 pounds or more.
o Any lifts involving of personnel platforms.
o Using a crane where fully extended outriggers and /or the 360 degree load
chart (if applicable) cannot be used.
o Operating a crane in a position where it could possibly exceed the minimum
distances from overhead powerlines.
o Any lifts over operating facilities where they may endanger personnel, the
public, or a project schedule.
o Any operations involving traveling with a lifted load.
o Using a bridge platform as a work platform (See Special Operations).
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Using overhead bridge platform for work, such as changing overhead lights,
is permissible provided a Professional Engineer or the crane manufacturer
has determined that work can safely be performed from the platform or
walkway. This determination will need to be in writing. For AJIC operations,
an assessment of the platform by a third- party Professional Engineer is
required. Additional provisions placed on this type of operation include:
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Appendix F-1
Critical Lift Plan Form
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Appendix F-1
Critical Lift Plan Form
(Continued)
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Appendix F-1
Critical Lift Plan Form
(Continued)
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Appendix F-1
Critical Lift Plan Form
(Continued)
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Appendix F-1
Critical Lift Plan Form
(Continued)
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APPENDIX G
Crane Inspection Requirements
Pre-use (Daily/shift)
A qualified person shall visually inspect the crane's carrier, controls, rigging and operating
mechanism prior to the first operation on any work shift. Any unsafe conditions shall be
corrected promptly. Defective components of equipment which create an imminent safety
hazard shall be replaced, repaired or adjusted prior to use. Daily visual inspections by the
operator or other qualified person shall be made of/for:
Quarterly
Periodic shall be conducted at least four times a year. The annual certification, can serve as one
of the required periodic inspections. The periodic inspections shall be evenly spaced or as close
to evenly spaced as scheduling permits through the year. Cranes shall not be operated more
than 750 hours, between periodic inspections. The inspection shall include the following in
addition to the items in daily/work shift inspection:
Annual (Comprehensive)
At least every 12 months the equipment shall be inspected by a certificating agency and shall
include the following:
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Appendix G -1
Crane Inspection Form
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Appendix G-2
Rigging Inspection Form
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