NEW CONTAINER TERMINAL DAMIETTA PORT

REINFORCEMENT CAGES LIFTING PLAN

Serial no:
 NEW CONTAINER TERMINAL DAMIETTA PORT
REINFORCEMENT CAGES LIFTING PLAN

Contents
1. INTRODUCTION
2. SCOPE
2.1 Lifting reinforcement cages
3. REFERENCES
4. RESPONSIBILITIES AND QUALIFICATIONS OF KEY STAFF
4.1 Planning and control
4.2 Site foreman
4.3 Crane operator
5. LIFTING EQUIPMENTS AND LIFTING GEARS
5.1 Telescopic crane
5.2 Lifting gears
5.2.1 Types of Lifting Gear
5.2.2 Inspection and Color Coding of Lifting Gear
5.3 Inspection, examination and maintenance
6. LOADS TO BE LIFTED
6.1 Reinforcement cages
7. LIFTING OPERATIONS
7.1 General arrangement
7.2 Rigging method
7.3 Precautions to be taken before the lifting operation
7.4 Particular lifts with one crane
7.4.1 Short reinforcement cage section
7.4.2 Lifting points
7.5 3 Capacity of cranes and lifting gears

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8 . ATTACHMENTS.
8.1 calibration Crane.
8.2 Riggers certifications .
8.3 Pre inspection for crane .
8.4 Load chart for crane
8.5 Steel wire rope certification .
8.6 Shackles certifications.
8.7 Spreader beam calibration.
8.9 Shop drawing for load.

APPENDIX

Appendix 1 Register of Lifting Gears available on site

Appendix 2 Color code system on lifting gears
Appendix 3 Hand signals
Appendix 4 Loads weight, dimension and the required lifting gear
Appendix 5 Lifting equipment calibration certificate
Appendix 6 Steel cage lifting using one crane
Appendix 7 Lifting operations risk assessment
Appendix 8 Lifting operations job hazard analysis

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1. INTRODUCTION

ARAB CONTRACTORS has been awarded to expand the Container Terminal Damietta Port to keep pace
with development.
The purpose of this specific procedure is to describe the lifting operations carried out by ARAB
CONTRACTORS in this project location and to guide the ARAB CONTRACTORS team to cope effectively
with the related requirements and risk. This document should be read in conjunction with arab
contractors's project qualityplan, other method statements and the HSE plan.

2. SCOPE
Lifting reinforcement cages from fabrication area to site or storage area with specifications:

 Reinforcement cages for barrettes and diaphragm withspecifications :

 Cage 1( length= 12m ,weight= 4.7ton )
 Cage 2( length=22m , weight = 12 ton )
 Cage 3( length= 17.5 m ,weight = 17.5)

3. REFERENCES
( ISO 14001, ISO 45001, Law 4/1994 for environment, Hse plane ,osha constrction manuel,
Law 12/2003 )

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4. RESPONSIBILITIES AND QUALIFICATIONS OF KEY STAFF

4.1 Planning and control

The HSE engineer is in charge to plan and control all lifting operations. He
shall review periodically the lifting plan and incorporate any findings and/or
comments from the construction manager in case of any new load/elements
to be lifted or any new lifting equipment becoming available on site and the
HSE inspector shall appoint suitable staff with the adequate qualification and
experience for the lifting operations, including Site foreman and crane
operators. The HSE manager shall review the procedure and together with his
team of Hse team leader on site control the execution of the works and assist
the lifting operations where required.

4.2 Site foreman

The responsibilities of the Site foreman can be summarized as follows:
a) Oversee critical lifting activities in his responsible area.
b) Instruct crane operator, designate flagman, to conduct lifting operation under the height
restriction limit.
c) Report to Site Superintendent any situation requiring rectificationregarding lifting operation.
d) Temporary suspend lifting operations in case of emergency.
e) Assist Hse team leader to conduct safety training and incident investigation in regard to lifting
operation.

4.3 Crane operator

The responsibilities of the crane operator can be summarized as follows:
a) Carry out functional tests to the lifting appliance prior to its operation to ensure safety.
b) Operate the lifting appliance in accordance with manufacturer's instructions.
C) Take due consideration with local environment site conditions and nearby activities .

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Each Crane Operator shall have the following minimum qualification:

a) Have attained the age of 18 years.

b) Hold a valid approved operating license issued by athird party of that

particular type of plant.

c) Be fit, with particular regard to eyesight, hearing and reflexes.

d) Have been trained in the general principles of slinging and be able toestablish

weights and judge distances, height and clearances.

e) Understand fully different types of communication signs betweenthe parties

concerned.

f) With sound site safety knowledge and skill.

5. LIFTING EQUIPMENT AND LIFTING GEARS

5.1 Telescopic crane

Arab contractors is using telescopic cranes with a capacity suitable to lift the biggest load in the
project technical data sheet together with the loading table is attached in (will be observed to avoid
overloads in parts of the structure which are beyond their design capabilities.

5.2 Lifting gears

5.2.1 Types of Lifting Gear
Various types of lifting gear will be used for the execution of the works.(Appendix (1) ) includes non-
exhaustive register of Lifting Gear may be available on site.
The HSE inspector is in charge to update the register continuously.All certificates of the lifting gear are available
upon request.

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5.2.2 Inspection and Color Coding of Lifting Gear

The common color-coding system according to the best practice in company is used on site to monitor
the inspection and certification status of the lifting gear and indicate that the lifting gear is approved for
use in the respective period. (Appendix (2)) includes the color code system on lifting gears.
The HSE inspector shall ensure that the certification and stamping of lifting gear are satisfactory upon
their arrival on Site. On the last working week of each month, the HSE inspector will issue copies of
the updated register of the Lifting Gear to area supervisors. The supervisor will then check all
equipment on their batch for compatibility with the register. The supervisor will particularly ensure
that stamping is still legible and the coloring is appropriate.

Any equipment in doubt shall be removed from the working area. They will be quarantined, re-certified or
scrapped accordingly. The HSE inspector will arrange to paint the equipment under quarantine red.
On the following days; all lifting equipment shall be inspected by the HSE inspector who shall also check the
validity of certificates. The HSE inspector shall ensure that all equipment is painted with the appropriate
color and an updated register of such equipment kept. If the equipment is faulty, then it shall be painted
red and the area supervisor be advised to remove it from the Site immediately.
During day-to-day operations, it is the responsibility for all concerned (Site foreman crane operator and
rigger) to ensure that proper lifting equipment is used.

5.3 Inspection, examination and maintenance

Annual maintenance, examination and testing of the crane by third party, including the automatic safe load
indicator, all safety devices, mechanical and structural elements should be arranged to ascertain their
compliance with the requirements stated in the British standard.
Al maintenance and servicing works must be performed by trained and qualified personnel. All
maintenance and repair works carried out must be clearly recorded.
Moreover, the maintenance crew should also specify the reason why repair works have been carried out.
Whenever any major repairs are carried out to a crane, it must be tested, examined and certificated as per
statutory requirements. All valid certificates of testing and examination of the cranes should be properly
maintained and ready for verification.

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6 . LOADS TO BE LIFTED

6.1 Reinforcement cages.

The reinforcement cages are one of the largest and heaviest loads to be lifted. For lifting, the cage lifting
points shall be used together with the adequate lifting wire ropes, chains, pulleys and spreader beam
based on to the cage length.
The steel cage must be well welded to ensure adequate robustness for temporary lifting stresses.
(Appendix 6) includes steel cage lifting by spreader beam system using one crane.

7. LIFTING OPERATIONS

7.1 General arrangement

A site foreman is appointed to supervise the operation at each work site. The signals to each crane
operator should be clear and rehearsed (Appendix 3) The lifting by crane would be planned carefully, and
an accurate assessment of the share of the load which is to be carried by crane. An accurate assessment of
the working location and operation radius is to be assessed to ensure no accidental collusion will occur.
Foreman and crane operator must ensure the plant and equipment is to avoid being located at any areas
marked keep clear.
The function of the cranes during a specific lifting operation might be exchanged to suite the limited space
conditions. However and in any case the loads and capacities of each involved items need to be checked
prior lifting.
Appendix 7 Lifting operations risk assessment
Appendix 8 Lifting operations job hazard analysis .

7.2 Rigging method

To avoid the risk of the slipping or displacement of any part of the load as well as the falling down of the
load, particular attention should be paid to the provisions of proper rigging procedures and precautions.
Site foreman will ensure that the person who direct and handle the loads have received training in the
principles of the operation, are able to estimate weights and judge distances, heights and clearances, and
capable of selecting tackle and lifting gear as well as rigging method suitable for the loads to be lifted, and
are capable of directing the movement of the crane and load to ensure the safety of all.

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7.3 Precautions to be taken before the lifting operation

Proper rigging methods shall be established. Only suitable lifting gear, equipment and tackle shall be
employed and painted in adopted color as the color code schedule.
Particular consideration shall be given to the balance of the loads to be lifted. The type of sling and the
slinging methods used shall ensure that the load would not topple or slip.
Every lifting gear, equipment or tackle to be used shall comply with the statutory requirements concerning
the construction, safe working loads, marking of safe working loads, testing, examination, inspection, etc,
Where a wire rope sling is used, the sling shall not be allowed to damage the load, nor shall the sling itself
be damaged.

If the sling is to be attached to the load, the points used for attachment shall be suitable and adequate for
the purpose of lifting the whole load. Suitable packing shall be provided and used to prevent damage to
slings by sharp edges on loads. When using multi-legged slings to lift loads in which one end is much
heavier than the other, the decision to select the appropriate sling shall be based on the most heavily
loaded leg rather than the total weight.

7.4 Particular lifts with one crane

7.4.1 Short reinforcement cage section

The first and bottom reinforcement cage section with a length of 22 m will be lifted by telescopic crane.
Due to the total cage weight and the lifting radius it might be required that the top cage section is lifted by
a crane with a sufficient capacity. The lifting of the cages starts at the transport trailer and will end at the
panel location. The top of the cage will be connected to a spreader beam and is attached to the crawler
crane or telescopic crane. To ensure smooth and safe lifting of the cage the foreman will communicate
very close with the crane operator.
7.5.2 Lifting points
The lifting gear shall be unhooked at man-level according to the following procedure:
a) By using spreader beam with twelve points for rigging with equal distance . by taken in consideration
that one side is heavy than the other side .
b) The main hook connected to spreader beam by four single wire ropes with different length .

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7.5.3 Capacity of cranes and lifting gears

Each individual winch has the capacity to lift the full cage weight, including the auxiliary winch of the crane.
Thus, no overload of any winch can occur. Also, each lifting appliance is so arranged and fixed that it is at
no time loaded beyond its safe working load, or rendered unstable in the raising of lowering of the bad.

Each of the lifting gear used has sufficient capacity to lift the entire weight of the cage.

8. CONTROL OF LIFTING OPERATION

a) Control of lifting operation of crane is established to ensure that the lifting operation is carried out
safely.
b) Ensure the plants to be used are maintaine sound working order.
c) Ensure crane fitted with Safe Load Indicator.
d) Ensure all crane hooks supplied are fitted with a safety latch.
e) Ensure all lifting appliance and lifting gears supplied are tested, certificated and registered by
professional Engineer.
f) Apply for plant label after plants are ready for lifting.
g) Counter check all lifting appliances and lifting gears to be used are fully complied with legal and
contractual requirement.
h) Assess and identified hazards 'if any".
i) Carry out pre- operation check.
j) Ensure safe load indicator are in good working order.
k) Observe the height restriction of the crane operating
I) Maintain a clear and unobstructed passage way of at least 600mm width between the slewing or other
moving parts of mobile crane and other fixtures.
m) Ensure that all personnel are clear of the load before lifting and area fenced off no one allowed to walk
under the lifted Object.
n) Use of taglines rope in appropriate circumstances.
o) Attach or display the weight of equipment, reinforcement cage, generator and other designation, weight
and lifting gears to be used for information and reference.

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p) Watch out for overhead obstructions particularly overhead power lines.

q) Ensure that the upper ends of slings are connected by means of a shackle, ring or link of adequate
strength.
r) Stop lifting operations if the wind speed exceeds (10 m / s).
s) Stop the engine, engage brakes and remove the engine ignition key.
(Appendix 1) Register of Lifting Gears available on site

Item Dimension

Single wire rope sling with shackles D= 22mm, L=6M , Load= 6.2T

Single wire rope sling with shackles D= 19mm, L=6M , Load= 4.6T

Single wire rope sling with shackles D= 16mm, L=2M , Load= 3.2T

Single wire rope sling with shackles D= 32mm, L=7M , Load= 27.8T

Sing le leg synthetic sling L=6m,W=150mm,load=5t

Sing le leg synthetic sling L=6m,W=300mm,load=10t

Spreader beam 18.0 m

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(Appendix 2) Color code system on lifting gears.

Month color
January
February Blue
March
April
May Green
June
July
August Yellow
September
October
November White
December

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(Appendix 4) Hand signals

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(Appendix 5) Loads weight, dimension and the required lifting gear

Weight
Plant Dimension (m) (ton) Lifting gear
Cage 1 2.8m x 1m x 12m 4.7 Four leg chain s ling with hooks

Cage 2 2.8m x 1m x 22m 12 Four leg chain and spreader beam

Cage 3 2.8m x 1m x 22m 17.5 Four leg chain and spreader beam

12 ton

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FOR twelve vertical wires distributed in equal distance :

S.W.L for each wire in spreader beam legs = 1 ton

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Wire rope selection for spreader beam :

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Shackles selection for leg wires:

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For spreader beam : For inclined wire 45 :

S.w.l = 25 ton DIAM = 5/8 Inch

length= 18.6m length= 8 m

width =1.6m For inclined wire 60 :

hight = .35 m DIAM = 5/8 inch

Length = 7.5 m

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Selection of main wires for spreader beam

For more safe making selection for angle 45 for two wires :

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For more safe using angle 45 for two wires:

14 ton

.9238 4

S.W.L FOR EACH WIRE 3.788 TON for each wire

According to angle 45 for each wire

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Wire rope selection for main wire connected to spreader beam with angle 45 degree .

Using two leg wire with length 8m size 5/8 inch and two leg wire with 7.5 m with size 5/8 inch .

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Shackles selection for main wires of spreader beam :

This figure shows that effect of postion of wire at shackle eye at different angle gives
different loud factor .

W .L .L FOR WIRE = 4 TON

Loading degree will be zero
So, W.L .L * 1= 4 TON

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Shackles selection for main wires of spreader beam :

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Overall selections:

1 : main wires Connected to spreader beam

1:1 wiers no : 4

1:2 wire size : 5/8 inch

2 : shackles for main wire

2:1 shackles no : 4

2:2 shacles size : 3 /4 inch

3: Spreader beam

3:1 wire no:12

3:2 wire size : 3/8 inch

4: shacles for spreader beam

4:1 shacles no : 24

4:2 Shackles size : 7/16 inch

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Appendix 7 Lifting operations risk assessment

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Appendix 8 Lifting operations job hazard analysis

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8.1 Crane calibration.

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8.2 Rigger certifications:

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8.2 Pre inspection for crane .

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8.3 Load chart for crane

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8.4 Steel wire rope certification .

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8.5 Shackles certifications:

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8.6 Spreader beam calibration.

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8.9 Shop drawing for load :

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