Lift Plan

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 First Time submission

 Introduction
 Scope
 Glossary of Terms
 Reference Documents
 Rules for Safe Lifting Operations
 Responsibilities, Competence and Training of Personnel Involved in Lifting Operations
 Responsibilities
 Person Responsible for Lifting Operations
 Competent Person
 Crane Operator
 Competence and Training
 Planning of Crane Operations
 Define the Lift
 Planning
 Lift Categorisation
 Risk Assessment
 Lift Plan
 Assessment of a Lifting Operation

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  Tandem Lift Additional Factors of Safety
 Crane Siting Considerations and Assessment
 Crane Daily Checks and Inspections
 Crane Access Ladders, Walkways and Hatches
 Housekeeping
 Pre-start Checks
 Start Up of Prime Mover
 Pre-Operations Checks and Function Tests
 Safety Equipment
 Checks to be Carried Out During Operation of the Crane
 Execution
 Communication of Lift Plan
 Communication
 Hand Signals
 Radio Communication
 Controlling Access to the Lift Area
 Conducting the Lifting Operation
 Moving the Load

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  Load Handling
 General Instructions for Crane Operators
 The Crane Operator Must NOT
 The Crane Operator MUST
 Banksman and Load Handler (Slinger) Procedures
 General Instructions for Banksmen
 Reacting to Changing Circumstances
 Typical Adverse Weather Guidelines
 Annexure
 Lift Plan
 Cage types & weight
 Organization chart
 Load chart
 Risk assessment
 Emergency Evacuation Plan & Emergency response team
 Test certificates
 Operator certificates
 Medical Certificate s

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Second Time Submission for same Activity ( Due to Change in Crane or Any other
etc)

 Purpose
 Scope of Work
 Reference
 Definition & Abbreviations
 Rules for lifting operation
 Materials
 Responsibility & Authority
 Design Calculation
 Design and load calculation for lifting Frame
 Construction Sequence
 Lift Plan
 Cage types & weight
 Organization chart
 Load chart
 Risk assessment
 Emergency Evacuation Plan & Emergency response team
 Test certificates
 Operator certificates
 Medical Certificate s

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 Rules for Safe Lifting Operations

 Lifting operations using cranes should only commence if:

 1. An assessment of the lift has been undertaken and the
lift method has been determined and planned by a
competent person
 2. Crane Operators are trained and deemed competent for
that Equipment
 3. Rigging of the load is carried out by competent persons
 4. All lifting equipment and accessories have been 3rd party
certified for use within the last 6 months, as a minimum
 5. All lifting equipment and accessories have been visually
inspected before each use by a competent person
 6. The load does not exceed the dynamic or static capacity
of the lifting equipment
 7. Any safety devices installed on the equipment are fully
operational

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Types of
Cranes
 Mobile

 Hydraulic

 Overhead

 Gantry

 Tower
 Planning Before Start-
•
Up
Level the crane and ensure support surface is firm and
able to support the load
• Contact power line owners and determine precautions.
Know the location and voltage of overhead power lines.
• Know the basic crane capacities, limitations, and job site
restrictions, such as the location of power lines, unstable
soil, or high winds.
• Make other personnel aware of hoisting activities.
• Barricade areas within swing radius.
• Ensure proper maintenance and inspections.
• Determine safe areas to store materials and place
machinery.
 Competent Person

The competent person

must inspect all
machinery and equipment
prior to each use, and
during use, to make sure
it is in safe operating
condition.

If it needs fixing, take it

out of service and don’t
use it until it is fixed
 Load Capacity - Speed -
Warnings
• Make sure the
crane operator can
see the:
• Rated Load
Capacities
• Operating Speeds
• Special Hazard
Warning or
Instruction Load Rating Chart
 Know the Weight of the Load

Ensure lift calculations are correct

Ensure load is within load chart rating for boom
length and load radius of crane
Crane is rated by the maximum weight it will lift at
a minimum radius and minimum boom length –
the further from its center point, the less it will lift
 Load Limiting
Factors
Not level
Wind
Side loads
On its wheels
Lifting over the side
Use of extensions, jibs and other
attachments
Limits of wire rope, slings and lifting
devices
Mobile Cranes – Lifting
Principles
• Center of Gravity

• Leverage

• Stability

• Structural Integrity
 Load Example – 30 ton
crane
• Will lift 27000 kgs at 10 feet from the center pin
of the crane
• Based on level surface, no wind, and outriggers
fully extended
• At 25 feet from the center pin with an 80 foot
boom, the capacity is only 6,800 Kgs
• At 74 feet from the center pin, the capacity is
only 2000 kgs
Load
s
 Responsibilities, Competence and Training of
Personnel Involved in Lifting Operations

 Crane Operator
 Competence and Training

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 Planning of Crane Operations

 The planning process shall address:

 Identification of hazards and restricted areas;
 Selection of competent personnel;
 Specification of the minimum number of people required to conduct the
lifting operation;
 Selection of Lifting Equipment;
 Communication of lift requirements and hazards;
 Procedures for changing the Lift Plan;
 Emergency, recovery and contingency plans
 Planning the lift
◦ Correct crane
◦ Space for access, egress and movement
◦ Suitable ground conditions
◦ Crane is level
◦ Underground services are protected
◦ No overhead or side obstructions
◦ Overhead power lines are isolated

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  Site Conditions
◦ Access/egress routes
◦ Inclines/gradients
◦ Location of adjacent buildings
◦ Location of overhead lines
◦ Ground firm enough to support crane and
outriggers
◦ No voids exist e.g. manholes, drains etc

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  Planning the lift
◦ Area around lift is demarcated
◦ Load is within SWL of crane
◦ Location of lifting points ensure load is level
◦ Lifting points are strong enough to take the load
◦ There are no persons under the load AT ANY TIME

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 Lifting Accessories

 Ropes, Web Sings , Chain Pulley

 Chains
 Eyebolts
 D Shackle

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 Safe Use of Ropes & Wires
 Must be in good condition before use I.e. not frayed
or corroded
 Ropes & wires must be protected from sharp edges of
load by use of packing
 No knots or hitches in slings or lifting ropes
 Never drag ropes or wires over the ground
 When using more than one sling, ensure they are of
the same material

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 Safe Use of Chains

 Never use chains with links locked or stretched

 Never hammer distorted links into position
 Never use corroded or worn chains
 Do not drag a chain from under a load
 Do not drop chains from height
 Do not use a chain over sharp corners without
padding
 Chain life is increased by lubrication

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 Safe Use of Lifting Accessories

 Never use hooks if there is any distortion or cracks

 Rings and shackles must be checked to see they are
not distorted or cracked

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 Storage of Ropes, Wires, Chains & Lifting
Accessories

 Trained and competent stores

 Stores must be dry, well ventilated and free from
corrosion
 Ropes must be stored away from sunlight and heaters
 Stored material should have a systematic layout

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 Storage of Ropes, Wires, Chains & Lifting Accessories

 Store should have area where simple maintenance

can be carried out
 Store should be secure
 An are where paperwork can be carried out should be
provided

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 Risk Assessment

 The Risk Assessment shall address, but is not limited

to, the following aspects and activities:
 Weight, size, shape and centre of gravity of load;
 Availability of approved lifting points on load;
 Method of slinging, attaching and detaching the load;
 Overturning, load integrity and the need for tag lines
 Suitability and condition of the Lifting Equipment to
be used;
 Initial and final load position and how it will get there;
 Lifting over live equipment;
 Number and duration of lifts;

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  Conflicting tasks in area;
 Environmental conditions, including weather and
permissible limits;
 Lighting in the pick-up and laydown areas;
 Proximity hazards, obstructions, path of load;
 Working under suspended loads;
 Access and emergency escape routes for the Lifting
Equipment Operator and load handlers
 Experience, competence and training of personnel;
 Number of people required for task;
 Pre-Use Inspection of equipment by the Operator;
 Visibility of the load by the Operator and / or person
guiding the load;
 Communication between all personnel taking part in the
lifting operation
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 Lift Plan

 A Lift Plan shall be prepared or identified for every

lift. The Lift Plan shall, as a minimum, identify:
 The competent person planning the lift;
 Equipment required;
 Personnel required and their particular roles;
 Step-by-step instructions;
 Communication methods to be used;
 Contingency and rescue plans

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 Assessment of a Lifting Operation

 the Crane Operator should make the following assessment:

 Verify that there is single point accountability for the lifting
operation;
 Identify the personnel involved in the lifting operation;
 Review the Risk Assessment;
 Confirm that all hazards associated with the lifting
operation have been identified and mitigated;
 Review the Lift Plan;
 Verify that the Lift Plan has been approved by a Competent
Person and test that person’s competence;
 Confirm that the crane is capable of lifting the load by
considering weight, size and shape;

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  Verify that the crane and other lifting equipment being used
is certified for use;
 Verify that all those involved in the lifting operation have
participated in a toolbox talk at which the risks and hazards
and control measures were clearly described;
 Verify that a visual inspection of all lifting equipment and
accessories has been completed;
 Confirm the Banksman / Signaller’s level of competence;
 Confirm the Load Handlers’ levels of competence;
 Test that the communication methodology is suitable and
understood by all personnel involved in the lifting
operation;
 Test the emergency response and contingency procedures;
 Test the safety culture – will people ‘STOP’ the job if there
is an unsafe act or omission?

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 Tandem Lift Additional Factors of Safety

 Lifts involving two or more cranes are complex

operations requiring considerable skill and planning.
As a result, multiple crane lifts (or tandem lifts) must
be planned and carried out under the supervision of a
competent person.

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 Crane Siting Considerations and Assessment

 Crane Daily Checks and Inspections

 Crane Access Ladders, Walkways and Hatches
 Housekeeping
 Pre-start Checks
 Pre-Operations Checks and Function Tests
 Safety Equipment
 Checks to be Carried Out During Operation of
the Crane

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 Execution

 Communication of Lift Plan

 Hand Signals
 Controlling Access to the Lift Area
 Conducting the Lifting Operation

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 Moving the Load

 Load Handling
 Weather Conditions
 Tag Lines
 Lifting Over People
 Structures Close to Lifting
 Crane Radius

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 Weight Calculation
 Example Cage –Type
S.No Description Weight Remarks

Lifting accessories for ---------------------

S.No Item Weight (MT)

1 Lifting Frame
2 Web slings
3 Wire ropes
4 Hook Block
5 Master Ring
6 D shackle

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S.No Description Weight Lifting Total Wt Type of Remarks
Of part Access(Mt (MT) Lift
(Mt) )

S.No Item Total Type of Workin Boom No of 100% SWL

Wt of Crane g Length Falls Load .80% X
Item Radius Load –
Simple
lift
.75 % x
load –
Tandem
Lift

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 Multi-Crane Lifts

 Two cranes- horizontal load

 Two cranes- vertical load
 Tailing a vertical load
 More than two cranes-
horizontal loads

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 Multi-Crane Lifts
May be preferred when:

 Handling long pieces

 When obstructions may restrict a single crane
 Utilization of equipment on site
 The extra capacity works well with the nature of the
load
 Loads must be placed at an angle
 When dictated by center of gravity issues
 To offload from double-bolstered railcars or hauling
equipment

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 Multi-Crane Lifts
Things to Consider:

 Nearly all crane and lifting safety plans mandate a

reduction in chart capacity for multi-crane lifts (some
exclude tail cranes)
 A greater chance of side loading either crane exists
 Load distribution can change if one crane gets
noticeably higher than the other
 Swinging and hoisting at the same time are not
recommended
 If one crane fails, the other will have all of the load
 A first rate signalman is required as well as good
communications

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Multi-Crane Lifts

Two Cranes –
Horizontal Loads
 The two cranes used on
this concrete beam
allowed the beam to be
landed first on one end
 The two cranes were
probably on the jobsite,
resulting in cost savings

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Multi-Crane Lifts

Two Cranes –
Horizontal
Loads
 Here two matched
cranes lift an
asymmetrical load
 Careful CG
calculation and load
distribution is very
important

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Multi-Crane Lifts

Two Cranes –
Horizontal Loads
 Two unequal cranes
lifting a process module
 This lift was carefully
planned, allowing the
larger crane to lift at a
greater radius and
allowing for a
proportional lift

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Multi-Crane
Lifts
Two Cranes –
Horizontal Loads

 Connecting two similar

cranes with a long lift beam
enables the cranes to
reduce their respective
operating radii, thereby
increasing their lifting
capacities

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Multi-Crane Lifts

Two Cranes –
Horizontal Loads
 This is an excellent
use of two cranes
 The duct needs to be
lifted at an angle for
correct placement
 With a single crane
lift, the rigging must
be selected to
provide the correct
angle

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Multi-Crane Lifts

More Than Two Cranes

 Lifts like this roof
raising are normally
restricted to lifting only
 Loadings must be
carefully calculated
 Communication is most
critical
 Chart deductions are
essential
 Ground surface should
be level, firm, and
matted as deemed
necessary

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Multi-Crane Lifts

More Than Two Cranes: Roll

Up

 Another possibility is this

this roll-up of an offshore
jacket section
 The many cranes will lift
only and walk in tightly-
controlled unison until the
jacket section is rotated to
the desired position

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Multi-Crane Lifts

TWO CRANES: VERTICAL

LIFTS
 Utilizing two cranes to make a
vertical lift should require a high
level of planning . It is essential
to consider:
◦ The orientation and the initial
layout
◦ Boom side clearance and two-
blocking
◦ The changing of loads on all
cranes
◦ Minimum and maximum radii
◦ Method of safely unhooking
the rigging
◦ Insure one crane doesn’t get
ahead of the other
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Multi-Crane Lifts

Two Cranes: Tailing

 Most larger vertical loads
require trailing with a
crane or an equivalent
tailing device
 Sometimes two tail cranes
are used
 The crane or device must
be able suspend (or
support) the proportionate
load- whether moving into
the hook of the main
erection crane or remaining
at radius while the erection
crane booms out to the tail
crane
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Multi-Crane
Lifts

Two Cranes:
Tailing
 Not all vertical
loads require
tailing with a
second crane

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Multi-Crane Lifts

Tailing to the
Vertical
 Not all up
endings require
a tail crane

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Multi-Crane Lifts

Multiple Cranes:
Tailing

 This is a typical erection of

a pressure vessel using
two erection cranes and a
tail crane
 Note that the tail load
should be relatively low
due to the location of the
lifting operation.
 This slide is used to
illustrate how tail loads 55
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Major Causes of Crane
Accidents
• Contact with power lines

• Overturns

• Falls

• Mechanical failures
 How Do Accidents
Occur?
• Instability – unsecured load, load capacity
exceeded, or ground not level or too soft

• Lack of communication - the point of

operation is a distance from the crane
operator or not in full view of the operator

• Lack of training

• Inadequate maintenance or inspection

Who is at Risk

• Operators

• Persons at Crane
Site
 Improper Load

Improper loads or speeds can result

in the tipping of the crane
Improper Load
Improper Load
 Power Lines

Stay clear
Stay clear
from power
lines at least
10 feet
power lines
at least 10
feet
 Hand Signals

An illustration of
the signals must
be posted at the
job site
 Swing Radius

Stay out of the swing radius of the crane –

Make sure there are barrier guards showing swing radius
Operator Visibility

Broken Window

Make sure broken windows or other obstructions

do not prevent the operator from seeing
Ladders

Ladder

Use ladders to get to the upper portion of the cab

 Guardrails

Runways and steps need to have guardrails,

handholds and slip resistant surfaces
Suspended Loads

Don’t stand under suspended loads

 Supporting Surface

Cranes must be on a firm supporting surface and

level within 1 percent
 Rigging Equipment Slings

Types of slings include alloy steel chain, wire

rope, metal mesh, natural or synthetic fiber rope,
and synthetic web.

Chain Wire rope Metal mesh Synthetic

 Annual Inspections

Inspection of the
hoisting machinery
must be made by a
competent person
The employer must
maintain a record of
these inspections Crane wasn’t inspected
and tipped over
What to Inspect
 Correct air pressure and no
leaks
 Tires properly inflated
 Clearance for tail swing
 Wire rope wear
 Physical damage to crane
 Loose or missing hardware,
nuts, or bolts
 Fluid leaks
Remove From Service

Immediately remove damaged or

defective slings from service
Damaged wire rope

Crushed Rope
Broken Strands
Worn Part
 Summary

 An unstable load, lack of communication, lack of

training, and inadequate maintenance or inspection
are major contributors to crane accidents.
 Operators or others working in the area can be
victims to “struck by" and "caught in" injuries.
 Contact with power lines causes many accidents.
 A competent person must inspect a crane regularly
to ensure it is in proper order.
 Planning and training reduces accidents.