Cranes Hoisting and Rigging

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Cranes Hoisting and Rigging

Contents

Approved by Michael Wisherop

Revised 09/11

NOTE:

. . . . . Denotes a new section.

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27.1 Policy

27.2 Scope

27.3 Applicability

27.4 Roles and Responsibilities

27.5 Definitions

27.6 Required Work Processes

Work Process A. General Requirements for Crane Operation

Work Process B. Procurement and Maintenance of Cranes and Hoisting and Rigging

Equipment

Work Process C. Authorization and Qualification to Use Cranes

Work Process D. Restricted Operations

Work Process E. Mobile Cranes
http://www.lbl.gov/ehs/pub3000/CH27.html#27.1http://www.lbl.gov/ehs/pub3000/CH27.html#27.2http://www.lbl.gov/ehs/pub3000/CH27.html#27.3http://www.lbl.gov/ehs/pub3000/CH27.html#27.3http://www.lbl.gov/ehs/pub3000/CH27.html#27.4http://www.lbl.gov/ehs/pub3000/CH27.html#27.4http://www.lbl.gov/ehs/pub3000/CH27.html#27.5http://www.lbl.gov/ehs/pub3000/CH27.html#27.5http://www.lbl.gov/ehs/pub3000/CH27.html#27.6http://www.lbl.gov/ehs/pub3000/CH27.html#27.6http://www.lbl.gov/ehs/pub3000/CH27.html#27.6ahttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6ahttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6bhttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6bhttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6bhttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6chttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6chttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6dhttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6dhttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6ehttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6ehttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6ehttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6dhttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6chttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6bhttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6bhttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6ahttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6http://www.lbl.gov/ehs/pub3000/CH27.html#27.5http://www.lbl.gov/ehs/pub3000/CH27.html#27.4http://www.lbl.gov/ehs/pub3000/CH27.html#27.3http://www.lbl.gov/ehs/pub3000/CH27.html#27.2http://www.lbl.gov/ehs/pub3000/CH27.html#27.1


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Work Process F. Crane Inspections

Work Process G. Rigging and Other Below-the-Hook Devices and Fixtures

27.7 Standards

27.8 Related PUB-3000 Chapters

27.9 References

Appendix A. Typical Pre-use Inspection Tags

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27.1 Policy

Persons involved in crane or hoist operations at Lawrence Berkeley National Laboratory

(Berkeley Lab) must:

Be awareof the hazards related to the equipment and the load

Know the methods for controlling those hazards Follow the proper operating procedures applicable to the type of lift and equipment

The designated operator must be qualified and authorized to use specific equipment.

Crane, hoist, and rigging equipment must be procured through the Facilities Division, as

well as properly inspected, tested, and maintained.

27.2 Scope

Berkeley Labs Crane Safety Program is implemented through planning, authorization,

qualification, and the appropriate use of properly inspected and rated hoisting equipment

and rigging. Lifting and moving loads with forklifts is covered in PUB-3000, Chapter 28,

Forklifts and Other Powered Industrial Trucks. Construction operations involving cranes are

covered in Chapter 10, Construction Safety.
http://www.lbl.gov/ehs/pub3000/CH27.html#27.6fhttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6fhttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6ghttp://www.lbl.gov/ehs/pub3000/CH27.html#27.7http://www.lbl.gov/ehs/pub3000/CH27.html#27.7http://www.lbl.gov/ehs/pub3000/CH27.html#27.8http://www.lbl.gov/ehs/pub3000/CH27.html#27.8http://www.lbl.gov/ehs/pub3000/CH27.html#27.9http://www.lbl.gov/ehs/pub3000/CH27.html#27.ahttp://www.lbl.gov/ehs/pub3000/CH27.html#27.ahttp://www.lbl.gov/ehs/pub3000/CH27.html#27.9http://www.lbl.gov/ehs/pub3000/CH27.html#27.8http://www.lbl.gov/ehs/pub3000/CH27.html#27.7http://www.lbl.gov/ehs/pub3000/CH27.html#27.6ghttp://www.lbl.gov/ehs/pub3000/CH27.html#27.6f


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27.3 Applicability

This policy establishes requirements for Berkeley Labs Crane, Hoisting, and Rigging Safety

Program and applies to work with any crane or hoist operated at Laboratory-owned or -

leased property, as well as Laboratory-managed field research. This program applies to thefollowing Berkeley Lab personnel:

1. Employees2. Affiliates3. Construction contractors4. Nonconstruction contractors and vendors

27.4 Roles and Responsibilities

27.4.1 Supervisors and Work Leads

Supervisors must make certain that personnel know how to safely operate cranes and

hoists, and how to move objects safely. Only those employees who are formally qualified by

training and certification may operate a crane or hoist. Qualified supervisors or designated

qualified work leads must enforce the use of safe lifting techniques, and maintain lifting

equipment in good mechanical and operating condition.

27.4.2 Crane Manager

A Berkeley Lab employee must be identified as the Crane Manager for each Laboratory-

owned crane or hoist (unless it is locked out). The following requirements for the Crane

Manager apply:

The identification of the Crane Manager must be made in writing to the Environment,Health & Safety (EH&S) Division Crane Safety Subject Matter Expert (SME),

[email protected], or Mail Stop 75B0101.

The Crane Manager must have a valid certificate for the operation of the crane inquestion.

The Crane Manager is responsible for controlling use of the crane, and limiting use ofthe crane to qualified operators. The Crane Manager is the custodian of any keys or

other mechanisms for limiting use of the crane.

The Crane Manager is responsible for maintaining any logbooks used in lieu ofinspection tags.
mailto:[email protected]:[email protected]:[email protected]


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If a Crane Manager is absent, cranes under his or her control may be used only bypreviously authorized operators, unless a qualified backup Crane Manager has been

identified to the Crane Safety SME.

When a Crane Manager vacancy occurs, the Division Safety Coordinator must identify areplacement, and notify the EH&S Crane Safety SME ([email protected], Mail Stop

75B0101) of the change. The Crane Safety SME will notify the Facilities Division Crane

Maintenance Vendor to lock all cranes and hoists for which no Crane Manager has been

identified. These cranes and hoists will be locked in the OFF position until a Crane Manager

is identified.

27.4.3 Employees (Operators, Riggers, and Helpers)

Employees must be appropriately trained, medically qualified, and demonstrate safe

operation of the cranes they use. For cranes with greater than two-ton capacity, operators

must possess a valid Berkeley Lab Crane Operators License. Operation of mobile cranes is

restricted to those who have been certified as competent and qualified mobile crane

operators by an independent certification agency. All employees involved in hoisting

operations including riggers, helpers, and observers are required to follow all established

safety regulations relating to safe lifting and handling techniques.

27.4.4 Mechanical Engineering Designee

The Mechanical Engineering Designee will review and approve Engineering Safety Notes for

lifting fixtures and high-value/high-consequence lifts/moves on behalf of the Engineering

Division Director and for the Mechanical Engineering Subcommittee of the Safety Review

Committee. The Mechanical Engineering Designee may approve reasonable engineering

alternatives not in conflict with the Laboratory Environment, Safety & Health Standards Set.

He or she is also available to furnish guidance to Laboratory staff, free of charge. Contact

[email protected] contact the Mechanical Engineering Designee.

27.4.5 Responsible Designer

The Responsible Designer is accountable for incorporating the requirements of this chapter

into the design of lifting fixtures and procedures, and for initiating the required proof

testing. The Responsible Designer must obtain design approval by means of an Engineering

Safety Note.

27.4.6 Customer Management
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Customer Management is accountable for defining and requesting any lift/move;

determining which lifts are high-consequence/high-value lifts/moves; writing lifting

procedures where required; providing technical information on relevant characteristics of

the apparatus, including special lifting fixtures when required; providing suggestions on

rigging and moving; and assigning someone to represent the customer during planning andcoordination of all aspects of the job being performed. Customer Management can have the

Facilities Division prepare the Engineering Safety Note and manage the move if requested

by the customer on the Work Request. Customer Management is also responsible for

ensuring that lifting devices and lifting fixtures are properly documented and inspected, and

that they are used and maintained safely.

27.4.7 Facilities Division Structural Engineering Group Designee

The Facilities Division Structural Engineering Group Designee will evaluate building floor

loading, lifting fixtures, and lifting devices for structural adequacy; review and approve

Engineering Safety Notes for lifting fixtures, lifting devices, and high-consequence/high-

value lifts on behalf of the Facilities Division and the Safety Advisory Committee (SAC)

Mechanical Engineering Subcommittee; establish design parameters for all cranes and

hoists; and provide guidance on wind loading for outdoor moves/lifts. The Facilities Division

Structural Engineering Group Designee is also available to provide guidance to Laboratory

staff on these matters, free of charge. [email protected] contact the Facilities

Division Structural Engineering Group Designee.

27.4.8 Facilities Division Rigging Supervisor

The Facilities Division Rigging Supervisor or his or her designee will provide guidance and

supervision for routine lifts when requested, participate in the development and review of

high-consequence/high-value lifts/moves, and participate in pre-lift meetings.

27.4.9 Facilities Division Crane Maintenance Vendor

The Facilities Division Crane Maintenance Vendor will arrange for all inspection, testing, and

certification of cranes, hoists, and rigging. On request, the subcontractor will also arrangefor the testing and certification of lifting devices and lifting fixtures. Call ext. 7667 or e-mail

[email protected] contact the Crane Maintenance Vendor.

27.4.10 Facilities Division Maintenance Manager
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The Facilities Division Maintenance Manager establishes the scope of work for the Facilities

Division Crane Maintenance Vendor. Additionally, the Maintenance Manager ensures (by

using technical advice from the Crane Maintenance Vendor) that Laboratory purchases of

crane, hoist, and rigging equipment, components, and devices are traceable (through

documentation) to a reputable U.S. manufacturer.

27.4.11 EH&S Division Crane Safety SME

The EH&S Division Crane Safety SME manages this program. Furthermore, the SME will

review all high-consequence/high-value lift/move Engineering Safety Notes for conformance

to the Crane, Hoisting and Rigging Program Requirements, and will participate in pre-lift

meetings for high-consequence/high-value lifts/moves. [email protected]

contact the Crane Safety SME.

27.4.12 Person In Charge

The Person In Charge (PIC) is the (customer) manager, engineer, or other responsible

person (other than the operator) appointed to be responsible for the safe handling of high-

consequence/ high-value loads.

27.5 Definitions

Crane A machine that is used for lifting and lowering a load vertically and moving it

horizontally, and that has a hoisting mechanism as an integral part of it

Engineering Note A detailed description of a (fixture) design; or a detailed description

of a high- consequence/ high- value lift/move, including protection of the load, rigging, and

method(s) of transport5

High-Consequence/High-Value Lift/Move A designation of parts, components,

assemblies, or lifting operations by the customer (i.e., the manager who requires the items

to be moved) or a program organization, because the effect of those items falling from the

crane, or colliding with other objects, could:

Cause damage in excess of $500,000o This requirement does not apply to routine movements of shielding blocks

performed by members of the professional rigging crew

Cause significant work delay or programmatic impact Cause undetectable damage resulting in future operational or safety problems
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Result in significant release of radioactivity or other undesirable conditions Present a potentially unacceptable risk of personnel injury or property damage

In addition, any lift/move that requires the simultaneous use of both the main and auxiliary

hoists of a given crane or the simultaneous use of two cranes shall be considered a high-consequence/high-value lift/move.

Hoist A device that applies a force for lifting and lowering.

Lifting Device A device used below the hoisting hook, other than a sling, for attaching

loads to a hoist. These devices are arranged into four categories:

Structural and Mechanical Lifting Devices (e.g., spreader bars, plate clamps, grippingdevices, etc.)

Vacuum Lifting Devices Close Proximity Lifting Magnets Remotely Operated Lifting Magnets

Lifting Fixture A fixture used below the hoisting hook designed and engineered for

lifting a specific item

Mobile Crane A crane system fixed to a vehicle (typically a truck)

Overhead Crane

A crane system fixed to a structure, including but not limited to bridgecranes, monorail cranes, gantry cranes, and jib cranes

Rigging The hardware or equipment used to safely attach a load to a hook or lifting

device. The art or process of safely attaching a load to a hook by means of an adequately

rated and properly applied sling and related hardware

27.6 Required Work Processes

Work Process A. General Requirements for Crane Operation

The work flowchart below provides a step-by-step overview of crane and hoist operations

requirements (gohereto download a PDF of the flowchart):
http://www.lbl.gov/ehs/pub3000/CH27-CraneProcess.pdfhttp://www.lbl.gov/ehs/pub3000/CH27-CraneProcess.pdfhttp://www.lbl.gov/ehs/pub3000/CH27-CraneProcess.pdfhttp://www.lbl.gov/ehs/pub3000/CH27-CraneProcess.pdf


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The following rules apply to all use of crane and hoist operations at Berkeley Lab.

Whoever needs to move a load must:o First determine the value of the load and consequences of a failed moveo Determine if the load needs to be moved by a craneo Determine who can operate the crane


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Loads meeting the definition of High-Consequence/High-Value Lifts/Moves or otherrestricted operations (see Work Process D) require more detailed planning and may

require the lift to be performed by the Facilities Division Riggers.

Operators must be authorized by Line Management to use cranes. Operators must be authorized by the Crane Manager to use a specific crane. Operators must be qualified to use the type of crane they intend to use. Operators must plan each lift, taking into account the path of travel to avoid contact

with personnel and objects.

Loads meeting the definition of High-Consequence/High-Value Lifts/Moves or otherrestricted operations (see Work Process B) require more detailed planning and may

require the lift to be performed by the Facilities Division Riggers.

Operators must inspect the crane and associated rigging prior to using the crane. Cranes and rigging found to be deficient must be taken out of service, and cannot be

used unless repaired and recertified by the Facilities Division Crane MaintenanceVendor.

Cranes and rigging must be rated to lift the intended load; no load (including rigging,devices, and lifting fixtures) may exceed the limits of the crane and rigging. If an

employee is unsure of the weight of a load, or if the load weight exceeds 75% of the

cranes capacity, contact the Facilities Division Rigging Supervisor for assistance.

Crane testing by the Facilities Division Crane Service contractor is the only exception

to this rule.

Operators are responsible for ensuring that the load is properly rigged to avoidshifting during the lift. Test lifts of less than one foot from the ground to check forload shifting are permitted.

All personnel who are operating a crane or hoist, are participating in the lift, or arelocated within 15 feet of the vertical plane of the load where the undercarriage of

the bridge is more than 12 feet from the ground must wear hard hats. Post or

barricade the area as needed.

Sturdy work gloves must be worn when handling wire rope or loads with rough orsharp edges or splinters.

Suspended Loads

These rules apply to operators of suspended loads:

Test brakes under load when load is 80% of the crane's rated load. Raise the load afew inches and apply the brakes.


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Ensure loads are never lowered below the point where less than two full wraps ofrope remain on the hoisting drum.

Do not allow hoisting chains or ropes to kink or twist, or to wrap around the load. Attach the load to the load block hook ONLY by means of slings or other approved

devices; NEVER wrap the hoist rope around the load. Ensure loads are well secured and properly balanced in the sling or lifting device

before it is lifted more than a few inches.

Avoid suddenly accelerating or decelerating the moving load. Do not allow the load to contact obstructions. Do not allow loads moved with any material-handling equipment to pass over any

personnel.

Select the load path to eliminate the possibility of injury to employees should thematerial-handling equipment fail.

Do not permit work on suspended loads. Rest the load on adequate cribbing if itneeds to be worked on.

Never leave a suspended load unattended nor leave the controls while the load issuspended. Lower the load to the floor or the working surface or onto cribbing, and

secure the material-handling equipment before leaving the load unattended.

Component Failure or Unintended Movement

If any component fails during a lift, or if there is any uncontrolled or unintended motion of

the load during the lift, the lift must be terminated immediately in the safest manner

possible. Immediately notify the Crane Manager of the component failure. Contact EH&S

and the Facilities Division Rigging Supervisor.

Lifting may only resume after the failure or unintended motion has been investigated, and

appropriate corrective steps have been implemented.

Securing Cranes

Any electric-powered crane, when not attended by a qualified operator during an entire shift

and off-hours, must be secured by locked controls or equivalent means to prevent access to

the crane, such as locking the doors or locking up radio controls. Only the Crane Manager or

another qualified and authorized user of the secured crane may have control of the locking

mechanism.

Work Process B. Procurement and Maintenance of Cranes and Hoisting and Rigging

Equipment


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Approval from the Facilities Division Maintenance Manager must be obtained before

purchasing hoists or cranes, or lifting equipment such as shackles, clevises, wire rope or

fabric slings, or spreader bars (strongbacks). Procurement will not process any purchase

orders for such equipment without this approval. The preferred method for ordering hoisting

and rigging equipment is to request that the Facilities Division Maintenance Manager ordesignee (ext. 7667) order the items, using an account number provided by the requester.

If used equipment is procured, it must be inspected and certified to meet all applicable

standards in force at the time of the acquisition.

For Berkeley Labdesigned and/or fabricated lifting devices, see Work Process G.

When equipment is received, the recipient must contact the Facilities Division Crane

Maintenance Vendor (ext. 7667 [email protected]) to have the equipment inventoried

for routine inspection and maintenance. All hoisting and rigging equipment (except when

impractical, e.g., shackles, swivel lifting rings, etc.) used at the Laboratory must have a

Laboratory proof-load tag attached with a current inspection sticker. The user, supervisor,

and operator are directly responsible for verifying the presence of current, proper tagging of

hoisting and rigging equipment prior to use.

Work Process C. Authorization and Qualification to Use Cranes

All crane use must be authorized by an employees Job Hazards Analysis (JHA), and by the

Crane Manager for the particular crane(s) to be operated. The Crane Manager is a qualified

crane operator who has been designated as the individual responsible for the safe operation

of a specific crane. Before operating a crane in an area for the first time or in a new

application, employees must discuss the proposed crane use with the Crane Manager and

obtain approval. The Crane Manager will determine whether the operator is familiar with the

controls for that particular crane and knows how to properly rig loads, and will verify that

crane use will not conflict with other operations in the area.

Cranes may also be operated by qualified Crane Service personnel who have been

authorized by either a JHA (for the on-site Facilities Division Crane Maintenance Vendor) ora SWJHA, and have been subcontracted to install, maintain, or repair cranes.

Qualifications, Training, Certification, and Approval Requirements for Overhead Crane

and Hoist Operators
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The operation of overhead cranes and hoists is restricted to trained personnel who have

completed Berkeley Labrequired training, and who have been certified in accordance with

the requirements of this chapter. This includes the operation of cranes without a load for

any reason. Requirements for operating mobile cranes can be found in Work Process F.

To become certified for operating cranes up to a two-ton capacity, the following

requirements must be met:

All prospective operators of cranes and hoists up to a two-ton capacity must meetthe health requirements that would entitle them to operate a motor vehicle in the

state of California. Individuals who do not hold a valid drivers license must be

examined and approved by Health Services at Berkeley Lab.

The prospective operator must complete EHS0210, Crane/Hoist Operator 2 Tonsor Less. This course includes hands-on instruction, and a certificate will be issued

after the successful completion of the course.

Note that crane and hoist operators with this certification may NOT operate cranes

or hoists with a capacity of greater than two tons to lift loads of less than two tons

or without any load.

To become certified for operating overhead cranes or hoists with a capacity of greater than

two tons, the following is required:

All prospective crane operators must complete an application and must pass amedical examination and/or review of medical information on file at Health Services

prior to training. The application must identify a qualified crane operator who will

provide hands-on instruction and close supervision during an initial training period.

The supervisor and the operator who will provide the instruction must sign the

application and agree to the initial training. If the prospective operator has prior

experience operating cranes, he or she may be examined and certified without an

initial training period.

The prospective operator must complete EHS0206 (Crane/Hoist Operator Greaterthan 2 Tons). Upon completion ofthis classroom training, a learners permit is issued

when needed, and the individual may operate cranes and hoists under the direct

supervision of the operator identified on the application. The learners permit will

expire no later than 60 days from the date of issuance.

When the prospective operator is ready, he or she may contact an overhead-cranepractical-examination instructor to be examined on the operation of the specific


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crane to be operated most frequently. A list of qualified overhead-crane practical-

examination instructors is maintained by the EH&S Division Training Group.

Crane operators must renew their training every three years, and must be medically

recertified every three years.

Work Process D. Restricted Operations

High-Consequence/High-Value Lifts and Moves

The customer (i.e., the manager who requires the items to be moved) or a program

organization designates parts, components, assemblies, or lifting operations as high-

consequence/high-value lifts/moves, because the effect of those items falling from the

crane, or colliding with other objects, could:

Cause damage in excess of $500,000o This requirement does not apply to routine movements of shielding blocks

performed by members of the professional rigging crew.

Cause significant work delay or programmatic impact Cause undetectable damage resulting in future operational or safety problems Result in significant release of radioactivity or other undesirable conditions Present a potentially unacceptable risk of personnel injury or property damage

In addition, any lift/move that requires the simultaneous use of both the main and auxiliaryhoists of a given crane or the simultaneous use of two cranes must be considered a high-

consequence/high-value lift/move.

High-Consequence/High-Value Lift/Move Requirements

A detailed, step-by-step procedure in the form of an Engineering Note must be prepared for

each high-consequence/high-value lift/move. This requirement covers lifts and moves

performed with forklifts or cranes. An Engineering Note template may be obtained from the

Engineering Division athttps://dcc.lbl.gov/dcc/EngNotes.php. While high-

consequence/high-value lift procedures are customarily prepared for one-time use, general

high-consequence/high-value lift procedures may be employed to accomplish routine,

recurrent high-consequence/high-value lift operations. For example, a general high-

consequence/high-value lift procedure may be applied to lift shielding blocks or a frequently

lifted item. Examples can be found through the search page of the Berkeley Lab Engineering
https://dcc.lbl.gov/dcc/EngNotes.phphttps://dcc.lbl.gov/dcc/EngNotes.phphttps://dcc.lbl.gov/dcc/EngNotes.phphttps://dcc.lbl.gov/dcc/EngNotes.php


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Note Repository athttps://dcc.lbl.gov/dcc/EngNotes.php(enter the keywords high value

in the Title 3 field).

The customer, i.e., the Laboratory manager who requires the item to be moved, is

responsible for preparing the high-consequence/high-value lift/move Safety EngineeringNote. The customer can discharge this responsibility by indicating on the Facilities Work

Request that the scope of work should include preparation of the Engineering Safety Note

and management of the move. It is the responsibility of the customer to notify all personnel

whose approval is required early in the process. See High-Consequence/High-Value Move

Lift/Move Approval below.

Approvers have special expertise and are available to provide guidance during the design of

the lifting procedure. Please allow sufficient time for the review-and-approval process. There

is no charge for the review-and-approval process.

The procedure must contain the following:

Identification of the item to be moved Identification of the Laboratory manager or engineer who is responsible for planning

the lift

Identification of the rigging supervisor or designated qualified rigger (other than theequipment operator) who will be the Person In Charge (PIC) of all aspects of the lift

while the load is suspended

Special precautions Weight of the item Total hook load (all component parts of the item plus tackle and load-measuring

devices)

Determination of the center of gravity A list of each piece of equipment and each accessory (e.g., slings, spreader bars,

yokes) to be used in the lift

Each accessory must be identified by type and rated capacity If a portable item to be used has no manufacturers serial number, a Berkeley Lab

identification number must be assigned and affixed to the item

Surveillance procedures, checkpoints, and estimated instrument readings (if used)must be listed to enable confirmation that the lift is proceeding as planned

Calculation of stresses to be generated in the item during lifting and determination ofthe adequacy and proper labeling of the attachment points of the item to be lifted.

A rigging sketch or sketches that include the following:
https://dcc.lbl.gov/dcc/EngNotes.phphttps://dcc.lbl.gov/dcc/EngNotes.phphttps://dcc.lbl.gov/dcc/EngNotes.phphttps://dcc.lbl.gov/dcc/EngNotes.php


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o Lifting pointso Load vectors at all stages of the lift/moveo Sling angles at all stages of the lift/moveo Accessories usedo Method(s) of attachmento Method of rotating about either horizontal axis, if applicableo Other factors affecting the capacity of the equipment or accessorieso Identification of the capacity (or limit) of equipment and loado Identification of the expected load in each item of equipment and each

accessory

A load-path sketch of the load path with the expected height of the load at eachpoint in the lift

Where appropriate, floor loading diagrams are to be included to provide for settingthe load down at any point in the path if that should be necessary.

A travel sketch, either as a part of the load-path sketch or a separate sketch,indicating the planned travel path, and lifting and travel speeds

Where clearances are an issue, a detailed drawing with verified dimensions thatdemonstrates the lift can be accomplished as planned

An assessment of wind loading and weather concerns for all outdoor work Obtain assistance from the Facilities Division Structural Engineering Group for wind

loading concerns.

A checklist detailing each step of the procedure, with each step initialed by theLaboratory manager or engineer responsible for the planning of the lift

A sign-off sheet where all personnel involved in the lift verify that they are familiarwith the contents of the procedure

Load tests and practice lifts, if required Verification that all primary and secondary hoisting equipment is within the current

inspection and test time requirements as specified in this chapter (for example,

yearly periodic inspections and certification)

High-Consequence/High-Value Lift/Move Approval

The procedure must be reviewed and approved by:

Customer management The Engineering Division Mechanical Engineering Department Designee The Facilities Department Structural Engineering Group The Facilities Department Rigging Supervisor


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The EH&S Division DesigneeAll reviewers should be consulted early in the process to ensure their concerns are

addressed, avoiding the need for later revisions to the procedure.

Unanticipated conditions may require on-the-spot changes of the lift procedure. Approvers

of the lift procedure should be present during the lift or at least immediately available to

approve changes. Changes must be recorded on the procedure and initialed by all available

approvers before they are implemented.

Personnel Participating in High-Consequence/High-Value Lifts/Moves

Each person involved in a high-consequence/high-value lift/move must be familiar with the

procedure before beginning work. A pre-lift meeting with all participating personnel must be

held before the lift. All participating personnel must initial the procedure sign-off sheet to

verify that they are familiar with the procedure.

Cab-Operated Cranes

Operation of cranes from a cab is restricted to professional riggers. The following rules apply

to cab-operated cranes:

Do not store personal belongings (including necessary clothing) in a manner thatinterferes with operations.

Store other necessary equipment (tools, oil cans, waste, extra fuses, etc.) in thetoolbox. Do not store equipment loosely in or about the cab.

Heavy Lifts

Heavy lifts should be made by the professional rigging crew that performs such work

routinely. Where there is a need for other personnel to lift loads over 10,000 lb., and lifts

exceeding 75% of the cranes maximum capacity, the proposed lift must be reviewed with

and approved informally by the supervisor of the professional rigging crew or his or her

designee.

Tilting Loads

Using a crane to tilt a load (standing up a load that is lying down or vice versa) carries a

significant risk of shock-loading the crane or losing control of the load. When such

operations involve loads that exceed 50% of the rated capacity of the crane, they must be


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reviewed by and may be performed only with the informal approval of the supervisor of the

professional rigging crew or his or her designee. If two hooks are required to tilt the load,

follow the high-consequence/high-value lift procedures listed above.

Work Process E. Mobile Cranes

The operation of mobile cranes is restricted to those who have been certified as competent

and qualified mobile crane operators by an independent certification agency. The Facilities

Division Riggers have authorized and qualified mobile crane operators.

Mobile crane operations for construction have additional requirements, which are found in

PUB-3000, Chapter 10. For the purpose of the Berkeley Lab Cranes, Hoisting, and Rigging

Program, small truck-mounted jib cranes with capacities of less than 2 tons are not

considered mobile cranes. Mobile crane operations are conducted in accordance with all

applicable Occupational Safety and Health Administration (OSHA) (and Cal/OSHA for

construction) requirements.

Any mobile crane, when not attended by a qualified operator during an entire shift or during

off-hours, must be secured by locked controls or equivalent means to prevent access to the

crane, such as locking the doors or locking up radio controls. Only the Crane Manager or

another qualified and authorized user of the secured crane may have control of the locking

mechanism.

Work Process F. Crane Inspections

Each crane or hoist must be inspected by a qualified crane operator before use, during any

given work shift. The inspection can be documented either on a tag attached to the crane

controls or in a log that is kept with the key to the crane controls. If the crane is not used

during any shift, it does not need to be inspected. However, each crane must be given a

documented operator inspection at least once a month whether or not it is used during the

month of the inspection. Inspection tags will be collected by the Facilities Division Crane and

Hoist Services Contractor and kept on record. Where applicable, crane inspection logs will

be reviewed by the Crane and Hoist Services Contractor. Typical crane inspection checklistsare shown inAppendix Aof this PUB-3000 chapter.

All other required equipment inspections and tests are performed by the Facilities Division

Crane and Hoist Services Contractor. Equipment and the frequency of equipment

inspections and tests are listed in a Facilities Division database as required by applicable
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regulations and/or standards. Facilities Division Crane Maintenance Vendor work orders are

automatically generated monthly and are based on information in the database.

Work Process G. Rigging and Other Below-the-Hook Devices and Fixtures

The crane operator is responsible for verifying that the load is properly rigged. The crane

operator must also take the following precautions when performing work:

Thoroughly inspect rigging before use (document the inspection on the Daily CraneInspection Tag).

Remove defective rigging from service. DO NOT USE and DO NOT REPAIR defectiverigging.

All other required rigging inspections and tests are performed by the FacilitiesDivision Crane and Hoist Services Contractor. The frequency of these various

inspections and tests are detailed in Facilities Division work orders.

Only use slings in accordance with the manufacturers recommendations. Use engineered attachment points and standard hardware (swivel lift rings, shackles,

and nylon slings) wherever possible.

Verify that all slings and hardware are rated for more than the expected load and areappropriate for the intended type of load and configuration.

Verify that all slings and special lifting hardware have current Berkeley Labinspection tags.

Never shorten slings with knots, bolts, or other makeshift devices. Never load rigging in excess of its rated capacities. Use padding to protect natural fiber or synthetic slings from damage (e.g., contact

with sharp edges).

Verify loads are balanced to prevent slippage (e.g., when using a basket hitch). Remove slings from a load when the load is not resting on the sling. Contact the EH&S Crane and Hoist Subject Matter Expert ([email protected]) or

the Facilities Division Crane Maintenance Vendor (ext. 7667) before rigging is used in

any manner or environment (e.g., used in close proximity with corrosives or

degrading chemicals, operated in temperature extremes of20F or +180F, etc.)

that may compromise its construction or strength.

Inspection and Testing of Lifting Devices

Each division is responsible for the safety and pre-use inspection of its lifting devices

(such as screw pin shackles, hoist rings, commercial equipment, etc.) and for its lifting

fixtures (such as spreader bars, special slings, equipment designed at Berkeley Lab, etc.).
mailto:[email protected]:[email protected]:[email protected]


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Berkeley Lab proof-load tags and inspection stickers must be current, where

applicable. Special-purpose lifting fixtures must be marked with a Laboratory equipment

number and labeled to identify applicable Engineering Safety Notes for fixture design and/or

high-consequence/high-value lifts/moves.

All lifting fixtures designed at the Laboratory must be proof-tested to twice their maximum

rated loads before being placed in service. A Non-Destructive Examination (NDE) is required

after the proof test. The exact type of NDE must be specified in the Engineering Safety Note

for the lifting fixture. The rated capacity must be marked on the lifting fixture so that it is

clearly visible to the equipment operator.

Order commercially available lifting fixtures through the Facilities Division Maintenance

Manager or Designee to assure they are ordered with a certificate of proof load testing. For

commercial lifting fixtures without certified load ratings, an Engineering Safety Note must

be written to determine the safe load capacity and furnish guidance for load testing.

Where the lifting fixture cannot be proof-tested because it is an integral part or component

of the experimental device, equivalent alternative safety precautions acceptable to the

Mechanical Engineering designee must be described in the Engineering Safety Note, which

delineates the lift procedure.

All lifting device pins of 5 cm (2 in.) in diameter or larger must have a magnetic-particle

inspection before they are placed in service. These pins are always part of a lifting device or

fixture. Make arrangements with the Facilities Division Crane Maintenance Vendor, ext.

7667, or theWork Request Center, ext. 6274, to have lifting fixtures inspected.

Active lifting devices and fixtures must be examined by an NDE at least once every four

years (or upon request), using magnetic-particle detection or other appropriate methods.

Make arrangements to have lifting fixtures inspected with the Facilities Division Crane

Maintenance Vendor, ext. 7667, or contact theWork Request Center, ext. 6274. Records

must be maintained by the Facilities Division and NDE organizations. Inactive lifting devices

and fixtures must be clearly marked STOP: DO NOT USE, and must be load tested and

certified prior to renewed use.

The Responsible User must ensure that:

Proof-testing is performed by the Facilities Division on all lifting fixtures designed atthe Laboratory, before they are placed in service

Adequate test records are kept
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Lifting devices and fixtures are used and maintained correctlyThe Responsible Designer must obtain design approval by means of an Engineering Safety

Note, as described below. For equipment designed at the Laboratory, the Responsible

Designer must provide the user with the information required to operate the lifting device orfixture safely. The Facilities Division will provide a test report to the user upon request.

Design of Lifting Fixtures

A qualified engineer must be designated to be responsible for the design, fabrication, and

testing of lifting fixtures not purchased commercially. The actual physical testing usually will

be performed by the Facilities Division in accordance with the written test procedure

specified by the Project Engineer.

All lifting fixtures designed or fabricated at the Laboratory must be covered by an

Engineering Safety Note. The Engineering Safety Note must include the calculation of lifting

fixture stresses and deflections, and must be reviewed and approved by:

The Responsible Designer Customer Management The Engineering Division Mechanical Engineering Department designee The Facilities Division Planning, Design & Construction Department, Structural

Engineering Group designee

The Facilities Division Plant Operations Department Rigging Supervisor The EH&S Division designee

The design stress for lifting fixtures or lifting attachment points must not exceed one-fifth

the ultimate strength of the material at its operating temperature. If welded fabrication is

used, the design stress must take into consideration any weakening effects of welding, such

as those that occur in aluminum alloys.

If practical, avoid welding in the fabrication of lifting fixtures. If welding must be used,

design and fabrication in conformance with the latest standards of the American WeldingSociety (AWS) are required. Careful, thoughtful design and follow-up are required.

Follow these rules for all lifting fixtures:

All welds in lifting fixtures must be certified welds, performed by certified welders,and inspected and certified by certified weld inspectors.


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If at all possible, do not allow welds to be subjected to tearing loads. Stresses inwelds must be substantially uniform.

Where possible, design lifting fixtures so that the main loads are carried only bystructural members, plates, or shear pins rather than by welds. Examine this

possibility carefully. Proof-test lifting fixtures to twice the maximum rated load. Follow by a

nondestructive examination. X-ray primary load-carrying welds and welds in

tension, or perform other suitable subsurface crack-detection examinations.

The screw-thread engagement required for conservative development of the fullstrength of a screw fastener depends upon the screw-fastener material and the

material of the threaded member.

o If the fastener is made of the same material as the female threaded member e.g., a low-carbon steel bolt and a hole threaded into low-carbon steel

an engagement of at least 1 diameters is required.o A hardened steel screw (Allen screw) in mild steel requires at least 2

diameters of engagement.

o A low-carbon screw fastener, threaded into a tapped hole in aluminum alloy,copper, or cast iron must have a threaded engagement of 1 diameters.

o Other material combinations must be approved by the Mechanical EngineeringDepartment designee.

Safety hoist rings may be used to make lifts up to their rated load whenscrewed 2 hoist-ring bolt diameters into materials such as aluminum alloy,

copper, or cast iron. When special high-strength bolts are required, test any bolt used as part of

Laboratory-designed lifting fixtures or pickup devices to two times its rated load. A

crack-detection inspection must be performed after the load test to ensure integrity.

Try to maintain a supply of tested bolts in the event that one is lost, or better yet, to

have the bolt on a permanent lanyard. Once a lifting device or fixture has been

delivered to the user, the user is responsible for ensuring that the proper bolt is

inserted to the proper depth and correctly torqued.

When the lifting fixture also serves as a shipping container or frame holding theexperimental device during transport, specify tie-down requirements and otherspecial shipping requirements to ensure the integrity of the experimental device,

e.g., anticipate flexing of the truck bed, acceleration due to bumps and potholes,

and/or vibration.

Label lifting attachment points adequately to ensure proper and safe use of thefixture.


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Any deviation from these rules requires equivalent alternative safety measures that have

been explicitly approved by the Mechanical Engineering Department designee.

Single-Bolt Pickup Devices

When equipment is designed to be crane-lifted at a single point with a single-bolt pickup

device, the vertical lifting load through the screw thread of the bolt must be in line with the

axis of the bolt so the load will remain level when it is lifted. With this bolt alignment, the lift

will be through the center of gravity and will be safer, since the load will not tilt or kick out

when it is lifted. A single-bolt pickup device must be used, such as a safety hoist ring or an

equivalent in-house device that is carefully designed and maintained. The threaded

engagement must comply with the requirements in the Design of Lifting Fixtures section,

above.

When a load is to be crane-lifted by slings from a crane hook through two, three, or four

pickup points located at the corners of the load, and without the use of a spreader bar, the

forces at the lift points are nonvertical. Again, a single-bolt pickup device, such as a safety

hoist ring or an equivalent in-house device that is carefully designed and maintained must

be used at each pickup point.

Eyebolts without shoulders are not allowed for use in lifting any load. Eyebolts with

shoulders are permitted for lifting loads when the following conditions are met:

These devices shall be rated for the load and approved for the application, e.g., acarbon steel eyebolt rated at 1,500 lb. Threaded into a carbon steel block.

The load is in line with the axis of the eyebolt, and side loads are minimal (aspreader bar may be required).

The thread engagement is at least 2 bolt diameters. The eyebolts are torqued to amanufacturers recommendations, if given, or another reasonable torque

substantially greater than finger tight. Angled sling usage is allowable if a

manufacturers recommendations for load reduction are given.

The use of unrated eyebolts or eyebolts in applications not specifically approved by themanufacturer must be specifically approved by an Engineering Safety Note.

27.7 Standards

29 CFR 1910, Occupational Safety and Health Standards for General Industry, Subpart N

Materials Handling and Storage, Paragraphs:


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1910.179, Overhead and Gantry Crane

1910.180, Crawler, Locomotive and Truck Cranes

1910.184, Slings

29 CFR 1926, Occupational Safety and Health Standards for Construction, 1926 Subpart CC,

Paragraph 1926.251, Rigging Equipment for Material Handling

California Code of Regulations, Title 8, Subchapter 4, Construction Safety Orders (as it

pertains to cranes used in construction work)

27.8 Related PUB-3000 Chapters

Chapter 24, Environment, Health and Safety (EH&S) Training Chapter 10,Appendix A, Code of Safe Practices

27.9 References

ASME HST-1M, PerformanceStandard for Electric Chain Hoists ASME HST-2M, Performance Standard for Hand Chain Manually Operated Chain

Hoists

ASME HST-3M, Performance Standard for Manual Lever Operated Chain Hoists

ASME HST-4M, Performance Standard for Electric Overhead Wire Rope Hoists ASME HST-5M, Performance Standard for Air Chain Hoists ASME HST-6M, Performance Standard for Air Wire Rope Hoists Crane Manufacturers Association of America, Inc. (CMAA) Specification No. 61,

Electric Overhead Traveling (EOT) Cranes

CMAA Specification No. 70, Specifications for Top Riding Bridge and Gantry TypeMultiple Girder Electric Overhead Traveling Cranes

CMAA Specification No. 74, Specification for Top Running and Under Running SingleGirder Electric Traveling Cranes Utilizing Under Running Trolley Hoists

DOE-STD-1090-2004, Hoisting & Rigging

Appendix A. Typical Pre-use Inspection Tag
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Figure A-1. Front of Daily Crane Inspection Tag


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Figure A-2. Back of Daily Crane Inspection Tag

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