2016 CRW - An inside look at Kiewit's Crane & Rigging Management System

Kiewit Crane & Rigging Management

Bret Shields

• Corporate Crane Procedures Manual

• Corporate Rigging Manual

• Career Development

Corporate Crane Procedures Manual

Section 1 – Crane Procedures

Section 2 – Glossary Of Definitions

Section 3 – Crane Operations

Section 4 – Boom & Pendant Lines

Section 5 - Revisions

CCP Manual Section 1

• Section 1-A: Authorized Operator Program• Section 1-E: Lift Planning• Section 1-S: Site Specific Crane Management

Plan• Section 1-Z: Incident Reporting

CCP Section 1-A: Authorized Operators

Detailed Incident Description: The crane was being used as a concrete pile driving rig. When traveling to get the next pile, the operator lifted the hammer in the leads about 4’ off of the ground and set his brake. Once the crane arrived at the next pile, the crew began to rig it up with the #2 line. In the process of tightening up on the #2 line, the operator mistakenly took the brake off of the hammer line, causing it to free fall 4’ to the ground. Upon striking the ground, the hammer damaged three of the four lump guides and the pile gate bars. No one was within 25’ of the hammer and no one was hurt. Root Cause(s):

Operator hit wrong brake release Contributing Factors:

Lack of concentration by the operator. Operator was not the daily operator on this machine. He was designated to operate the 4100 but had

been running a 999 since October 2009. Corrective Measures/Maintenance:

Operator was sent home for 3 days for equipment damage. Both pile driving crews were shut down in the morning and the incident was discussed. Operator will be re-designated by the jobsite Equipment Manager on the 4100 (15-3139) The operator will discuss the incident at the Jobsite Crane Operators meeting A change in crane operator will be identified on the Play of the Day. Operator shadowed the daily

operator for the day prior to running 4100.




CCP Section 1-A: Authorized Examiners • Understand details of the Authorized Operator process• Use good judgment to assess qualifications of operator candidates• Keep updated on procedures and regulations• Be familiar with crane’s operator’s manuals and LMI systems• Be consistent in applying assessment of operators; ask the right questions• Don’t be pressured in to not disqualifying an operator• Don’t be afraid to ask questions; use your other resources• Communicate to operators that they have the authority to stop an operation if they feel it is not safe• You are the company’s representative to decide whether a person is qualified to operate our cranes

CCP Section 1-E: Lift Planning

Lift Planning Requirements• Critical Lift Criteria

• Mobile Cranes• Tower Cranes• Overhead Cranes




Planning/Approval Matrix• Lift Types as Defined in CCP• Planning Requirements• Approval Requirements


On the Spot Lift Plan Book• Used for “General Lifts” • Completed by Operator• Reviewed with the Crew• Page 1 – Under 75% of crane capacity


On the Spot Lift Plan Book Page 2• 75 – 85% of crane capacity• Verification by Superintendent• Address additional hazards

CCP Section 1-S: Site Specific Crane Management Plan


CCP Section 1-S: Site Specific Crane Management PlanMAP Question # Risk Statement District/ Area Project

Fixed Facility

Shared Service

Regulation

Policy Comments

Crane Safety - Risk #1

All company owned and bare-rented cranes are required to have a documented daily inspection performed by a competent person prior to being operated each shift. OSHA 1926.1412(d) & CCP Section 1D

Yes, Shift inspections are being performed for all cranes. Project utilizing electronic DVI for cranes.


All company owned and bare-rented in service cranes are required to have a monthly inspection performed by a competent person. OSHA 1926.1412(e)

Yes, monthly inspections being scheduled and performed.


Company owned and bare-rented cranes are required to have a current annual inspection performed by a qualified person. OSHA 1926.1412(f)

All Co. owned cranes on site have current annual inspections.


Company owned and bare-rented cranes must only be operated by company-authorized operators for the type of crane assigned. CCP Section 1A

All crane operators authorized for the type of crane they are operating.


The company must ensure that each signal person is qualified prior to giving any signals, and documentation of the signal type qualification is available on-site. This applies to the Company, Subcontractors, and 3rd Parties. OSHA 1926.1428

Qualification documentation on site includes written test and practical test. Needs to be more questions on written test and more practical verification on voice siganls. Documentation retained on project SharePoint site. Need more visible recognition of qualified Signal Person in the field


One person in the rigging operation must be a qualified rigger. This applies to the Company, Subcontractors, and 3rd parties. CCP Section 1G and Section 2H

Rigger qualification documentation (training sign up sheet) maintained on project SharePoint site. Need more visible recognition of qualified Rigger in the field.


Subcontractor-operated cranes require documented daily inspections. CCP Section 4L

No direct subcontractors working for the project.


Subcontractor-operated cranes require documented monthly inspections. OSHA 1926.1412(e)

NA


3rd party fully-operated cranes require documented monthly inspections. OSHA 1926.1412(e)

NA - no 3rd party fully operated cranes being used on project.

Compliance Topic: Crane Safety - Orlando South Terminal Structures Project

Mitigation Action Plan• Site Specific ID of risk• Reviewed during Crane

Operation Assessments


Project Crane Operation Assessment• Senior Personnel – Crane “experts”• Study operations and evaluate risk areas• Improvement suggestions to job• 20-24 Projects per Year

Assessors:Project:Project Manager:DEM:CCM:Crane Supervisor:Total cranes on site Cranes Assessed

Yes No N/A

Signalman/Rigger Documentation:

Training / qualification process in placeDoes operator know who the Identified signalman/riggers are?

Crane Condition:

Overall appearance / condition of the cranes

Copy of current physical exam

Authorization for specific crane type / manufacturer

Personnel hoisting procedure

FAA compliant - Form: 7460.1

Critical lift planning

Anti collision program In place - I.E. tower cranes

On the spot lift plan

Lift director identified

Crane set-up

Operators knowledge of CCP ManualLift Planning:

Crane moves (planned?)

Have all crane incidents been reported?

Assembly / disassembly director

Operators manual / load charts / CCP manual in cab

Crane Operations:

Cranes leveled and on firm ground

Machine Files (Random Check):

On-hire reports completed

Daily/monthly / annual inspection reports

Repair records / backlog current / PM

Wire rope certification available

Cab cleanliness

Visual rope condition

Crane Operator Files (Random Checks)

Authorized operator

Indoctrinated in job site safety or escorted

Job hosts:

Categories

Site Crane Manager:

Project Crane Operations Assessment

Time:Job Location:

Date:

Proper signals being used I.E. radio communication

CCP Section 1-Z: Incident Reporting

CCP Section 1-Z: Incident Reporting

Corporate Rigging Manual

SECTION IPERSONNEL

A. Rigger IB. Rigger IIC. Lift DirectorD. Lift PlannerE. Master RiggerF. EngineerG. Signal PersonH. Chain of Command / Sequence of Events

People The knowledge, skills and abilities of persons who perform rigging tasks can enhance the safety and efficiency of our load handling activities while also reducing the associated risks. The capability of the person who performs rigging tasks originates with training, experience, hands-on practice and attention to detail. The following titles are often used in the load handling field, with the same individuals having additional craft or trade designations as pipefitters, boilermakers, iron workers, carpenters, millwrights, mechanics and the like. For Kiewit employees and other contract personnel who perform rigging tasks it is expected that they will have at least one of the qualification titles below as relates to their work assignments.

Corporate Rigging ManualQual. Level

NCCCO NCCER CIC Other

Trained/Qualified Kiewit Qualified

Rig I Approved Approved Approved Approved after successful KQ exam

Written exam required

Rig II Approved Approved Approved

Approved after successful KQ exams

Written exam, supervision observe work performance

Lift Director

Approved Not

Available Not

Available

Kiewit supervision observes LD performance

Kiewit supervision observes work performance

Signal Person

Approved Approved Approved

Approved after successful KQ exam

Oral or written exam, performance test required




SECTION IIEQUIPMENT AND ITS USE

A. SlingsB. Rigging HardwareC. Below-the-Hook Lifting DevicesD. Hoists and WinchesE. Jacks and Industrial RollersF. Personnel Lifting Systems

Introduction The following section provides information concerning the care, use and inspection of rigging equipment. The rigger should become familiar with the manufacturers’ guidelines and requirements as relate to usage and inspection. Repairs to any equipment should be performed by the manufacturer, their approved repair entity or a qualified person. Those performing rigging activities should select the rigging that best suits the application. The rigging shall have sufficient capacity to withstand the forces imposed as created by all or a portion of the load’s weight, its center-of-gravity and the angle of the rigging to the load. Rigging shall be protected as applicable during its use and re-inspected before its return to a storage location.

Corporate Rigging ManualSECTION III

RIGGING PRACTICESA. Load WeightsB. Center of GravityC. Hitch TypesD. Rigging ConsiderationsE. Rigging Selection and ProtectionF. Rigging Capacities Using Data ChartsG. Rigging Selection Using a Tape MeasureH. Rigging from CranesI. Rigging with Chain HoistsJ. Rigging with WinchesK. Rigging with Jacks and RollersL. Crib Piles and BlockingM. Load TurningN. Load Uprighting

Introduction Every rigging task should be approached by initially addressing the following three items:

load weight CG (center of gravity) rigging method (type, capacity, configuration and load control)

If those three elements are thoroughly evaluated, then the execution of the activity should be fairly simple and straightforward. Besides the ultimate rigging selection, the weight of the load often dictates which type of machine or LHE (load handling equipment) is needed to provide the lifting, pushing or pulling of the load during the load handling activity.


SECTION IVPLANNING

A. Lift ConsiderationsB. Lift CategorizationC. General Load Handling ActivitiesD. Critical Load Handling Activities

Introduction Planning is an important and integral part of the load handling process. Plans shall be detailed enough to give the impression that the load has been moved ‘on paper’ and that during the process, no stone was left unturned in regard to all facets of the operation. Risks shall be identified and mitigated to allow for the safest load handling activity possible.

Corporate Rigging ManualSECTION V

DATA AND FORMULASA. Capacities: Beams, Channel and Pipes B. Pad Eyes C. Load Angle Factors D. Rigging Block Load Factors E. Weights of Materials F. Center of Gravity and Load DistributionG. Rigging Tensions: Length / Height / RunH. D/d RatiosI. A2 + B2 = C2, Level & Incline Planes, FrictionJ. GeometryK. General EquationsL. Section PropertiesM. Work and Energy, Temperatures and Unit ConversionsN. Sling and Rigging Hardware CapacitiesO. Rigging Planning Form – 584RP

Introduction

From a planning or performing standpoint, nearly every rigging task requires some form of calculation. Often rigging equipment can be selected based on known angles along with the load’s weight and center of gravity. At other times, we need to closely estimate the anticipated tension that the rigging will experience prior to the load handling activity.

Career Development - 2015



• Riggers• Signal Persons• Authorized Operators • Front Line Supervisors• E-Learning• Skills/ Knowledge Verification

Career Development

• Strategic Partnerships– Industrial Training International

• Rigging Manual• E-Learning Modules• Online Skills Verification• Continuing Education Model• Rigging Train the Trainer

– Crosby • Online Knowledge Verification• Live Training• E-Learning Modules

Career Development

3 ea. Simulators• Manitowoc • Liebherr• Tower

• Signal Person Integration & Training