IL & FS Cuddalore Thermal Power Project

Procedure Rigging, Slinging and Lifting

OWNER

IL & FS TAMIL NADU POWER COMPANY LIMITED

CONSULTANT

Fichtner Consulting engineers(India)Pvt. Ltd

CONTRACTOR

SHANGDONG TIEJUN Electric Power Engineering Company Limited

0

Revision Description byPrepared byChecked ByApproved byDate

Table of Contents

11.Introduction

12.Definitions

13.Guidance for Use

23.1Rigging

23.1.1Rigging operation

33.1.2Hardware

33.2Lifting tackle

33.2.1Slings

53.2.2Lifting hooks

53.2.3Below-the-hook lifting devices

63.2.4Shackles, eye bolts, pulley blocks and gin wheels

63.2.5Shackles

63.2.6Eye bolts

63.2.7Pulley blocks and gin wheels

73.3Lifting operations

73.3.1Safe lifting practices

83.3.2Lifts using cranes/hoists with rigging

93.3.3Lift plan

103.3.4Suspended loads

113.3.5Tilting loads

114.Wind Monitoring

115.Inspection, Testing and Maintenance

126.Training

127.Records

1-1Annexure 1 -Lifting Tackle Inspection Checklist

1. IntroductionHeavy material handling with cranes or hoists can potentially be dangerous. To ensure the safety of such operations, the Subcontractor must exercise stringent controls over the use of such equipment, including below-the-hook components. In addition, the procurement, maintenance, and inspection of all such equipment must be strictly controlled.Improper design, use, or maintenance of fixtures, lifting devices, and rigging accessories can cause equipment to fail or a load to drop from the lifting system, resulting in personnel injury, death, damage to the environment or significant property loss.

2. DefinitionsRiggingThe process of safely attaching a load to a hook by means of adequately rated and properly applied slings and related hardware

Lifting tackleComponents or equipment used between the lifting appliance and the load, or on the load to grip it, but which is not an integrated part of the lifting appliance

Lifting applianceMachine or device used for vertical movement of a load, with or without horizontal movement, including cranes and hoists

Lifting equipmentCommon term for lifting appliances and lifting accessories

SlingWire rope, chain, synthetic web and metal mesh made into forms, with or without fittings, for handling loads

Lifting hookLoad-transmitting components used in conjunction with chains and other equipment to connect lifting and rigging attachments

Rigging hardware and accessoriesItems such as shackles, eyebolts, rings, links, swivel hoist rings, turnbuckles, wire rope clips, and load-indicating devices used on a crane or hoist between the hook and the item to be lifted

Rated capacity or safe working load limit (SWL)The maximum load the lifting equipment is designed to lift under specific conditions

Working load limit (WLL)The maximum load a lifting accessory is designed to lift at a specific configuration.

3. Guidance for UseGeneral Requirements:

All personnel involved in rigging or lifting operations shall be competent and appointed in writing,

No Loads will be lifted over any person at any stage, slewing area to be barricaded and rigger to ensure no person is inside the barricaded area.

All load bearing equipment capable of moving materials e.g., chain blocks, turfors, winches, jacks etc shall have an identification number visible on the unit and recorded in a register;

The register shall detail the type of equipment, the equipment number, SWL, the serial number of the unit, and the last inspection date; All rigging equipment shall be inspected before each use with a comprehensive inspection and service being undertaken by a competent person every three months and a tag, visible from a distance of at least 6 meters, complying with the relevant Project colour code for the period attached;

All slings, chains, webbing and composite slings designed for attaching a load shall be identified with a Safe Working Load (SWL);

Damaged slings and equipment shall not be used. They shall be tagged out of service and removed off site;

Ropes shall only be used as taglinesThe Subcontractor must ensure that workers who direct, rig and handle loads - have received training in the principles of the operation;

are able to establish weights and judge distances, heights and clearances;

are capable of selecting tackle and lifting gear as well as the rigging method suitable for the loads to be lifted; and are capable of directing the movement of the lifting device and load to ensure the safety of all personnel.

All rigging and lifting equipment, including hardware and accessories, must have a formally designated equipment custodian. The custodian is responsible for ensuring that all rigging and lifting equipment are reviewed for conformance to relevant specifications before it is put into service; equipment undergoes all required inspections; and non-compliant equipment is removed from service.3.1 RiggingThe rigging of loads must be accomplished with relative precision by trained, experienced personnel. To ensure that safe practices are followed, competent supervision must ensure that rigging equipment of adequate capacity is used for the job; rigging equipment is in safe working condition; loads are properly rigged; and rigging crew and other affected personnel maintain safety practices.

3.1.1 Rigging operationThe most important step in any rigging operation is determining the weight of the load to be hoisted. This information can be obtained from shipping papers, design plans, catalogue data, manufacturers specifications and other dependable sources. When such information is not available, the load weight has to be calculated. The load applied to any rigging or rigging assembly must not exceed the working load limit of any single component.

Loads must be rigged so as to prevent any parts from shifting or dislodging during the lift. Suspended loads must be securely slung and properly balanced before they are set in motion. After a rigging assembly has been made up and before any lift is attempted, the Subcontractor must ensure that

the assembly is certified safe for lifting by a qualified rigger or similar person with the necessary competence and experience in rigging to make such a judgement; and

a test lift of the assembly is undertaken in which the load is lifted a small distance from rest to ascertain its stability before the actual lift is undertaken.

Note:

Never wrap the hoist rope around the load. Attach the load to the hook by slings or other rigging devices adequate and suitable for the load being lifted.

3.1.2 HardwareComponents used for rigging must be marked as follows:

Rigging fittings must be marked with the manufacturer's identification, product identifier and the working load limit (WLL) or sufficient information to readily determine the WLL. The WLL of existing fittings not identified as specified in the previous paragraph must be determined by a qualified person and marked on the fitting.

A wire rope sling with a swaged or poured socket or a pressed fitting must be permanently identified with - its WLL; the angle on which the WLL is based; and

the name or mark of the sling manufacturer.Loose materials, such as stones, bricks, tiles or other objects must be lifted in a receptacle of adequate strength. Where a receptacle is used for raising or lowering such loose materials, the receptacle must be enclosed or constructed to prevent the accidental fall of any such objects.

Rigging hardware must be removed from service if damage is visible and must only be returned to service when approved by a qualified person. Remove equipment from service if damage such as the following is visible: Missing or illegible manufacturers name or trademark and/or rated load identification; Indications of heat damage, including weld spatter or arc strikes; Excessive pitting or corrosion; Bent, twisted, distorted, stretched, elongated, cracked or broken load-bearing components; Excessive nicks or gouges; A 10% reduction in the original or catalogue dimension at any point around the body or pins; Incomplete thread engagement; Excessive thread damage; Evidence of unauthorised modifications; Other conditions, including visible damage that cause doubt as to the continued use of the equipment; Swivel hoist rings that are unable to freely rotate or pivot; and Loose or missing nuts, bolts, cotter pins, snap rings or other fasteners and retaining devices on swivels.3.2 Lifting tackleEvery lifting tackle item bought, or otherwise obtained, must be accompanied by a test certificate. Wire and fibre slings are exempt from the above requirement but a certificate must be obtained showing the safe working load, including a reference to the batch sample test carried out on the material from which the rope of sling was made.

The Subcontractor must ensure that only lifting tackle with a minimum safety factor of four used;

lifting tackle has a minimum safety factor as indicated: 10 for natural fibre ropes; 6 for steel wire ropes, man-made fibre ropes and textile webbing; and 4 for high-tensile steel chains.

3.2.1 Slings

Workers involved in hoisting and rigging must exercise care when selecting and using slings. The selection of slings must be based on the size and type of the load and the environmental conditions of the workplace. Slings must be visually inspected before each use to ensure their effectiveness. Improper use of hoisting equipment, including slings, may result in overloading, excessive speed (e.g. taking up slack with a sudden jerk, shock loading) or sudden acceleration or deceleration of equipment.

There are generally six types of slings: chains, wire rope, metal mesh, natural fibre rope, synthetic fibre rope and synthetic web. Slings are usually categorised into three groups, namely chains, wire rope, and fibre rope and synthetic web. Each type has its own particular advantages and disadvantages. Factors to consider when choosing the best sling for the job include size, weight, shape, temperature, the sensitivity of the material being moved and the environmental conditions under which the sling will be used. The following guide may be useful in selecting the appropriate sling:

Chains Chains are strong and able to adapt to the shape of the load. Care must be taken when using chain slings because sudden shocks will damage them. This may result in sling failure and possible injury to workers or damage to the load. Chain slings must be visually inspected prior to use. During the inspection, pay particular attention to any stretching, nicks, gouges and wear in excess of the allowances made by the manufacturer. These signs indicate that the sling may be unsafe and must be removed from service immediately. Wire rope Wire rope is composed of individual wires that have been twisted to form strands. Strands are then twisted to form a wire rope. When wire rope has a fibre core, it is usually more flexible but less resistant to environmental damage. Conversely, wire rope with a core that is made of a wire rope strand tends to have greater strength and is more resistant to heat damage. When selecting a wire rope sling to give the best service, there are four characteristics to consider: Strength of wire rope is a function of its size (e.g., diameter of the rope), grade and construction and must be sufficient to accommodate the maximum applied load.

Fatigue (bending without failure) of wire rope is caused by the development of small cracks during small radius bends. The best means for preventing fatigue failure of wire rope slings is to use blocking or padding to increase the bend radius. Abrasive wear is the ability of wire rope to withstand abrasion and is determined by the size and number of individual wires used to make up the rope. Smaller wires bend more readily and offer greater flexibility, but are less able to withstand abrasion. Larger wires are less flexible, but withstand abrasion better. Abuse or misuse of wire rope slings will cause their failure long before any other factor. Abuse can lead to serious structural damage, resulting in kinks or bird caging. (Which is where the wire rope strands are forcibly untwisted and become spread outwards.) To prevent injuries to workers and prolong the life of the sling, strict adherence to safe and proper use of wire rope slings is essential. Wire rope slings must be visually inspected before use. Slings with excessive broken wires, severe corrosion, localised wear, damage to end-fittings (e.g., hooks, rings, links, or collars) or damage to the rope structure (e.g., kinks, bird caging, distortion) must be removed from service and discarded. Fibre rope and synthetic web slings Fibre rope and synthetic web slings are used primarily for temporary work, such as construction or painting, and are the best choice for use on expensive loads, highly finished or fragile parts and delicate equipment. Fibre rope slings deteriorate on contact with acids and caustics and must therefore not be used around these substances. Fibre rope slings that exhibit cuts, gouges, worn surface areas, brittle or discoloured fibres, melting or charring must be discarded. A build-up of powder-like sawdust on the inside of a fibre rope indicates excessive internal wear and that the sling is unsafe. Finally, if the rope fibres separate easily when scratched with a fingernail, it indicates that the sling has suffered some kind of chemical damage and should be discarded. Synthetic web slings are commonly made of nylon, polypropylene or polyester and have the following properties in common: Strength depending on their size, Convenience and safety synthetic web slings adjust to the load contour and hold it with a tight, non-slip grip.

Load protection unlike other sling materials, synthetic web is less likely to mar, deface or scratch highly polished surfaces.

Shock absorbency regardless of the construction material, shock loading (e.g., excessive speed and rapid acceleration or deceleration) of slings should be minimised. However, it should be noted that synthetic web slings can absorb heavy shocks without damage.

Temperature resistance the lifting capacity of synthetic web is unaffected by temperatures of up to 80 Celsius.

Economy and long life synthetic web slings have a low initial cost and a long service life. They are unaffected by mildew, rot, bacteria, they resist some chemical action and have excellent abrasion resistance.

Synthetic web slings must be inspected before use and must be removed from service if found to have chemical burns, melting or charring of any part of the surface, snags, tears, or cuts, broken stitches, distorted fittings, or wear or elongation beyond the manufacturers specifications. Lifting equipment must be stored appropriately to protect the equipment from damage, preferably in a dry, indoor location.3.2.2 Lifting hooksLifting hooks are usually equipped with a safety latch to prevent disengagement of the lifting wire rope sling, chain or rope to which the load is attached. The hook and safety latch must be inspected before use. The hook may not be used if it is worn or damaged, or if the safety latch is damaged or missing. Using open hooks is prohibited when rigging loads for lifting.

Load disengagement can cause severe injury or death. The use of a hook with a safety latch does not preclude accidental detachment of a slack sling or a load from the hook. Visual verification of proper hook engagement is required in all instances.

Note:

Do not - exceed the WLL of the hook (or lift any load in excess of the rated capacity of the weakest rigging component); or

use a hook in alkaline or acidic conditions.

3.2.3 Below-the-hook lifting devicesA name-plate or other permanent marking must be on a spreader bar or specialised below-the-hook lifting device and must display the manufacturer's name and address;

serial number;

weight of the device, if more than 45 kg; and

the working load limit (certified by a professional engineer or established by the lifting device manufacturer).A spreader bar and any other specialised below-the-hook lifting device must be considered as part of the lifted load.

3.2.4 Shackles, eye bolts, pulley blocks and gin wheels3.2.5 Shackles

When using shackles: Use shackles for their intended purpose only. Apply the load slowly do not jerk. Do not apply angular loads to round pin shackles. De-rate screw pin and bolt-type shackles when angular load is applied. Do not heat or weld shackles. Shackles and pins have matching serial numbers and may not be interchanged. Changing pins between shackles can result in uncertified or old items of lifting tackle being used and safe working loads exceeded. Ensure that shackles are matched to the grade of sling in use; the correct shackle pin is used never replace a pin with a bolt and nut; and threaded shackle pins are secured in place with split pins prior to use.3.2.6 Eye bolts

Plain or shoulderless eye bolts or ring bolts should only be used for vertical loadings, as angle loading on shoulderless bolts could possibly result in the bolts bending or breaking. Shoulder eye bolts can however be used with vertical or angled loadings. Eye bolts must be screwed down to the shoulder or until the threaded section bottoms out. Care must be taken to prevent the use of incompatible threads.

Eye bolts may only be used in combination with hooks when a shackle that comfortably accommodates the hook is fitted between the hook and the eye bolt. Slings may not be passed through eye bolts and should only be used in conjunction with shackles, with the eye of the sling attached to the shackle.

3.2.7 Pulley blocks and gin wheels

Workers using pulley blocks or gin wheels must:

Ensure that the pulley block/gin wheel is in sound condition and good working order; Take action to ensure the immediate repair or replacement of damaged parts, with recommended parts only, before using the pulley block/gin wheel; Ensure that the support for the pulley block/gin wheel is capable of withstanding a load of at least 1 times the safe working load of the block; Keep the pulley block/gin wheel clean for optimal and safe performance; Keep the work area clean and tidy and free from equipment and materials not directly involved in the use of the pulley block/gin wheel; Ensure that all non-essential persons keep a safe distance while the pulley block is in use; Ensure that load slings are fully engaged in the load hook and that the hook safety bar is in the closed position; Raise and lower loads on the pulley in a smooth, controlled manner do not shock-load the pulley block/gin wheel by allowing the attached load to fall freely, even over very short distances; Use the pulley block/gin wheel only for lifting and not for suspending a load; Use the pulley block/gin wheel only with rope of the specified diameter.

Note:

Do not attempt to free a jammed rope or pulley while a load is attached use alternative means to support the load, then unhook the rope from the load and release the jam;

try to raise a load with more than one pulley block use a single block of adequate capacity; or use the pulley block to drag the load across the floor always position the load directly below the block

All lifting tackle must be - stored in a suitable and secure covered location that has been dedicated for the purpose; colour coded lifting accessories that are incorrectly colour-coded are to be stored in a separate, clearly marked area and returned for re-inspection, certification and colour coding;

checked before being used to confirm they are correctly rated for the work to be done;

visually examined for defects and damage prior to use (see Annexure 1 for a typical checklist), and equipment in unacceptable condition must be tagged as damaged and not fit for use and set aside in the same location as incorrectly colour-coded tackle for repair or disposal;

used only within their certified working load limits (WLL); and

removed from service for inspection, testing and re-certification if it is suspected that they have been subjected to loads in excess of their rated capacities.

3.3 Lifting operations3.3.1 Safe lifting practices

There are four primary safety factors to consider when lifting a load:

Load size, weight, and centre of gravity the hoist hook must be located directly above the loads centre of gravity to allow a level lift to be made. Dangerous tilting will result if the hook is too far on either side of a loads centre of gravity, which would in turn cause unequal stress in the sling legs. Load imbalances must be corrected immediately.

Number of sling legs and their angle with the horizontal the smaller the angle between the sling legs and the horizontal, the greater the stress on the individual sling legs. This increased stress effectively decreases the weight that can be safely lifted with any given sling size. Large (heavy) loads can be safely moved by keeping this angle as large as possible and, when necessary, distributing the weight of the load among more sling legs.

Rated capacity of the sling the rated capacity of slings vary and is dependent on the type of material the sling is made of, the size of the sling and the type of hitch. Workers must know the capacity of the sling, and can obtain this information through charts or tables available from the manufacturer. The rated capacity of a sling must not be exceeded under any circumstances.

History of care and use abuse and misuse of slings are the leading causes of sling failure. Following the manufacturers recommendations for proper care and use are essential for maximum sling service life and safety.

When fitting the sling to a load, steps must be taken to ensure that sling legs are free of any tendency to kink;

only the eye termination or link is placed on the lifting appliance hook;

sling terminations are properly seated on the hook and without overcrowding;

the load is effectively secured by the sling;

the relevant leg angle does not exceed that for which the sling is rated and marked;

the sling is not bent around any corners that might damage or reduce the effective strength of the sling where necessary, suitable packing pieces must be used;

when using a choke hitch - the choke angle is allowed to form itself naturally and is not forced;

a thimble or stirrup is used at the eye whenever possible to reduce damage to the rope and thereby prolong the life of both the eye and the main part of the rope;

a choke hitched sling is not used to turn, rotate or drag a load unless special precautions are taken to ensure that neither the sling nor the load is damaged; and

a tag line or control rope is attached to ensure that the swing or rotation of the load can be controlled.

The load line must be brought over the loads centre of gravity before the lift is started. Make sure that everyone stands clear when loads are being lifted. First lift the load only a few centimetres to test the rigging and balance. Keep the load under control at all times. Where personnel may be endangered by a rotating or swaying load, use one or more taglines to prevent uncontrolled motion.Loads must be safely landed and properly blocked before the load is unhooked and the lifting tackle is removed.

Protect your hands and fingersWhen slack in a sling is being taken up, keep hands and fingers out of the space between the sling and the load to prevent them from being trapped and crushed, and step away before the lift is made.

3.3.2 Lifts using cranes/hoists with riggingDo:

Define the load path (the path along which the load will travel and the orientation it will be in while it is being lifted and the location and orientation where it will be set down).

Choose lifting tackle that is rated for the prescribed load.

Identify the loads characteristics (centre of gravity, physical dimensions, weight, lifting points, etc.).

Establish the rigging requirements before the lift is performed. Identify and avoid potential pinch points (where an individual or a component of the lifting equipment or load may be caught between two surfaces).

Consider the loads balance, configuration, dimensions and attachment points.Dont: Use cranes/hoists for side pulls.

Cause the crane/hoist to lift, lower, or travel while anyone is on the load or the hook.

Carry loads over people.

Leave a suspended load unattended land the load before leaving it.

Change direction quickly.

Suddenly accelerate or decelerate the moving load.

Contact any obstruction.

Operate hoisting and rigging equipment when physically or otherwise unfit.

Use screw pin shackles if the pin can roll under the load and unscrew.

3.3.3 Lift planAll lifts must be planned. For simple routine operations, the following sequence will be considered sufficient and work orders need only reference the sequence:

1. Determine the weight of the load.2. Choose equipment suitable for the weight, environment and stability requirements and assess the need for tag lines.3. Ensure that the equipment has a valid inspection certificate and clearly indicates its WLL for all configurations.4. Ensure that the route of the lift and the final destination is clear from obstructions that could cause trips, slips or falls and that the surface can sustain the weight. An authorised signaller/dogger must act as a guide, should the lifting equipment operator not have a clear view of the lifting operation.

5. Fit the lifting tackle to the load and inform others with regard to their safety.6. Cautiously lift the load a couple of centimetres to assess its stability and degree of movement. Set down the load and adjust it if necessary.

7. Proceed with the lift and position the load.

8. Remove lifting tackle and clear up the area.

A documented lift plan must be developed for critical lifts. A lift is considered critical under any of the following circumstances: If - the item being lifted could result in the release of radioactive or hazardous material into the environment, which could exceed the established permissible environmental limits (PEL), if it were to be damaged or upset.

the item being lifted is unique, vital to a system, facility, or project operation and irreplaceable or irreparable if it were to be damaged. the cost to replace or repair the item being lifted, or the delay in operations of having the item damaged would have a severe negative impact on facility, organisation, or budget to the extent that it would affect programme commitments.

the item, although non-critical, is to be lifted above or in close proximity to inhabited areas, ongoing operations, electrical wires or a critical item or component.

the load being lifted is 95% or more of the cranes chart rating for the maximum radius that will be experienced.

the load is lifted by two cranes, with the load share greater than or equal to more than 70% of one or both cranes chart rating at the maximum load path radius.

the manager who has responsibility for the load, requests that it be handled as a critical lift.

A step-by-step plan or work instructions must be prepared or approved by a technically qualified person and must contain the following:1. Identity of the item(s) to be lifted

2. Special precautions, if any (such as mats for mobile cranes)

3. Weight of the item and total weight of the load. (For mobile cranes, see the manufacturers instructions regarding components and attachments that must be considered as part of the load.)

4. Location of the loads centre of gravity

5. A list that specifies each piece of equipment (e.g. crane, hoist), accessories and rigging components (e.g. slings, shackles, spreader bars, yokes) to be used for the lift. (This list must identify each piece of equipment by type and rated capacity.)

6. Designated checkpoints or hold points and estimated instrument readings as relevant, so that job progress can be checked against the plan. Hold points or sign-off points must be provided for personnel assigned to witness the work

7. Rigging sketch(es), which include the following:

7. lift point identification;7. method(s) of attachment;7. load angle factors, e.g. vertical and horizontal vectors of sling loads;7. sling angles;7. accessories used;7. other factors affecting the equipment capacity; and7. rated capacity of equipment in the configuration(s) in which it will be used for mobile cranes, many factors affect rated capacity, including boom length, boom angle and work area.8. A load-path sketch that shows the load path and height at key points in the job. Include crane position(s) relative to the load and relative to surrounding obstructions for lifts with mobile cranes. Where appropriate, include floor- or soil-loading diagrams.9. A sketch indicating lifting and travel speed limitations this may be noted on the load path sketch or on a separate sketch.10. A sign-off sheet to verify that equipment and hardware inspections and tests are current.

11. Practice lifts are recommended if used, requirements for the practice lift must be documented in the plan.Note:

Although individual plans are prepared for individual critical lifts, more general (multi-use) plans may be employed to accomplish recurrent critical lifts. For example, a general plan may be used to lift an item or series of similar items that are handled repeatedly in the same manner.

3.3.4 Suspended loadsFollow these rules for suspended loads:

Do not allow loads moved with any material-handling equipment to pass over any personnel.

Select the load path to eliminate the risk of injury to employees if the material-handling equipment should fail.

Do not work on suspended loads rest the load on adequate cribbing if it needs to be worked on.

Never leave a suspended load unattended lower it to the floor, the working surface or onto cribbing and secure the material-handling equipment before leaving the load unattended.

Should it be necessary to leave a suspended load, the area must be barricaded and hazard signs placed so as to prevent access to the area. Those required to work under a suspended load must be given written instruction in the form of a work order or procedure.

3.3.5 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 reviewed by, and may only be performed with the formal approval of the professional rigging crew supervisor or his designate.

4. Wind Monitoring

Wind speed will be potential hazard for lifting, rigging, and at height activities when exceeding the safe limit of the cranes specification as per OSHA requirements. In order to carry out those activities safely, wind speed need to be monitored to make sure it is in the safe limit.

Measurement of wind speed shall be conducted every day during working hours

Measurement result will be recorded on the special form and to be filed properly.

When the measurement shows that wind speed exceeding speed limit, personnel in charge must instruct all Crane operators and Riggers to suspend lifting activities until further notice.

When the wind speed over a measurement must be taken. If the measurement shows that the wind speed in safe limit, personnel in charge must inform Crane Operators and Riggers to resume work. All Crane operators needs to be trained in this procedure and take responsibility for wind readings, they should also have the knowledge that lifting is not allowed in excessive wind speed situations and adhere to this procedure strictly5. Inspection, Testing and MaintenanceAll lifting tackle must be tested before being put into service and thereafter inspected every six months. Ensure that the equipment is in order, has a test certificate for the correct safe working load and that the equipment is properly marked, identified and entered in the equipment register. Any items of lifting tackle, if found to be defective or unsafe for use, or that do not bear an identification number and a safe working load, must be clearly marked as such and permanently removed from the site.The installation, inspection, testing, repair, maintenance and modification of all components, tools, machinery and equipment used for rigging must be carried out in accordance with - the manufacturer's instructions; and

any standard the components, tools, machinery and equipment are required to meet, or as specified by a professional engineer.All items of lifting equipment must, before being put into service for the first time, be subjected to a proof load test in accordance with statutory requirements and a test certificate must be issued. Modified or repaired items of lifting equipment must also be proof tested before being used.

6. TrainingA qualified professional rigger must be in continual possession of a valid certificate of competency by an accredited certifying entity for the type of rigging equipment to be used. Certificate renewal is in accordance with the certifying entitys renewal schedule. In addition, riggers must be aware of common hazards, factors that reduce capacity, the inspection and use of slings and safe practices in rigging, lifting, and landing loads.Workers involved in hoisting and rigging operations should receive training in the following:

Sling and hitch types

Sling capacity determination

Equipment inspection, care and maintenance

Load weight and centre of gravity determination

Safe lifting techniques.7. RecordsRecords of all documentation detailing the lifting equipment conformity to relevant standards, maintenance requirements, etc., and records of all examination, inspection, testing and maintenance undertaken on an item are retained for the life of the item.Annexure 1 - Lifting Tackle Inspection Checklist

SubcontractorProjectLocation/site

Responsible personInspector nameScheduled date

Inspection (actual) date

Item #Item DescriptionYesNoN/AComments

1. Web Slings

1.1. No increased stiffness of sling material?

1.2. No acid or caustic burns?

1.3. No melted, burned or weld spatter damage?

1.4. No holes, tears, cuts, snags?

1.5. No broken or worn stitching?

1.6. No excessive abrasive wear?

1.7. No knots in any part of the sling?

1.8. No crushed webbing or embedded particles?

1.9. Sling colour not bleached?

1.10. Manufacturers ID and WLL?

2. Wire Rope Slings

2.1. No broken wires?

2.2. No worn and/or abraded wires?

2.3. No fatigue fractures?

2.4. No reduction in rope diameter?

2.5. No stretch?

2.6. No corrosion?

2.7. Sufficient lubrication?

2.8. Splices not damaged, and adequate?

2.9. Not corroded, cracked, bent or worn?

2.10. Properly applied connections?

2.11. No kinks?

2.12. No heat damage?

2.13. No electric arc?

2.14. Manufacturers ID and WLL?

3. Chains

3.1. Wear not exceeding 15% of a link diameter?

3.2. Links not binding?

3.3. Not cut, nicked, cracked, gouged, burned or corrosion-pitted?

3.4. Not twisted or bent?

3.5. No elongation caused by stretching?

4. Hooks

4.1. Distortions such as bending, or twisting not exceeding 10 from the plane of the unbent hook?

4.2. Increased throat opening not exceeding 15%?

4.3. Wear not exceeding 10% of the original dimension?

4.4. No cracks, severe nicks or gouges?

4.5. Latch in place and operational?

4.6. Hook attachment and securing means?

4.7. Manufacturers ID and WLL?

5. Shackles

5.1. Shackle pins fit freely and without binding?

5.2. The pin shows no sign of deformation?

5.3. No defect that will interfere with serviceability?

5.4. Manufacturers ID and WLL?

6. Eye Bolts

6.1. Not cracked or bent?

6.2. Threads not damaged?

6.3. Shank not undercut and smoothly radiused into the plane of the shoulder?

6.4. Manufacturers ID and WLL?

7. Pulley Blocks and Gin Wheels

7.1. Smooth and free of surface defects that may damage rigging?

7.2. Rollers, bushes, bearings, sheaves, axles not worn and rotating freely?

7.3. No abnormal noise when operating?

7.4. Attachment and securing means?

7.5. Side plates free from distortion?

7.6. No corrosion?

7.7. Manufacturers ID and WLL?

Actions required:

CAR/PAR reference:NOTE:

CAR/PAR (Corrective/Preventive Action Request):

All actions are managed through the action management process referenced from here to enable follow-up and close-out of inspection actions.

Inspector signature:

Issue 1 2010