CLIENT CLIENT’S REPRESENTATIVE CONTRACTOR

Date: 23th JANUARY 2023

Project DAMMAM Warehouse – NUPCO

Client NUPCO – Saudi Arabia
Consultant JASARA
Contractor Creet International Cont. Co. Ltd
Doc - Title Tranformer and Generator Lifting Plan
 Lifting Safety Plan

Guidelines for Lifting Plan for

Lifting Operations In Workplaces

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 Lifting Safety Plan

Table of Contents

1. Introduction ...................................................................................................... 4
1.1 Scope................................................................................................................. 4
1.2 Target audience ................................................................................................. 5
1.3 Objective ............................................................................................................ 5
1.4 Site Survey ......................................................................................................... 5
1.5 Risk Assessment ................................................................................................ 5
2. Classifications of Lifts Types ......................................................................... 6
2.1 Routine Lifts ....................................................................................................... 6
2.2 Non-Routine Lifts ................................................................................................ 7
2.3 Flow Chart for Identification of Routine or Non-Routine Lifting Activities ............ 9
2.4 Planning and Execution of Routine and Non-Routine Lifts .............................. 10
3. Roles & Responsibilities ............................................................................... 11
3.1 Directors, Operation Managers, and Project Managers .................................... 11
3.2 Competent Person(s) ....................................................................................... 11
3.3 Supervisors ...................................................................................................... 12
3.4 Operators /Riggers /Signalmen......................................................................... 12
4. Description of Load(s) to be Lifted............................................................... 13
4.1 Details of Load(s) to be Lifted .......................................................................... 13
4.2 Load Crucial Information. ................................................................................. 13
4.3 Load(s) Weight(s) Including Lifting Gear........................................................... 15
4.4 Centre of Gravity (CG) of the load .................................................................... 15
5. Crane Selection.............................................................................................. 15
5.1 Details of the Crane .......................................................................................... 15
5.2 Bearing Capacity .............................................................................................. 18
5.3 Used Crane Capacity ....................................................................................... 19
6. Ground and Surrounding Conditions. ........................................................... 20
6.1 Ground & Outriggers ........................................................................................ 21
6.2 Access & Lifting Location.................................................................................. 22
6.3 Excavations ...................................................................................................... 22
6.4 Overhead Structure .......................................................................................... 22
7. Crane(s) Sitting & Lifting Study .................................................................... 23
7.1 Boom Clearance ............................................................................................... 24
7.2 Boom Height & Angle ....................................................................................... 24
7.3 Pick Up & Place Down Radius .......................................................................... 25
7.4 Unit of Measurement Used in Drawing ............................................................. 26

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8. Creating a Rigging Study/Plan ...................................................................... 27

8.1 Centre of Gravity of the Lift ............................................................................... 27
8.2 Lifting Lugs/Pad-Eyes....................................................................................... 30
8.3 Type of Rigging and Lifting Capacity ................................................................ 31
8.4 Sling Angles/lengths/SWL ................................................................................ 32
8.5 Shackles/Beams/Links/SWL ............................................................................. 33
9. Method Statement .......................................................................................... 33
10. Personnel & Training ..................................................................................... 33
11. Operational Requirements ............................................................................ 33
12. Customer Provision ....................................................................................... 33
13. Weather Conditions ....................................................................................... 33
13.1 Wind conditions ........................................................................... 34
13.2Effect of wind on crane..................................................................................... 34
13.3 Effect of wind on load ....................................................................................... 35
14. Communications ............................................................................................ 35
Acknowledgement.................................................................................................. 39

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 Lifting Safety Plan

1. Introduction

WSH Council understands that the successful control of lifting operations and safe use of lift
equipment requires a high level of management commitment, professional competence and
adequate resources. Fundamental to the success of any Lifting Operation is the fact that it
must be accepted by managers, those responsible for lifting operations and employees prior
to the commencement. These stakeholders must do all that is reasonably practicable to
achieve compliance with statutory duties arising from health and safety legislation, Council
guidance and advice.

Lifting of objects generally takes place at construction sites, shipyards, factories and other
industrial situations such as offloading with a forklift truck, containers at a warehouse or at a
commercial area. Good practice and correct lifting methods can move large objects efficiently,
safely and reduce manual handling operations. Incorrect lifting methods however, can lead to
major accidents and fatalities. The process of carrying out correct and safe lifting operations
involves a range of requirements which must be considered during the planning of any lifting
operation.

This set of guidelines must be read in conjunction with the Code of Practice (CP) on Safe
Lifting Operations in the Workplaces which act as an overarching document regarding lifting
operations and the use of lifting equipment.

1.1 Scope

Besides reiterating the key responsibilities of those involved in a lifting operating, these set of
guidelines offer further guidance for the organisation, assessment, planning, implementation,
management of change and the development of safe systems of work for lifting operations. It
is not a definitive document and does not describe in any detail the individual requirements of
a particular lifting operation or piece of lifting equipment.

In order to assist stakeholders in the development of a comprehensive lifting plan, the

guidelines should be used as a reference, to aide managers, competent personnel
responsible for lifting operations, lifting equipment and employees to consider the safety
factors when they assess, plan, supervise and carry out lifting activities. Managers who use or
hire in lifting equipment must ensure their service specific procedures regarding lifting
operations and lifting equipment links to and follows the requirements as outlined in these
guidelines.

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1.2 Target audience

The guidelines serve to assist key stakeholders, Responsible Persons, Appointed Persons,
Competent Persons, Project Managers, Crane Supplier Management, Lifting Supervisors etc.,
in the process of planning lifting operations and help ensure the transfer of vital safety, health
& environmental information required within the development of lift planning.

The provisions of these guidelines should be applied separately for all industry sectors that
require a crane or lifting equipment to lift / hoist any objects, regardless of whether above or
below ground level. Similarly, the provisions of these guidelines should be applied separately
for each differing sites in a multi-site project.

1.3 Objective

Planning is an essential component in every lifting operation at all workplaces. In line with the
Workplace Safety and Health Act (WSH Act), reducing risk at source is one of the components
to improving workplace and worksite safety. To address risk at source, there is a need to look
at whom and what creates the risks, every effort should then be made to eliminate or minimize
such risks to the lowest possible levels.

While the WSH Act imposes a duty on the occupiers, employers and principals of a workplace,
the risks inherent in the planning of all lifting activities are required to be addressed, with
mitigating actions identified and implemented. Additionally, accidents are often as a result of
either poor planning or lack of communication between or among stakeholders, this
sometimes resulting in loss of vital information that is fundamental to the safety of the
operation. The process to ensure transfer and communication of all relevant information and
documents is therefore recorded in the Lifting Plan. Essentially, No Plan - No Lift!

Appendix 1 outlines various stakeholders’ involvement in planning a safe lifting operation.

1.4 Site Survey

It is essential that a survey be conducted to establish what the load to be lifted is, what all the
characteristics are, weight, size, type of lifting lugs etc., what the ground conditions are, where
it has to be lifted from and to, what the access route is like, etc. The survey must be completed
by a competent person(s).

1.5 Risk Assessment

The site survey is an ideal time to begin a risk assessment of the proposed lifting operations
that will be carried out. The aim of the risk assessment is to prevent incidents and/or accidents
that arise from hazards* during the lifting operations. With the identified hazards, the risks^
posed by these hazards can be reduced to as low as reasonably practical through the
implementation of control measures, using the principle of the hierarchy of controls.

*hazards A hazard is anything that with a potential to cause harm.

^risks Risk is the likelihood that an accident can occur due to a hazard and as a result,
how badly someone is hurt. This largely depends on the implementation of control
measures, the working conditions of the control measures and site conditions. For
example, a control measure that is higher up on the hierarchy of control (such as
engineering controls) would result in a lower risk.

Other potential hazards that may present a risk to the lifting operation from other activities in

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the vicinity should also be considered. This can be easily done during the site survey.
Examples of other hazards and associated risks include, narrow access, excavations,
pipe-racks, overhead structures, other plant operating in the vicinity of the lifting area etc.

A sample of a risk assessment for lifting operations can be found in Appendix 2.

It is essential that the information within the risk assessment is translated into implementation
on-site. Checks should be done to ensure that control measures are in place and in good
working condition.

As site conditions may change, the following table may be used to check that control measures
indicated in the risk assessments are put in place and that they remain applicable to the actual
site conditions.

Step No. Task Control Measures Suitable and

Implemented?
(to ✓ if it is a
yes answer

2. Classifications of Lifts Types

There are generally two types of lift, Routine and Non-Routine. Categorising the type of lifts
before planning the lift and documenting in a lifting plan is critical because it allows for the
proper assessment of the amount of risk present in the lifting operation and the level of control
required in mitigating the risks involved.

2.1 Routine Lifts

Routine lifting operations may be executed under a basic lift plan. These plans must clearly
define the limitations on the loads, lifting methods and areas of operation. A Risk Assessment
will be required in each case, and authorized prior to commencement. A Non-Routine may
also be completed using similar documents but will require greater detail. Prior to any lifting
operation commencing, a review of the lift plan must be conducted.

Example: Routine Lifts - Example: Routine Lifts –

Bundle of rebars / I-Beam Receptacle

A Routine Lift is a lift which conforms to the following factors:

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Within the normal operating parameters of the crane

Lifting over non-sensitive areas
Suitable environmental conditions
Load has known and evaluated weight, shape and centre of gravity
Standard rigging arrangements
Routine repetitive lifting operations using the same equipment
Load has pre-determined weight, shape and centre of gravity
Single function or series of functions repeated manually or automatically
Order of function repeated
Same equipment
Same competent Crane Operators
Load under 75% of rated load of the load chart
Equipment specifically installed by a competent operator/ installer
Load has known and evaluated weight
Centre of gravity below the lifting hook
Use of a certified lifting point
Ample headroom
Not within sensitive, difficult or restricted areas
Single lifting machine
Unlikely to be affected by changing environmental conditions
Standard rigging arrangements
Suitable lay-down area available

Note: Routine lifting operations require the above factors to be considered but this list is not
exhaustive. The risk of each individual lift should be separately considered prior to
classifying the lifting operation as a routine one.

2.2 Non-Routine Lifts

Non- Routine lifting operations will require a more detailed Lifting Plan containing all of the
elements as described within these guidelines. The plan will have to be approved by a
Responsible Person prior to commencement of any Lifting Operation and any deviation
requirement identified from the plan, must also get the approval of the Responsible Person
prior to commencement of the lifting operation.

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Example: Non-Routine Example: Non-Routine Lift Example: Non-Routine Lift -

Lifts - Heavy Lift Tandem Lift Complex Lift

A Non-Routine Lift is a lift which conforms to the following factors:

Use of two or more Lifting Appliances, including tallying pipe using winch and
crane (tandem lift)
With sensitive, difficult or restricted areas
Lifts from one offshore vessel to another
Continuation of a lifting operation with different people
Lifting of machinery without lifting points
In environmental conditions likely to affect equipment performance
Load with unknown / difficult to estimate weight and/or centre of gravity
Non-standard rigging arrangements
Load lowered into or lifted from a confined space
Weight of load in excess of 75% rated load of the load chart

Note: Non-Routine lifting operations require the above factors to be considered but
this list is not exhaustive

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2.3 Flow Chart for Identification of Routine or Non-Routine Lifting Activities

START
No
Lifting more
Yes
than 50Ton

No

Requires Tandem Lift or Yes

Special Crane
Configuration (Fly Jib etc)

No

Operating over or near Yes

other building, sensitive,
difficult or restricted areas

No
Use of Special
Equipment, Man Yes
Basket, etc

No

Lifting of Machinery without Yes

known lifting points

No

Lifting more than 75% Yes

of rated load chart

No
Irregular shape / difficult Yes
to estimate weight and
Center of Gravity

Routine Lift

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2.4 Planning and Execution of Routine and Non-Routine Lifts

Identify need for lifting operation

PLANNING

Responsible person / lifting supervisor

to plan lift with technical / specialist
support as required
Routine Lift Non Routine Lift

Carry out risk assessment; Ensure all Carry out risk assessment (New or
risks are eliminated or reduced to Modified). Ensure all risks are
ALARP eliminated or reduced to an ALARP

Establish lifting plan by Responsible Establish lifting plan by

person Responsible person

Review and update if required / Lifting Plan (New or Engineered Lifts (Proje ct
approved by Responsible person modified) specific) and lifting pla n

Technical review by Competent person

and approved by Responsible person

EXECUTION
Appoint team appropriate for the lift
Ensu
plac

Tool box talk; Review risk assessment & Lift If a problem is detecte d
Plan; Emergency response & contingency plan; STOP WORK
Include all personnel involved in the lift; permit
to work in place
Revert to earlier position and review
risk Assessment - Carry out
management of change if required
During the lifting operation,
the lifting supervisor, Execute lifting operation with
signaller and rigger must be appropriate supervision
present

Debrief and note learning points

after lifting operation

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3. Roles & Responsibilities

3.1 Directors, Operation Managers, and Project Managers

These appointment holders must be aware of this guidance and understand their
responsibilities with regard to lifting operations, lifting equipment and the links to the relevant
health and safety legislation around lifting operations, ensuring that all lifting equipment used
for lifting operations is appropriate for the task, used correctly and that employees involved in
the organising, planning and use of lifting equipment are suitably trained.

In addition, Operation Managers must ensure in all cases where lifting equipment is being
used, that:

• All risks arising from operations involving lifting equipment are suitably and
sufficiently assessed by a competent person and appropriate control measures
implemented.
• All lifting operations are suitably planned, supervised and carried out in a safe
manner.
• Planning of a single lift or series of lifts must address the risks identified by the risk
assessment and that appropriate control measures have been implemented (safe
systems of work, lifting plans etc.)
• All relevant information, training and instruction are given to users of lifting
equipment and they are competent to carry out those tasks.
• All persons using lifting equipment must work within the agreed safe working
practices, reference information, instruction and training given.
• Systems exist for the reporting of and removing from use lifting equipment that has
developed a fault or defect.

3.2 Competent Person(s)

Persons who have been appointed or been given the responsibility for planning lifting
operations should have sufficient technical, practical and theoretical training, knowledge and
experience of the work they are likely to safely plan /assess the lift.

They shall:

Be capable of identifying the hazards and risks associated to lifting operations within
their area of work or the environment where the lifting operation will take place.
Be able to select the correct lifting equipment for the work. Understand the
characteristics of the lifting equipment they are selecting and the nature of the work
it will be carrying out.
Carry out and document risk assessments (lifting operation) or site surveys; have
the ability to communicate their findings to those involved in and affected by the
lifting operations.
Be able to create method statements or lifting plans and implement safe
systems of work for lifting operations.
Where appropriate seek additional support and expertise including the use of
external specialists to assist them with the planning of lifting operations.

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3.3 Supervisors

The appropriate supervision of lifting operations should be proportionate to

the level of risk and take into account those involved in a particular lifting
operation. Levels of supervision will be determined by the nature or
complexity of the work and the competence of those involved in using lifting
equipment and assisting with the lifting operation.

Persons who have been authorised to supervise lifting operations shall:

Have sufficient technical, practical and theoretical training,

knowledge and experience of the work being carried out.
Be briefed and instructed on the outcomes of the risk assessment and fully understand
the requirements of the safe system of work or lifting plan for the lifting operation to be
carried out and an understanding of all those involved in the task.
Supervise all complex or unusual lifting operations.
Monitor a sufficient number of lifting operations to ensure correct working practices are
being followed.
Where appropriate direct lifting operations, offering clear instructions to those involved.
Be able to assess changes in circumstances e.g. ground conditions, and where
appropriate stop a lifting operation if the risk is unacceptable or if it is considered
unsafe to carry on. Referring the concerns to their manager, competent person or
person responsible for planning lifting operations.

3.4 Operators /Riggers /Signalmen

They shall:

Not attempt any lifting operation or use lifting

equipment, without prior training/assessment,
guidance and appropriate supervision or which is
beyond the level of their competency.
Ensure that both routine and complex lifting operations
are not undertaken without a suitable and sufficient
risk assessment being carried out by a competent person.
Ensure they fully understand the lifting equipment, be familiar with how it
operates and the proposed lifting operation(s) they have been authorised to do
and that safe systems of work, training, guidance and advice are followed at all
times.
Carry out pre-use checks of lifting equipment prior to use, to ensure there are no
obvious visual defects.
Remove faulty or defective equipment from use, clearly record fault or defect on the
appropriate documents and report the issue to their manager or person in charge as
soon as is reasonably practicable. This includes reporting concerns they may have
regarding a lift operation to their supervisor or manager in the first instance and not
continuing with the operation.
Have an understanding of the emergency procedures relating to lifting equipment
in use and take part in training and periodic drills, where appropriate.

Details of a Lifting Plan

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4. Description of Load(s) to be Lifted

Sufficient information must be provided to give a clear, but brief, description that will clearly
identify the lift(s) to be undertaken. A separate risk assessment form will need to be
completed for every time the crane is moved to a new position, unless the risk assessment
has taken into account the hazards associated with all positions.

4.1 Details of Load(s) to be Lifted

It is extremely important that as many details as possible are gathered about the load/loads to
be lifted. The customer or client requiring the lift must provide the Competent Person with full
details of all loads to be lifted. Details of each load to be lifted must be entered on the risk
assessment form. The Competent Person must carefully consider all the loads to be lifted and
ensure that sufficient information is provided and recorded to enable other persons to see
how the lifts are to be performed in a safe manner.

4.2 Load Crucial Information.

No load must be lifted without the following crucial information:

- the load weight

- the overall dimensions (length, width and depth).
- indication of the position of centre of gravity.
- the lifting/slinging points
- the pickup radius
- the final location radius
- the height to which the load has to be lifted.
- the overall weight (load + all lifting accessories)

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Example of description of loads for a Routine Lift

Example of description of loads for a Non-Routine Lift

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4.3 Load(s) Weight(s) Including Lifting Gear

The most important thing that you require to know is the weight of the load. This information
should be given at the earliest point in the planning stage, it is from this information that your
crane selection will be made and all the planning around it. The weight of the load must be
accurate.

It is also important that the load dimensions are recorded, this will also help in the planning of
the lift, particularly to establish boom clearance, calculate required clearances when in
restricted and confined areas, it also allows calculation to be completed on wind sail area
giving a maximum wind speed that crane can operate in.

The weight of the load must include every piece of lifting gear involved in the lift from the hook
block downwards, ropes, beams, shackles, frames, slings etc.

A crane is not designed to be nor is it a weighing machine; weights must be known by other
means. However, every load lifted should in the first instance be lifted slowly from the ground,
should it start to exceed the given weight it must be placed back on the ground and the
Responsible Person / Competent Person must then take whatever actions are required to
re-plan the lifting operation.

4.4 Centre of Gravity (CG) of the load

To ensure that every lifting operation is under control and free of unplanned movement, the
CG must be known. In simple lifting terms with balanced loads the CG is generally in the
middle, this point will always be directly below the centre line of the crane hook block when
slung.

5. Crane Selection

Using the previously gathered information in conjunction with crane manufactures duty charts
it will allow the selection of a crane that is suitable with sufficient capacity to safely execute the
lifting operation.

5.1 Details of the Crane

Details of the preferred crane(s) to be used must be recorded within the Method Statement
and must include:
- the make and model;
- capacity
- jib length ( plus fly/luffer jib with offset where required );
- outrigger spread;
- outrigger load;
- maximum ground bearing capacity
- counterweight/super-lift counterweight required;
- weight of the crane.

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C. Crane Details:
Crane AC-100 (100TON)
Configuration Main Boom
Boom Length 33.7 M
Working Radius: 14 M
Corresponding SWL: 18000 KG

Example of Simple description of Lifting Equipment

Example of load chart identification for SWL

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Note: *For lifting old machinery or equipment as load, to add 25% buffer due to unknown
substances resided in the machinery or equipment (such as Oil, residue etc) to be lifted

Example of description of Lifting Equipment and Load Calculations

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5.2 Bearing Capacity

This must be the permissible load bearing capability of the ground at every position where the
crane is to be stood, as provided by an appropriate authority with knowledge of the site. The
Competent Person will need to determine the area of the outrigger supports/crawler
tracks/wheels etc. required to ensure that the maximum given ground pressure is not
exceeded. Details of the required supports must be recorded in the Method Statement.

Where the crane is supported by its outriggers during a lifting operation the maximum
outrigger load for the specific configuration, whilst lifting the load, will also need to be entered
within the Method Statement. These loadings can be obtained from the manufacturer’s
outrigger load tables.

Example of Identifying highest outrigger force with Load

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Example of Calculation for Ground Bearing Capacity

5.3 Used Crane Capacity

After crane selection has been made it is important that it is known how much spare capacity
there is left within the crane duty chart, this should be recorded within the plan. This is also at
times referred to as the “Safety Margin”. It should be remembered that many user, depending
on who they might be, will only use 75, 80 or maybe 90% of a rated duty chart. It may well be
necessary to select a larger capacity crane.

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6. Ground and Surrounding Conditions.

The responsibility for ensuring that the ground beneath the crane can withstand the loads
imposed by the crane during lifting should always rest with the user. However the customer
may well not have sufficient expertise to carry out an assessment of the ground, therefore
the Competent Person should ensure that the customer has consulted an appropriate
specialist such as specialist professional engineer in geotechnical engineering (P.E,
Geotechnical) to ensure that the ground will sustain the loads imposed by the crane. A
typical ground pressure chart in given below.

A Typical Ground Pressure Chart

Where the Competent Person has any concerns or doubts about ground conditions it should
be noted by the Responsible Person and no lifting should commence until all issues have
been satisfactorily resolved.

All Crane Hire/Contracting organizations such as occupiers of work sites or factories must
provide their user with the worst case scenarios of pressures that can be applied during a
lifting operation with a specific crane type lifting a known load weight.

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6.1 Ground & Outriggers

When lifting on outriggers the outrigger beams and jacks must be extended in accordance
with the manufacturer’s instructions for the crane. The Competent Person must ensure that
there is sufficient space at the crane siting location for this to be achieved. The crane rated
capacity indicator must be set in accordance with the manufacturer’s operating
instructions.
It is important to realise that ground that has been backfilled without any means of
compaction will present a danger and must not be used to support a crane. Sufficient load
spreading materials, of adequate size and strength, must be used under each outrigger.
Ensure that the crane lifting area has been checked for voids and underground services.

X
Example of Poor Outrigger Set Up

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All normal routine & non-routine lifting

operations with hydraulic mobile cranes must
have outriggers fully blocked out using
appropriate load bearing mats.

Crawler Cranes are designed to walk but

careful and particular attention must be given
to the ground conditions. At the time of the
survey ground conditions should be
established. In many cases it will be necessary
to lay down large wooden or steel mats for the
crawlers to move around a site. During heavy
lifting it will always be necessary for the use of
large load spreading mats as shown. Load Bearing Mat

6.2 Access & Lifting Location

The Competent Person during his survey should take particular note and record the site
ground surface conditions on at least 2 occasions, the first relates to access for the crane
and transport vehicles (boom/ballast/counterweight carriers) to the site location and the
second being the actual location where the crane will be located when lifting the load/s. It is
important to discuss with the user the route to be used, as it is their responsibility to ensure
that the ground can support the loads that will be applied. The Competent Person must be
satisfied with the space provided and the access route to be used, also the nature of the
surface (e.g. blacktop, hard-core, concrete). For clarity, the route can be shown on the site
plan.

6.3 Excavations

Excavations can be a real hazard to lifting operations. During any survey all excavations in
close vicinity to a where a lifting operation will take place must be noted. Also on the day of a
lifting operation the area should be re-checked, many times on construction sites excavations
get dug without any communication to the lifting team.

a) Where the ground is compact and non-crumbling, the

distance of any part of the crane support timbers from
D
the excavation should be at least equal to the depth
of the excavation.

b) Where the ground is loose or crumbling, the distance

H of any part of the crane support timbers from the
excavation should be at least twice the depth of the
Relationship of Safe distance D with excavation.
Excavation Depth H
Note: Figures 4,5 & 6 of SS536:2008 provides further
guidance on Safe distance D from a slope with depth H
for various situations

6.4 Overhead Structure

Many serious injuries and fatalities within the Lifting Industry are as a result of crane booms
and hoisting ropes coming in contact with overhead structure such as MRT Tracks, building,
trees etc. All overhead structures must be noted during the initial survey and provisions made
to avoid them during the lifting operation.

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7. Crane(s) Sitting & Lifting Study

All crane/lifting operations must have some form of documents, from the simple lifting
operations where all analysis and information may be recorded on a Lifting plan in conjunction
with a Permit to Work, all the way up to the very complex lifting operation which will require a
very detailed and comprehensive Lifting Study.

The sitting plan can be in the form of a hand drawn sketch for the simple operations, with a
detailed engineered drawing for the more difficult and complex operations. In each case the
idea of having a sitting plan is to ensure that the crane or lifting machine is positioned on the
correct location to safely complete the intended operation. Margins as low as 1m can be the
difference between success and failure, it is recommended that a water based spray paint is
used to mark out where the crane will be sited for all complex lifting situations. Examples are
given below:

Example of Sitting Plan of Crane at Site

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Example of Siting Plan of Crane at Site

7.1 Boom Clearance

It is always necessary to know that there is sufficient boom clearance during any lifting
operation, particularly when working in restricted and confined areas. This should be
determined during the planning stage and recorded within the lifting plan. Equally the tail
swing should be determined.

7.2 Boom Height & Angle

Boom angle and height are pieces of important information that must be recorded within the
Lifting Plan. Not only do they help in the correct selection of a suitable crane, they also allow
calculation of clearances of buildings and other possible obstructions.

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Example of boom height and angle of load chart

7.3 Pick Up & Place Down Radius

Radius, like all other pieces of information is extremely important and fundamental to safe
lifting practices. When measuring radius, which again is part of requirements in the selection
of a suitable crane type, ensure that both the “Pick Up and Lay Down” measurements are
taken and recorded within the plan.

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Example of pick up and place down position

7.4 Unit of Measurement Used in Drawing

Where detailed drawings are being used it is important to mark the drawing with the correct
information, such as the unit of weight and dimension being used. Drawings must be of same
unit of measurement. All drawings must be signed by the originator and approved by a
Responsible Person / Competent Person. Always ensure that drawings are latest and final
versions. An example is shown below:

Example of drawing with dimension and standard unit of measurement

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8. Creating a Rigging Study/Plan

Along with all the content of Risk Assessments, Sitting Study and, Drawings which all come
together to form the Lifting Plan it is also necessary to complete the Lifting Plan by adding a
Rigging Study or Rigging Plan.

Essentially the Rigging study, particularly when planning non-routine and complex lifts, is a
detailed drawing showing the rigging configuration of all lifting points on the load and details of
all slings, beams, shackles, ropes, blocks etc. by size and SWL. It is designed to show all the
connection points, the forces applied to each and how it will be slung together.

Normal routine lifting where a Lifting Plan is used the drawing may be a hand drawn sketch
showing the rigging configuration. An example of a Rigging plan is show below:

An example of a Rigging plan

8.1 Centre of Gravity of the Lift

When preparing the lift and attaching the rigging it is important to follow the Rigging Study and
ensure that the CG is directly under the hook block of the lifting crane.

When a load is lifted by a crane the CG always hangs vertically beneath the hook. If the CG is
not under the hook when it is first lifted, then the load will tilt until it is. (see Figure below).

This can be a useful way of locating the CG of a load in the field. We know that the CG is
located somewhere along the vertical line through the hook. (See Figure blow again.) We all

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know this exercise: the load is lifted and does not stay horizontal. To make sure that the load
stays horizontal when lifted, we either change the lift point position of one of the slings or
lengthen or shorten one of the slings in such a way that the CG is exactly under the hook when
we lilt the load.

Figure : CG Beneath the Hook

With larger and off-set/off balanced loads the CG is more difficult to determine. Below is an
example of a load with an off-set CG. Normally this is the case at non symmetric elements.
Note the slinging arrangements and how a load becomes unstable when the CG is not directly
below the hook block.

Example of Center of Gravity (CG)

Note: For large objects which are being lifted, the CG. will have to be determined via
engineering method. The lifting lugs will also need to be designed for to ensure safe
lifting. Specific lifting gear can also be used to ensure that the hook is always above the
CG during the lifting operation.

When the CG is not equally spaced between the rigging points, the slings and fittings will not
carry an equal share of the load. The sling connected closest to the center of gravity will carry
the greatest share of the load.

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Sample Calculation:

Sling 2 is connected closer to the CG, therefore it will carry the greater share of the load:
Tension in/Load carried by Sling 2 = 5 x 2.43 / 3.04 = 4.0 tons
Tension in/Load carried by Sling 1 = 5 x 0.61 / 3.04 = 1.0 tons

Similarly, for two legged slings joined to the hook,

Sample Calculation:

Tension in/Load carried by Sling 1 = 5 x 0.61 x 3.44 / (2.43(2.43+0.61)) = 1.42 tons

Tension in/Load carried by Sling 2 = 5 x 2.43 x 2.5 / (2.43(2.43+0.61)) = 4.11 tons

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8.2 Lifting Lugs/Pad-Eyes

Attention must be paid to the lifting lugs or pad-eyes on any load that is about to be lifted. In
many cases they may be manufactured as an integral part of the load which will be covered by
calculation certification as part of item being lifted.

The following example illustrates the design of lifting lugs for lifting of concrete precast
element:

The design of the lifting lugs, pad-eyes and similar items shall be based on the concept of
global safety factors. The safety factor requires that the action E does not exceed the
admissible value of the resistance R. It shall be shown as:

E R
E: Action
R: Admissable load (resistance)

The minimum concrete strength at time of lifting is 15 N/mm².

Lifting lugs, pad-eyes and similar items which are intended to be used to lift precast elements
have to be considered as lifting anchors or lifting systems. The provisions therefore have to be
fulfilled even and especially if the lifting items become integral part of the load.

Ductility is a very important item, which means ripped rebars protruding from the precast
element are not covered from these provisions. Smooth bars and prestressing strands have to
be ductile to avoid brittle behaviour.

Cast-in lifting anchor with fulfilled provisions:

Example of lifting anchors as an integral part of the load

There will be cases where lifting lugs/pad-eyes will not be provided separately, but
self-produced in the precast yard. In such cases the Engineer / Competent Person must be
sure that they have current certification and are of sufficiently designed and verifiable proven
to cope with the lifting effects.

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Cast-in lifting anchor – self-produced in precast yard:

Example of Certified lifting lugs/pad-eyes that are provided

separately

To avoid any risks for human life and health and safety of employees in the precast yard and
construction site all lifting anchor systems and motions therewith have to be checked,
calculated and proven by an constructional engineer e.g. as consultant or technical engineer
in the precast yard. The resistance comes from supplier. In case of a given recommendation
provided by supplier, the responsible engineer has to check the complete situation of handling
too.

8.3 Type of Rigging and Lifting Capacity

Lifting gears or slings generally carry their loads in one of three primary sling hitches. Most
slings can be used in all three sling hitches, but some slings are designed for use in only one
hitch. Slings have the largest Work Load Limit when used in a basket hitch. The vertical hitch
Work Load Limit is 50% of the basket hitch (i.e. WLL of basket hitch = 2 x SWL). The synthetic
choker hitch Work Load Limit is a maximum of 80% (typically 70-75%) of the vertical hitch
Work Load Limit. Slings must be securely attached to the load and rigged in a manner to
provide for load control to prevent slipping, sliding and/or loss of the load. A trained, qualified
and knowledgeable user must determine the most appropriate method of rigging to help
ensure load control and a safe lift. The manual or the tag on the sling should be referred to for
more information on the actual ratings for each hitch type.

Different type of Rigging

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Example of tag on polyester webbing

sling showing the WLL factors

8.4 Sling Angles/lengths/SWL

In any lifting operation the rigging equipment will be selected based on the weight of the load
to be lifted. However, there are times when the angle of the slings gets overlooked and what
appears as the SWL on the tag or certificate is not sufficient to do the job. Every rigging study
where slings are part of the lifting gear must be checked to ensure that angles do not reduce
the lifting capacity below that of the weight of the load. A simple calculation can be done as
follows:

Example:
W = weight of load = 5 tons
Share of load on each leg = 2.5 tons
L = Length of sling = 4m
H = Height between hook and load = 3m
T = Tension in each sling = 4/3 x 2.5 = 1.333 x 2.5 = 3.33 tons
The total tension in the slings adds up to 6.66 tons which is much more than the actual weight
of load at 5 tons!

Note: Rigging is advised to proceed at 60° as far as possible. Slings should also be selected
with at least a 20% extra SWL as lifting is typically carried out at 60° sling angles.
When the rigging exceeds this sling angle, detailed calculations should be done to
determine the actual load on each leg of sling.

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8.5 Shackles/Beams/Links/SWL

The Competent Person must ensure that all lifting gear has current and valid certification prior
to the commencement of any lifting operation. Any shackles or links being used to join slings
together should also be sized to take into account the actual load that each section will be
taking.

9. Method Statement

When writing a Method Statement it is beneficial to write it in such a manner that it follows the
sequence of the events and actions required as the lifting operation progresses. This include
about personnel, about wind and several other items that are key to successful lifting.
Therefore the user is to ensure that all other items that are essential to successful lifting are
included in the method statement. If in doubt, consult a Competent Person.

The actual sequence and order of events should be described within the plan in simple easy to
read and understand in “one line bullet point style”. A Lifting Plan (as shown in Appendix 3 for
a Routine Lift sample) is an attachment to the Method Statement.

10. Personnel & Training

All personnel involved in any lifting operation must be trained, skilled and competent in their
role and have certificated evidence of proof. The Competent Person must ensure that all
members of the Lifting Team have the relevant qualifications and certification.

Always ensure that there are sufficient numbers in manpower resources to carry out the work
comfortably and without putting undue pressure on any member of the team. In the event that
there may be a trainee within the team, the Competent Person must ensure that they are
under constant supervision and not allowed to undertake unfamiliar tasks on their own.

11. Operational Requirements

Each Lifting Operation must be planned taking into consideration

the operational requirements of the site. In general when lifting
operations are taking place there are others involved and other
work activities going on in the close vicinity of the lift.

To ensure that the lifting area is secure and free from

unauthorized persons the area must be cordoned or barricaded
off. During the lift lookouts must be posted to prevent entry into
the lifting area, normally these people would be employees of the
customer/client as the Lifting Team have sufficient to do taking
care of the lift.

12. Customer Provision

It is the responsibility of the customer/client to ensure that all requested requirements are in
place on the day of the lift, i.e. good access to the lifting site, that the ground conditions are
level, sufficient and capable of withstanding the identified pressures.
13. Weather Conditions

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Weather has a major impact on any Lifting Operation. Wind is a major hazard that can disrupt
and put a lifting operation at risk. Cranes must never lift at wind speeds beyond those
recommended in the crane manufacturer’s instructions.

Additional to manufacturer recommendations, the larger the wind sail area of a load the more
risk it may bring, therefore it may be necessary to do a calculation to find out what the safe
wind operating speed will be. Many times it is very much less than that recommended by the
manufacturer.

13.1 Wind conditions

Sumatra squall (Monsoon winds)

Lifting operations are often elevated. In such high rise conditions, stronger winds
are expected, especially during the tropical monsoon seasons when strong wind
gusts (‘Sumatra’ squalls) can be experienced.

The maximum wind gust of up to 100km/h (est. 27.78m/s) has been recorded during
a passage of a Sumatra squall.

Mean surface wind speed

the mean surface wind speed is normally less than 20km/h (est. 5.56m/s).

The maximum recorded wind speed is unlikely to exceed 33m/s.

The following are the wind speeds expected

Wind speed relevant Code of Practice

33m/s basic wind speed (3 Code of Basic Data for the Design of
second gust speed) Buildings. Loading. Wind Loads – CP3
Chapter V Part 2
22m/s basic wind speed (hourly Loading for buildings. Code of Practice
mean speed) for Wind Loads – BS 6399:Part2
20m/s basic wind speed Actions on structures. General actions –
Wind actions – SS EN 1991-1-4
SS ENs will be the only prescribed design standards with effect from 01 Apr
2015.

13.2 Effect of wind on crane

One of the major factors affecting stability is the effect of wind. However, determining wind
speeds can sometimes present difficulties. This guideline recommends the use of a hand-held
wind speed device (anemometer). Wind imposes a horizontal load on the crane as well as on
the load. These cause instability to both the crane and the load which could result in
overturning. In normal safe working conditions, this tendency to overturn is counteracted by
the self-weight of the crane, and the stabilizing effect of the outriggers or stabilizers.

The jib or trolley parking position must be done according to the manufacturer’s

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requirements. This is particularly important for luffing jib cranes. If the jib angle is too high,
the risk of the jib being blown backwards over the A-frame is increased. If the jib angle is too
low, the forces acting on the crane will be increased.

13.3 Effect of wind on load

It is important to consider the load’s shape. Lifting of irregularly shaped loads will require more
consideration and possibly the consultation of manufacturer prior to the lift if necessary.

It is also important to consider the load weight to surface area ratio. As a rule of thumb, when
the load weight to surface area ratio is found to be significantly less than 1.0tons/m2, particular
attention should be paid to the wind conditions in the area. The lifting operation should be
stopped if the load is found to be moving about significantly.

Wind conditions in city area can be complex, as a result of the varying urban volumes of
adjacent buildings, which can block, channel and/or concentrate the wind as it passes
through, and may not concur with the clear directionality as studied in wind tunnel tests.

Where uncertain, the manufacturer of the crane should be consulted on the effects of wind on
the operation of the crane.

14. Communications

Failures in communications are often root causes of lifting incidents and can also be the most
difficult to detect.

Good training and adherence to correct procedures are vital but checking the actual situation
at the worksite is of utmost importance. For example:-

• Are the personnel concerned all from the same company?

• Do they all understand a common language?
• If not is there an established system of signals in strict use that they all know and
understand?
• Warning signage is displayed where the personnel are able to see it?
• What different methods of communication are able to be used?
• What communication is required between the worksite and the source of any
technical assistance elsewhere?

Communication also extends to warning personnel of the lifting activity and keeping the lift
area clear of personnel not involved in the lifting operation.

All members of the lifting team must be sure of their individual tasks and their team members'
roles in order to fully and easily communicate with one another. Designated signallers shall be
clearly and separately identifiable, by use of reflective jackets or other conspicuous clothing or
marking.

Good quality of communications is essential especially when any part of the lift is not clearly
visible to any of the team members. If a signal is not clear to a member of the lift team
operating any lifting equipment, then the operation shall cease to progress.

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Never start any lifting operation until all concerned have been briefed in a Pre-Start Meeting,
ensuring that they understand their role and responsibilities and that they have signed onto the
Permit-to-Work or record of attendance at the Pre-Start Meeting.

Workplace Safety &

Competent Person
Health Officer

Lifting Appliance
Lifting Supervisor Signaller
Operator

Lifting Team / Riggers

Example of Communication Diagram During Lifting Operations

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15. Importance of a Checklist

A checklist can mean the difference between failure and success. It may be only one element
in the successful execution of a safe lift, but it is a key element. When all the work has been
completed in preparation for the lifting operation it is always recommended and wise to use a
final checklist to ensure that all requirements are in place and in a safe condition. The
important points given below could form part of your own checklist:

Check position of crane(s)

Check outrigger positions and conditions of subsoil / supporting structure
Check foundation and shim plates of foundation if applicable
Check radius at pink-up position of load
Check radius at setting position of load and area between pick-up and set
position
Check boom length of crane and if applicable counterweight and superlift
counterweights
Check clearances with surrounding structures in connection with tail
swing of counterweight and superlift structure when slewing the crane
Check reefing of lift block and lift capacity
Check shackle pin sizes and lifting lug sizes
Check orientation and position of lifting and tail lugs
Check sling lengths and SWL
Check location of centre of gravity (CG) and verify it with CG on drawings
Check weight of load if possible
Check lifting trunion size and dimensions
Check condition of access road to foundation
Check general condition of crane and LMI
Check fuel, oil and condition of engines
Instruct operators and rigging crew in details about planned operation
Clearly mark operation area to stop unauthorised personnel from
entering the work area
Check medical aid on side in case of accidents
Plan your operations in details and think ahead

Note: Clearly these 21 points should be expanded upon, depending on the type and
complexity of your project. While they will act as a reminder to your staff, you should
remember that having a checklist may not safe-guard your project. For that you need
experienced people who attend to details, and staff who will go through that list as
automatically as any pilot before a flight.

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16. Rigging and De-Rigging of Mobile Hydraulic, Crawler Cranes & Tower
Cranes.

The rigging and de-rigging of cranes is correctly classified as” High Risk Activity”. Many
accidents and indeed in many cases there are more accidents resulting in injury and fatality
during these 2 phases of a lifting operation than what occur during the actual lifting process.

Rigging and de-rigging present many challenges and generate many hazards and associated
risks. During these phases of any lifting operation extreme caution and vigilance are required.
Much heavy work and working at height is required, particularly where larger capacity cranes
are in use. Careful documented planning of Hazard and Risk Analysis is required. De-rigging
also brings the added factors of rushing at the end of a lift to get clear of the site, equally after
a lift is complete and in many cases the crane operator is left to his own devices and alone to
complete the task, folding up the Fly – Jib on a small hydraulic is every bit as dangerous as
taking of the luffer on a large crawler.

Whilst all phases of a lifting operation require focus, vigilance, monitoring and control, the
elements of Rigging and De-rigging are very easily overlooked and taken for granted.
Appointed Persons/ Lift Supervisors must ensure that the Lifting Team are alert and familiar
with all hazards, associated risks and implemented control measures.

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Appendix 1 -Various stakeholders’ involvement in planning a safe lifting

operation.

Stage Occupier/ Competent Lifting Supervisor Lifting Team Consulta

of Responsible Person nt /
Activit Person / Contractor Technical
y Authority

Identify lifting
Define The

activity. Notify or Determine

appoint a scope of work
Lift

competent person
as appointed

Appoint competent personnel

The lifting plan and Assess risks to produce Risk

Risk Assessment Assessment
may be existing,
modified or new
t M
Lif Assess requirements to produce
ay
he Lifting Plan
T be
n
a
Finalise lift plan i
n
Pl vol
Ensure all equipment suitable for intended use
ve
d
www.astaco.ir
a
sr
Participate in
Lift

toolbox talk
Perform The

Overall Supervise
May be
Responsibility Lifting Carry out
involved as
of Lifting Activity on lift with
Activity appropriate
supervision

Conduct post j b debrief, note Provide

feed back
Learn and

lesso s learnt
for lessons
Record

Retain plan, Task Risk Assessment and

lessons learned

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