engineering learning guide for the safe use of lifting equipment and lifting tackle...

ENGINEERING

LEARNING GUIDE

FOR

THE SAFE USE OF LIFTING EQUIPMENT AND LIFTING TACKLE

VERSION: 2.0

IMPLEMENTATION DATE: 10 NOVEMBER 2010

REVISION DATE: 13 JULY 2011

REFERENCE NUMBER: ALLSM-EPR-ENG-SUP-0009

Anglo American - Platinum All Smelters Ref No ALLSM-EPR-ENG-SUP-0009 Date of Implementation 10 November 2010 Version No 2.0 Last Revision Date 13 July 2011

Smelters Standard of 29 This document is maintained on an electronic database. The printed version should be compared as it may be outdated. Date Printed: 30 September 2012

Learning Guide title The Safe Use of Lifting Equipment and Lifting Tackle

LG reference number No unit standard – this guide is applicable to Anglo Platinum Smelters

Version of this document V2

Date of LG issue August 2009

Last revision date of LG July 2011

Domain Manufacturing, Engineering and Technology

Your name

Date of this training

The facilitator



CONTENTS The following elements are contained in this learning guide: Topic Page

Foreword 4

Source references 4

Objective 4

Using this learning guide 4 - 5

Introduction 6

Specific Requirements for the “Safe Use of Lifting Equipment and Lifting Tackle” 6 - 27



FOREWORD We at Anglo Platinum Smelters believe that all accidents and incidents can be prevented Anglo Platinum holds Health and Safety as its highest value. Anglo Platinum Smelters have therefore implemented systems to promote safe and healthy working conditions. Safety rules, equipment and other measures do not, in themselves, protect the worker, or those nearby. Continuous vigilance and safe working habits are of paramount importance and final responsibility for safety is therefore yours. You must always ensure that the work you are about to carry out is safe for yourself and for your fellow workers. We therefore request that you make yourself conversant with this guide before carrying out any work involving the use of Lifting Equipment and Lifting Tackle (Lifting Operations) so that you are to apply the principles when carrying out this type of work. Essential Rules to Remember: Good communication skills always help to convey awareness to all the team members.

No work is so important that it should be conducted in an unsafe manner.

SOURCE REFERENCES In-company Standard Operating Procedures Subject matter experts MHSA reference Anglo Fatal Risk Standards and Guidelines – Lifting Operations (AFRS No. 8) OBJECTIVE You will be learning towards the outcome of understanding and applying the requirements for the “Safe Use of Lifting Equipment and Lifting Tackle” in terms of the Anglo Platinum Smelter Standard Procedure for “The Safe Installation, Use, Maintenance, Inspection, Testing and Keeping of Records of Lifting Equipment and Lifting Tackle”. You will be assessed, when you are confident that you may achieve the outcomes as listed, to determine your competency as measured against specific outcomes. This assessment will be in line with accepted best practices regarding assessment. USING THIS LEARNING GUIDE Various methods are used in this learning guide to assist you, the learner, in becoming competent in the “Safe use of Lifting Equipment and Lifting Tackle”.



Knowledge, Skills, Techniques (The What, How, When, How well) Specific outcome requirements are grouped to give information and details on the knowledge, skills and techniques applied in attaining proficiency in the Anglo Platinum Smelter Requirements for the “Safe use of Lifting Equipment and Lifting Tackle”. Theoretical and practical training will be provided in each of the following separate modules. When carrying out the theory part of the lessons, a test will be carried out after completing each module which upon passing, will allow the candidate to proceed to the next module: 1. Questions pertaining to the general physical condition of the candidate that must be answered before

continued attendance of the course on the “Safe use of Lifting Equipment and Lifting Tackle” is Permitted.

2. Persons who qualify to receive smelter specific training on the “Safe use of Lifting Equipment and Lifting

Tackle”. 3. Smelter “Lifting Operations” that require the “Safe use of Lifting Equipment and Lifting Tackle”. 4. Lifting Operations for which Lesson Plan is intended. 5. Definitions and Abbreviations used in the Lesson Plan. 6. Scope and Aim of Lesson Plan content. 7. Authorisation: (i) to attach, use and/or operate Lifting Equipment and Lifting Tackle.

(ii) to attach and Lift a Load 8. Pre-Work HIRA for Lifting Operations.

9. Lifting Hooks. 10. Rules pertaining to the use and transport of Chain Blocks, Tirfors, Rope Block and Tackle Assemblies

and/or other Portable Lifting Equipment. 11. Marking requirements and requirements for the correct use of Steel Wire Rope slings, Fibre Slings and

Chain slings. 12. Rules applicable to all Lifting Operations. 13. Rules applicable to loads made up of loose items. 14. Safe work requirements pertaining to Work Baskets. 15. Rules applicable to Non-Production Crane Operations.



1. Questions pertaining to the general fitness of the candidate that must be answered before

attendance of the “Safe Use of Lifting Equipment and Lifting Tackle” is permitted.

The following questions must be put to each candidate wishing to undergo training in the “Safe Use of Lifting Equipment and Lifting Tackle” until such time as the duty of screening out candidates who are unsuitable for this type of work is taken over by Anglo Platinum’s Medical Surveillance service providers.

The candidate must not be allowed to proceed any further if the answer to any of the questions is YES without permission from an Anglo Platinum approved medical surveillance service provider.

A record of the questions and answers must be kept for each candidate.

(i) Do you suffer from any abnormal heart condition or from any heart disease?

(ii) Do you suffer from abnormally high or low blood pressure?

(iii) Are you receiving treatment for blood pressure related problems?

(iv) Have you ever suffered from any epilepsy or other fits and/or blackouts?

(v) Have you ever suffered from any abnormal giddiness and/or difficulty with balance?

(vi) Do you suffer from any impaired limb function?

(vii) Do you suffer from any form of alcohol or drug dependency?

(viii) Have you ever suffered from any abnormal psychiatric illness and/or psychological strain?

(ix) Do you suffer from diabetes, no matter how slight your condition may be?

(x) Were any abnormalities relating to Pulse, Weight, Blood Pressure, Eye sight, Urinalysis detected when during your last you medical examination?

2. The following persons qualify to proceed with the training requirements specific to the “Safe

Use of Lifting Equipment and Lifting Tackle” in terms of the “Smelter Procedure for the Safe Installation, Use, Maintenance, Inspection, Testing and Keeping of Records of Lifting Equipment and Lifting Tackle”.

2.1 Qualified Riggers who have past the national trade test for Riggers. 2.2 Persons who have undergone training in “Safe Lifting Techniques” and who have been found

competent in such Safe Lifting Techniques by Anglo American’s Engineering Services Training Centre (ESTC).

Note: Persons authorised to carry out Basic Lifting Operations must first successfully completed the

Safe Lifting Techniques course at ESTC.



3. Smelter “Lifting Operations” that require the “Safe Use of Lifting Equipment and Lifting

Tackle”. 3.1 There are four types of Lifting Operations that are normally carried out at a Smelter. These Lifting

Operations are referred to as:

(i) Basic Lifting Operations:

Lifting Operations for loads that weigh less than three tonne and for which no operating procedure has been written.

(ii) Rigging Operations:

Lifting Operations that do not restrict the maximum weight that can be lifted to less than three tonne and for which no operating procedure has been written.

(iii) Production Crane Operations:

Production related Lifting Operations, involving the use of a crane and for which, an Operating Procedure has been prescribed for each specific operation.

(iv) None-Production Crane operations:

None-Production related Lifting Operations that require the use of mobile cranes, overhead travelling cranes or Tower Cranes.

It can obviously be argued that a person who picks up anything with his/her hands carries out a lifting operation of sorts but each of the four Lifting Operations mentioned above are carried out using equipment to lift loads. The Mine Health and Safety Act (MHSA) refers to this equipment as “Lifting Equipment and Lifting Tackle”.

4 Lifting Operations for which this Lesson Plan is intended.

Because Production Crane Operations have operating procedures for each specific operation and the persons involved in such operations are assessed and found competent accordingly, such persons are not required to undergo any further training in the “Safe Use of Lifting Equipment and Lifting Tackle”. This Lesson Plan deals specifically with the “Safe Use of Lifting Equipment and Lifting Tackle” when the following Lifting Operations are required: Basic Lifting Operations ; Rigging Operations ; and None-Production Crane Operations.

5 Definitions and Abbreviations used in the Lesson Plan.

MHSA definitions of Lifting Equipment and Lifting Tackle.

Lifting Equipment: Means any equipment or machine or arrangement of equipment or machines, intended or used for the lifting, lowering, suspension, or moving in suspension of any person or load.

This definition covers all equipment from a crowbar to a crane.



Lifting Tackle: Means any attachment, including attachments used to secure lifting

equipment or a load to lifting equipment (MHSA)

i.e. beam clamps, slings, lashing, turnbuckles, shackles etc.

Other Definitions of terminology and Abbreviations used in this Lesson Plan.

Drop Zone: The Drop Zone is defined as the area below a lift into which the lifted load (or part of the lifting equipment or lifting tackle being used for the lifting operation) may fall due to lifting equipment/tackle failure, malfunction or operator error.

Tag Line: A hand held line fastened to a load and used to stabilise a load that is being lifted. Dunnage: A resilient support material (such as wood strips of equal width) placed across the

landing area of a load to protect the bottom of the load from damage due to point load stresses.

Ancillary: Ancillary (crane) equipment means equipment designed for and used in connection

with a certain operation and on which the operation depends i.e. ladle lifting hooks, ancillary hoist etc.

MHSA: Mine Health ad Safety Act – Act 29 of 1996

SWL: Safe Working Load Capacity ESTC: Anglo American’s Engineering Services Training Centre

6 Scope and Aim of Lesson Plan content. Regulation 8.5(2) of the MHSA reads as follows: The employer must take reasonable measures to ensure that the installation, use (including the transport of persons), maintenance, inspection, testing and keeping of records of lifting equipment and lifting tackle are done in accordance, with a written operating procedure prepared and implemented for that purpose. This is why there is a Smelter Procedure called: PROCEDURE FOR THE SAFE INSTALLATION, USE, MAINTENANCE, INSPECTION, TESTING AND KEEPING OF RECORDS OF LIFTING EQUIPMENT AND LIFTING TACKLE. Note: (i) This Learning Process is not intended to teach you how the Installation, Maintenance,

Inspection, Testing and the keeping of Records of Lifting Equipment and Lifting Tackle must be carried out because these requirements are specialised and specific to persons appointed by the Responsible Engineer to carry out these functions in terms of the “PROCEDURE FOR THE SAFE INSTALLATION, USE, MAINTENANCE, INSPECTION, TESTING AND KEEPING OF RECORDS OF LIFTING EQUIPMENT AND LIFTING TACKLE”.

(ii) Neither is this Learning Process intended to teach you the practical aspects of how Basic

Lifting Operations or Rigging Operations are carried out because this is done:

By ESTC in the case of training received in Safe Lifting Techniques or;

During your apprenticeship as a Rigger.



The aim of this Learning Process is to ensure that you are informed of the basic safety rules that you must follow when you use “Lifting Equipment and Lifting Tackle” at a Smelter. No doubt, many of these rules have already been explained to you at ESTC when you received training in Basic Rigging or during your apprenticeship as a Rigger.

7 Authorisation: (i) to attach, use and/or operate Lifting Equipment and Lifting Tackle. (ii) to attach and Lift a Load

7.1 Regulation 8.5(5) of the MHSA requires the employer to “take reasonable measures to ensure that

only persons authorised in writing by the employer to do so, operate Lifting Equipment and Lifting Tackle”.

Therefore: Only persons who are trained, competent and authorised in writing (according to the

Responsible Engineer’s requirements) may use and/or operate “Lifting Equipment and Lifting Tackle” to lift loads.

i.e. (i) Persons who have been trained by ESTC in “Safe Lifting Techniques” may

be authorised to carry out Basic Lifting Operations at a Smelter using Lifting Equipment and Lifting Tackle provided that the total weight of the load being lifted does not exceed 3 Tonne.

(ii) Riggers may carry out rigging operations using Lifting Equipment and

Lifting Tackle.

(iii) Production crane operators may operate the specific crane and its ancillary equipment for which he/she has been trained and found competent to operate. The terms “crane and ancillary equipment” in this case also fall under the MHSA’s definition of Lifting Equipment and Lifting Tackle.

Production cranes are usually overhead travelling type cranes but other types of cranes can also be used for production purposes i.e. tower cranes, truck mounted cranes, pick and carry type cranes also known as mobilifts etc.

(iv) In the case of mobile cranes that are not used for production, mobile crane operators may operate the specific mobile crane and its ancillary equipment for which he/she has been trained and found competent to operate.

Mobile cranes include mobile jib cranes, pick and carry type cranes (also known as mobilifts), truck mounted cranes etc.

Always remember: (a) Non-Production related crane Lifting Operations involving the use

of Mobile and/or Overhead Travelling cranes may only be carried out under the direction of a Qualified Rigger or by a person trained in Basic Lifting Operations where the load does not exceed 3 Tonne.

Provided that in the case where the lifting operation is carried out under the direction of a person trained to carry out Basic Lifting Operations:

(i) The crane operator must be able to clearly see the load from the

point it is lifted to the point that it is placed.



(ii) The crane operator must always clearly see the person directing the lifting operation and an audible two way radio is used to give signals.

(iii) An alternative method by which signals will be communicated

should the above radio signalling device fail, must be established and understood by the crane operator and the person directing the lifting operation. This method must be detailed in the pre-work HIRA for the lift.

(iv) The load will not be lifted near or over unprotected equipment /

plant, equipment containing presurised air / gas or hazardous substances.

(vi) The pre-work HIRA for the work is approved and countersigned

as such by the responsible engineering foreman / supervisor concerned.

(b) Nobody, including a Rigger or person authorised to carry out Basic

Lifting Operations may operate a crane under any circumstances unless he/she has been trained, found competent and is authorised in writing to operate the particular crane.

(c) Pick and Carry type cranes (also known as Mobilifts) may not be used

for lifting loads in tandem under any circumstances. This subject will be dealt with in more detail under Section 3.4.2.

7.2 Portable Lifting Equipment and Lifting Tackle

(i) Portable Lifting Equipment and Lifting Tackle includes but is not limited to: Hand operated chain blocks with associated Lifting Tackle ; Hand operated lever hoists ; Compressed air hoists with associated Lifting Tackle ; Electrically operated wire rope hoists with associated Lifting Tackle and Hand operated rope pulling machines (tirfors) with associated Lifting Tackle.

It is a standard rule at Anglo Platinum Smelter Operations that only Portable Lifting Equipment and Lifting Tackle: clearly marked with its SWL rating; supplied on contract from an approved supplier and; which is maintained in a safe working condition. may be used for lifting a load.

(ii) Storage and issue of Portable Lifting Equipment and Lifting Tackle.

Portable Lifting Equipment and Lifting Tackle that is approved for use is usually controlled and issued from the rigger store or mechanical workshop store but this rule may differ from Smelter to Smelter. Make sure that you are informed by your Foreman/Supervisor on how this type of equipment is controlled, stored and issued for use.



7.3 Attachment of Lifting Equipment and Lifting Tackle to a Lifting Point.

The attaching of any Lifting Equipment and Lifting Tackle, including any Portable Lifting Equipment and Lifting Tackle, to a designated lifting Point or temporary Lifting Point may only be carried out by or under the direction of a Responsible Person:

(i) who is trained, competent and authorised to carry out the intended lifting operation; (ii) who must ensure that the SWL of the Lifting Point is capable of safely supporting the total

weight exerted by the Lifting Equipment as well as the Load being lifted. (iii) who must ensure that the attachment is carried out correctly and that there is no possibility of

the lifting equipment with its load becoming inadvertently detached; (iv) who must ensure that all lifting equipment is operated correctly and; (v) who must ensure that no persons are positioned within the drop zone of a suspended load.

Remember: If ever you are unsure of whether the SWL of the Lifting Point to which you are

about to attach Lifting Equipment and Lifting Tackle is capable of supporting the total weight exerted by the Lifting Equipment as well as the Load being lifted, do not proceed to attach the Lifting Equipment and Lifting Tackle but ask your Foreman/Supervisor for advice on how to proceed.

7.4 Load Attachment

The attaching of a load to Lifting Equipment and Lifting Tackle may only be carried out by or under the direction of a Responsible Person:

(i) who is trained, competent and authorised to carry out the intended lifting operation; (ii) who must ensure that the attachment is carried out correctly and that there is no possibility of

the load becoming inadvertently detached; (iii) who must ensure that all Lifting Equipment and Lifting Tackle is operated correctly and; (iv) who must ensure that no persons are positioned within the drop zone of a suspended load.

8 Pre-Work HIRA for Lifting Operations

A pre-work HIRA must always be carried out for the intended lifting operation taking into account:

The Emergency Procedures must be known and communicated to the lifting team.

i.e. what to do in the case of injury, damage to equipment on which the safety of persons depends, loss of emergency egress, what to do in the case of an evacuation emergency unrelated to the Lifting Operation being performed etc.

The person in charge must have a clear knowledge of the weight of the load/s about to be lifted

and communicate this information to his/her lifting team. Correct selection and use of Lifting Equipment and Lifting Tackle must be carried out. The person in charge must have a clear knowledge of the SWL capability of the designated

Lifting Point/s to which the Lifting Equipment will be attached. Where the need for a designated Lifting Point has not been identified for a particular Lifting

Operation, the person in charge must have a clear knowledge of the SWL capability of the structural members to which the Lifting Equipment will be attached.



The person in charge must have a clear knowledge of how the lifting equipment will be suspended and communicate this information to his/her lifting team.

The person in charge must have a clear knowledge of how the loads are to be landed. Checks

should be made to ensure that the lay-down area is adequately sized and capable of taking the weight of the load and inform his team accordingly.

Consideration must be given to Dunnage requirements so that this material is made available

before the lifting operation starts. Clear responsibilities and rolls of each person taking part in the Lifting Operation must be known

and communicated to the lifting team. A person may sometimes be required to give signals to the person controlling the Lifting

Equipment being used. When this is required, the lifting team must be clearly informed who the person designated to give signals is.

The person in charge must have a clear knowledge of the “drop Zone” and communicate this

information to his/her lifting team.

9 Requirements pertaining to Lifting Hooks

The MHSA requires that: every hook used for the lifting of loads must be designed and proportioned, or shall be provided with a device, so that no accidental disconnection of the load can take place.

Hooks are usually provided with a self closing, spring applied latch to prevent accidental disconnection of loads. It is seldom that you will come across hooks profiled to prevent accidental disconnection because these are usually designed for specific applications i.e. Molten Metal ladle crane hooks, shackles with drop-nose pins for load lifting platforms etc.

9.1 You are required to examine lifting hooks before use and immediately after attaching a load to a

hook to ensure that accidental disconnection of the load from the hook will not take place. This has been taught to you during your apprenticeship as a rigger or by ESTC.

APPENDIX 2: Typical Hooks fitted with Safety Catches is provided as an example.

9.2 If ever you find that you do not fully understand how a hook is designed to prevent accidental

disconnection or that you are unsure of whether accidental disconnection from the hook will be prevented, do not attach a load to the hook but ask your Foreman/Supervisor for assistance.

10 Rules pertaining to the use and transportation of Chain Blocks, Tirfors, Rope Block and Tackle Assemblies and/or other Portable Lifting Equipment.

10.1 Use of Chain Blocks

(i) Each Chain Block must be examined immediately prior to use, with particular attention being given to the condition of the SWL Marking, casing, chain guide mechanism, load chain, hand (messenger) chain and hook for signs of damage and the results of the examination must be recorded as part of the Pre-Work HIRA conducted for the intended Lifting Operation.

Never use a Chain Block unless you are satisfied that it is in good working order.



(ii) The attaching (hanging and/or hooking) a Chain Block from its Lifting Point (the point from which it is suspended) in preparation for a Lifting Operation must be carried out under the direction of the person Responsible for the intended Lifting Operation.

(iii) A single Chain Block, selected for the load to be lifted should always be used, unless lateral

rigging is required.

Note: It is not good practice to use a group of inadequately rated Chain Blocks to share the weight of a single load. i.e. if a 4-tonne load is to be lifted, one 5-tonne Chain Block should be used rather than two 3-tonne units because it is difficult to ensure that the load is shared equally on a tandem lift.

(iv) Where it is necessary to use two or more Chain Blocks to balance or manoeuvre a load,

each should be capable of carrying the entire load on its own. (v) The Chain Block intended to be used for lifting shall always be of a rated capacity larger

than the load it has to lift. (vi) The hand chain should not be jerked under any circumstances. (vii) The load must never be allowed to fall onto a Chain Block.

i.e. Chain Blocks are not to be used in a slack condition as “safety devices”.

(viii) Where a load has to be transferred from one Chain Block to another, the transfer has to be

as smooth as possible. (ix) Never use the load chain as a sling, i.e. choke-hitch the hook onto its own load chain. (x) Never insert the point of the load hook into the load chain in order to use the load chain as a

sling or for any other reason. (xi) Ensure that the load hook cannot accidentally disengage its load. (xii) The load chain must always carry its load in a straight line from the Chain Block to the load

hook (i.e. never pull around a corner). (xiii) Chain Blocks must be kept away from intense heat such as is generated by fires, boilers,

furnaces etc. (xiv) Chain Blocks must be kept away from water and mud. (xv) Chain Blocks must always be cleaned after use, before returning to storage.

(xvi) After use, every Chain Block must be examined for damage and general deterioration,

before being returned for storage – if any form of damage or excessive deterioration is found after use, it must be reported and pointed out to the Rigger, Mechanical Foreman or other Responsible Person in charge of the Chain Block. The defective Chain Block must not be returned to storage under any circumstances without this report being made because the Chain Block has now become dangerous and could injure somebody if it is inadvertently used.

10.2 Use of Tirfors.

(i) Each Tirfor must be examined, with particular attention being given to the condition of the SWL marking, Steel Wire Rope (SWR), the end attachment (thimble), hook, rope feed end,



and SWR clamping arrangement, before use for signs of damage and the results of the examination must be recorded as part of the Pre-Work HIRA conducted for the intended lifting operation. Never use a Tirfor unless you are satisfied that it is in good working order.

(ii) A Tirfor may not be used if there are any signs of rope kinking, rope damage in the form of

excessive flattening, excessive indentations and/or broken wires or other impact damage. (iii) Tirfor ropes must be laid out during usage in a manner that will not cause the ropes to pull

around sharp bends, become entangled and/or kinked. (iv) Tirfors must be placed in a manner that will not cause material or other equipment to interfere

with the “tugger” mechanism or damage the rope. (v) Care must always be taken not to subject the “tugger” mechanism, or any other part of the

Tirfor to unnecessary impact.

i.e. dropping, throwing tools/equipment onto the Tirfor etc. (vi) Tirfors must be kept away from intense heat such as is generated by fires, boilers, furnaces

etc. (vii) Tirfors must be kept away water and mud. (viii) Tirfors must always be cleaned after use, before returning to storage.

(ix) After use, Tirfor must be examined for damage and general deterioration, before being

returned for storage – if any form of damage or excessive deterioration is found after use, it must be reported and pointed out to the Rigger, Mechanical Foreman or other Responsible Person in charge of the Tirfor. The defective Tirfor must not be returned to storage under any circumstances without this report being made because the Tirfor has now become dangerous and could injure somebody if it is inadvertently used.

10.3 Use of Rope Block and Tackle assemblies.

(i) The use of a Rope Block and Tackle (Block and Tackle) assemblies for lifting a load may only

be carried out under the direction of a qualified rigger.

(ii) Block and Tackle assemblies are not equipped with braking systems that automatically hold a load when the lifting effort is released from the pull rope. It is therefore of the utmost importance that lifting crews are briefed on the importance of not inadvertently releasing the hold on the pull rope while a load is being lifted.

There should always be at least two persons holding the pull rope while a load is being lifted.

(iii) Each Block and Tackle assembly must be examined, with particular attention being given to

the condition of the SWL marking, reeving blocks, hook and rope before use for signs of damage and the results of the examination must be recorded as part of the Pre-Work HIRA conducted for the intended Lifting Operation. Never use a Block and Tackle Assembly unless you are satisfied that it is in good working order.

(iv) A Block and Tackle Assembly may not be used if there are any signs of rope knotting,

excessive rope chafing, impact or other form of rope damage. (v) Block and Tackle assemblies must be laid out and used in a manner that will not cause the

ropes to pull loads around or across sharp edges, become entangled and/or knotted.



(x) Block and Tackle assemblies must be kept away from intense heat such as is generated by fires, boilers, furnaces etc.

(xi) Block and Tackle assemblies must be kept away water and mud, especially when manila rope

is used.

Water may cause the manila rope to swell and get chafed as it goes around reeving pulleys during lifting operations. A manila rope that has become wet must be replaced.

(xii) Block and Tackle assemblies must always be placed in a neat configuration while not in use in

order to avoid inadvertent tangling or knotting of ropes.

(xiii) After use, every Block and Tackle assembly must be examined for damage and general deterioration, before being returned for storage – if any form of damage or excessive deterioration is found after use, it must be reported and pointed out to the Rigger, Mechanical Foreman or other Responsible Person in charge of it. The defective Block and Tackle assembly must not be returned to storage under any circumstances without this report being made because it has now become dangerous and could injure somebody if it is inadvertently used.

10.4 Use of other permitted Portable Lifting Equipment 10.5 The use of other permitted Portable Lifting Equipment for lifting a load may only be carried out under

the direction of a qualified rigger.

Such use must be carried out in accordance with the manufacturer’s instructions for the safe use thereof.

10.6 Transportation of Chain Blocks, Tirfors and/or Block and Tackle assemblies.

(i) Chain Blocks, Tirfors and Block and/or Tackle assemblies must be transported in a manner that will not allow the chains, ropes, hooks or any other part thereof to become caught/engaged into other Lifting Equipment and Lifting Tackle (or other equipment) during transportation.

(ii) Whenever possible, Chain Blocks, Tirfors and Block and/or Tackle assemblies should be

transported in a specific type of bag/container.

(iii) Chain Blocks, Tirfors and/or Block and Tackle assemblies must not be dragged on the ground or floor. Neither should the Chains or ropes of such equipment be dragged on the ground or floor.

(ii) The chains or ropes of Chain Blocks, Tirfors and/or Block and Tackle assemblies and Snatch

Blocks may not be used as load binders and/or lashing during transportation.

(iii) Chain Blocks, Tirfors and/or Block and Tackle assemblies must not be dumped/dropped. Care must be taken to avoid damage when placing or putting down such equipment for transportation.

(iv) Miscellaneous (other) tools/equipment/material must never be loaded on top of Chain Blocks,

Tirfors, Block and/or Tackle assemblies.



10.7 Transportation of other Portable Lifting Equipment and Lifting Tackle Assemblies.

The same rules would obviously apply to the transportation of any other portable Lifting Equipment and Lifting Tackle.

11 Marking requirements and requirements for the correct use of Steel Wire Rope slings, Fibre

slings and Chain slings 11.1 Marking requirements applicable to all slings i.e. Steel Wire Rope slings, Fibre slings and

Chain slings:

Each sling must always carry the following markings:

(a) The Manufacture’s name and seal.

(b) Identification Number and its SWL.

(c) The date of Manufacture.

(d) A place where the Smelter concerned can/must permanently mark the date that the sling was first put into service – this date will be used to determine the service life of the sling.

(e) Colour coded markings indicating that the sling has been examined and found suitable for continued use within the previous three months.

11.2 General good practice rules applicable to all slings: Always select the correct sling for the task.

This has already been taught to you during your apprenticeship training as a rigger or at ESTC when you were trained Safe Lifting Techniques.

If you are in any way unsure of the correct sling/s to use for a task, do not proceed with the work but ask your Foreman/Supervisor for assistance.

Slings must be inspected prior to use and the results of such pre-use inspections must be

recorded as part of the pre-work HIRA requirements.

Before using any sling, make sure you are informed of what colour code marking has been used to establish that the sling has been examined and found suitable for extended use.

Remember: Each sling must always carry colour code markings indicating that the sling

has been examined within the previous three months and found suitable for continued use.

When applying a load, take up the slack slowly and apply the load without sudden (impact)

loading to the sling. Avoid sudden jerks when lifting.

In the case of steel wire rope slings, where surface protection of the object being slung is

required, the sling/s must be wrapped with a suitable covering.



When using more than one sling or a permitted multi-leg sling, always load the slings as evenly as possible.

After use, every sling must be examined for damage and general deterioration, before being

returned for storage – if any form of damage or excessive deterioration is found after use, it must be reported and pointed out to the Rigger, Mechanical Foreman or other Responsible Person in charge of the sling. The defective sling must not be returned to storage under any circumstances without this report being made because the sling has now become dangerous and could injure somebody if it is inadvertently used.

Never: use a sling if the inspection colour code marking has not been applied or if the sling

has the incorrect inspection colour marking. Never: remove the sling’s inspection colour coding markings. Never: use a sling unless it has been marked with its SWL rating. Never: use a sling unless its rated SWL is adequate for the load it must support.

Never: overload slings. Never: shorten a sling by tying knots in it, by tying it into Crosby clamps, by wrapping the

sling around the hook of the lifting device or by any other means. Never: join slings (strips) together by bolts, wire, Crosby clamps etc. to make one sling out

of several.

Never: cross, twist, kink or knot a sling. Never: allow loads to fall onto slings.

Never: drag a sling from under a load.

Never: drag a sling along the ground.

Never: fail to report that a sling has become damaged during use. If any form of damage or excessive deterioration is found after use, it must be reported and pointed out to the Rigger, Mechanical Foreman or other Responsible Person in charge of the sling. The sling must not be returned to storage under any circumstances without this report being made because the sling has now become dangerous and could injure somebody if it is inadvertently used.

11.3 Safety rules specific to Fibre slings:

Never: hammer a Fibre sling into position, not even with a copper hammer! Never: use a fibre sling, especially a nylon sling, where it can be damaged, burnt or melted by

molten metal, hot metal splatter, grinding sparks etc.

The heat generated by welding, soldering brazing and/or flame cutting will burn through natural fibre slings and/or melt synthetic fibre slings.

Never: allow Hot Work to take place in the proximity of fibre slings where heat generated

by welding and/or flame cutting, hot metal splatter or grinding sparks can cause



damage to fibre slings. Regardless of whether or not a load is suspended at the time.

Never: use a fibre sling over corners or edges sharp enough to cut or put undue strain on the

fibre sling. 11.4 Safety rules specific to Chain slings

Never: use a Chain sling in which the links are locked, stretched or are without free

movement. Never: use an excessively pitted, corroded or worn Chain sling.

Never: insert bolts or spikes through the links of a Chain sling to shorten the sling.

Never: carry the load on the point of a Chain sling hook. Never: hammer a Chain sling’s hook into position.

11.5 Safety rules applicable to using more than one sling to lift a load: The suspension of loads that require the use of more than one sling requires careful

consideration to ensure that the sling legs are loaded as evenly as possible.

You have been taught how to do this during your apprenticeship as a Rigger or when you received training on Safe Lifting Techniques at ESTC.

Multi-leg slings: are only permitted where such a sling is required for a specific application.

i.e. the attachments of a Workbasket (boatswain’s chair or other

conveyance), the attachment of material baskets/cages etc.

12 Rules applicable to all Lifting Operations 12.1 The designed safe working load lifting capacity (SWL) must be always clearly marked and

conspicuously displayed on all Lifting equipment and Lifting Tackle. 12.2 Never use any Lifting Equipment and Lifting Tackle unless its Safe Working Load lifting capacity

(SWL) is clearly displayed and you are absolutely sure of its SWL. 12.3 Under no circumstances may the SWL of any Lifting Equipment and Lifting Tackle be exceeded.

12.4 Loads suspended from Lifting Equipment and Lifting Tackle may not be left unattended under any

circumstances.

12.5 No load may be lifted unless the weight of the load is known by the person intending to use and operate the Lifting Equipment and Lifting Tackle.

The aforementioned person in charge of the Lifting Operation must ensure that the load being lifted does not exceed the SWL of the Lifting Equipment and Lifting Tackle intended to be used. He/She must also satisfy himself/herself that the load has been secured to the extent that the load or any part thereof will not fall during the intended lifting operations.



12.6 The person intending to use and/or operate Lifting Equipment and Lifting Tackle must conduct a thorough examination (pre-use check) of the Lifting Equipment and Lifting Tackle at the start of each shift (in the case where Lifting Equipment and Lifting Tackle is being used for a longer period than one shift) Tackle and/or before use for the first time during any shift.

As part of the aforementioned pre-use check, the Lifting Equipment and Lifting Tackle must be examined for damage, corrosion and other factors that could affect the safe use of the Lifting Equipment and Lifting Tackle. If any faults are found during the inspection, the faulty Lifting Equipment or items of Lifting Tackle may not be used. Tell your Foreman/Supervisor about the faults so that you can obtain instructions on how to proceed further with your work. Note: Do not simply return the faulty equipment to storage and/or exchange the faulty equipment

without making sure that the Responsible Foreman/Supervisor in charge of the equipment has been made aware of the fact that the equipment is defective and unsafe for further use.

12.7 The raising and lowering of loads should as far as possible be carried out in a vertical direction.

When completing an upward or downward motion, loads must be eased to a stop as evenly as possible. Side loading of cranes or any other type of Lifting Equipment and Lifting Tackle i.e. dragging loads horizontally is not permitted. Horizontal dragging of loads could result in: Loads swinging out of control, ladles or other containers being tipped over, injury due to molten metal or hazardous substance spills, injury/damage as a result of ladles or other containers tipping onto persons/equipment etc. In the case of Mobile cranes, lifting jibs/booms may not be used as a means of pushing or pulling loads into position. This dangerous practice could result in: Tipping the crane over ; Bending the crane boom ; Breaking or damaging the head sheaves ; Damage to hoist ropes ; Load swinging out of control.

12.8 Load swinging must be prevented as far as possible by performing lateral/side load movements as smoothly as possible without any sudden stops, starts and/or jerks.

Wherever possible, a tag line must be used to prevent free hanging loads (especially long loads) from swinging uncontrollably.

12.9 Shock loading (caused by sudden acceleration/deceleration jerks and or sudden unnecessary stops)

when a load is suspended can/may cause the SWL of the Lifting Equipment and Lifting Tackle being used to be exceeded. Shock loading and sudden stops/starts must therefore be avoided.

12.10 The area affected by the intended lifting operation must be identified beforehand. Inadvertent access

into this area by persons who are not required/authorised to enter the area must therefore be prevented by suitably demarcating the area with barricading which must be (yellow and black striped) barrier tape as a minimum.

Only persons directly involved in the lifting operation may be allowed into this area.

12.11 Drop Zone Protection

No person may be allowed within the Drop Zone of a load, especially not directly underneath a load suspended by LMET.



Note: The Drop Zone is defined as; the area below a lift into which the lifted load (or part of the lifting equipment or lifting tackle being used for the lifting operation) may fall due to lifting equipment/tackle failure/malfunction or operator error.

Persons involved in a Lifting Operation must place themselves as far as practicable outside of the Drop Zone. No person shall be allowed into the drop zone (below a suspended load or suspended lifting equipment/tackle) whether the load is hung vertically or on an inclination.

If for any reason, entry into the drop zone appears to be an urgent necessity, such entry may only be allowed subject to the written permission of the Responsible Engineer who must determine the hazards, associated risks and risk control measures necessary for entry.

12.12 A load must never be moved over people and persons must not be allowed to place themselves

under a suspended load under any circumstances.

i.e. persons may only work under a load that has been supported by blocks, trestles or other solid footing that safely supports the entire weight, in compliance with a safe work procedure.

12.13 In the case where signals are being used to direct the person controlling Lifting Equipment, a person must be designated to give signals for each particular Lifting Operation and the person operating the Lifting Equipment must only respond to the person who is designated to give signals for the particular lifting operation.

But Remember: (i) The method by which signals are given must be clearly established and

understood by the person designated to give signals and the Lifting Equipment operator.

Appendix 1: Typical Hand Signals used for Basic Lifting Operations is

provided as information for this purpose.

Do not find yourself in a situation where the signals that are being given are not understood.

(ii) The aforementioned person controlling the Lifting Equipment must obey a

STOP signal at any time, no matter who gives the signal.

(iii) When any person other than the person authorised to give signals gives a STOP signal, the reason for such a signal must be ascertained and the lifting procedure for the particular rigging/lifting operation in progress must be modified/changed if necessary to ensure ongoing safety.

The pre-work HIRA must also be modified/changed and all persons involved in the lifting operation must be informed/briefed on the necessity for the changes.

(iv) The Person designated to give signals must be clearly visible to the Lifting

Equipment Operator at all times. (v) In the case where a person is designated to give signals, this designation

must be communicated to the Lifting Crew and his/her name must be recorded in the Pre-Work HIRA for the intended Lifting Operation.

12.14 The person in charge of any lifting operation must, as far as is reasonably practicable, check the stability of loads during lifting operations.



Remember: this includes checking for correct lifting, placing as well as the securing of loads for transportation after placement.

12.15 In the case of electrical or compressed air driven Lifting Equipment, limit switches or other devices

are installed that will prevent inadvertent directional overtravel including but not limited to vertical lift overtravel.

These limit switches or other overtravel limiting devices may not be used for the purpose of conveniently stopping loads during normal operating conditions. i.e. the load must be stopped before the Lifting Equipment reaches its vertical directional

overtravel limit.

12.16 Persons in charge of Lifting Operations and their team members must wear prominent reflective signage sewn onto there safety clothing indicating that they are engaged in a Lifting Operation and that they should not be distracted.

It is a Smelter rule that distracting the attention of persons who are engaged in Lifting Operations is not permitted – the above signage sewn onto the safety clothing of Lifting team members will assist in reminding and informing other persons of the rule.

13 Rules applicable to loads made up of loose items

Always remember the following Rule when intending to lift loads that are made up of loose items: Unless an approved basket, cage, lifting net or other container specifically designed for this purpose is used when loads containing loose items are lifted simultaneously to prevent any part of such a load falling during lifting operations, the securing of a load made up of loose parts or parts that could become loose during lifting operations must be carried out by a Competent Rigger.

14 Safe work requirements pertaining to Work Baskets.

The Safe work requirements pertaining to Work Baskets is covered in the Smelter Procedure for Working at Heights. Training in this regard is therefore provided in the Lesson Plan for Working at heights but as a requirement of this Lesson Plan it is important that you remember the following: (i) A Work Basket includes any Work Box, Boatswain’s chair, cradle, cage or any other

conveyance suspended from a crane in order to provide elevated work access to persons. (ii) The Lifting of persons in a Workbasket may only be carried out under the Supervision of a

qualified Rigger authorised in writing by the Responsible Engineer.

15 Rules applicable to Non-Production Crane Operations

i.e. None-Production related Lifting Operations involving the use of Mobile Cranes, Overhead Travelling Cranes or Tower Cranes.

15.1 Classification (of Non-Production Crane Operations).

Non-Production Crane Operations (Lifting Operations) that require the use of Mobile Cranes Overhead Travelling Cranes or Tower Cranes are classified by the following terminology:



(i) A Routine Lift ; (ii) A Serious Lift and (iii) A Critical Lift

15.2 Conditions Specific to Routine Lifts

A Routine Lift is any non-production related Lifting operation involving the use of a Mobile Crane, Overhead Travelling Crane or Tower Crane that does not include any condition that classifies the lift as a Serious Lift or Critical Lift. Refer to Appendix 3 - Lift Complexity Table for ascertaining the conditions that will result in a Routine ; Serious or Critical Lift Classification.

15.3 Authorisation required to proceed with Routine ; Serious or Critical Lifts.

(a) Routine Lift

The rigger/responsible person can proceed without further authorisation after he/she has carried out the Pre-Work HIRA and has the right to call for assistance from his/her foreman.

(b) Serious Lift The Responsible Engineering Foreman needs to authorise the Lifting Plan (method statement) and HIRA and has the right to call for assistance from the Responsible Engineer.

(c) Critical Lift The Responsible Engineer must authorise the lifting plan (method statement) and HIRA and has the right to call upon third party advice if necessary.

15.4 Competency Requirements for Routine Lifts. (i) A Routine Lift requiring the use of a Mobile Crane may only be carried out under the

direction of a Qualified Rigger where the load exceeds 3 Tonne or by a person trained in basic lifting operations where the load does not exceed 3 Tonne.

(ii) Non-Production related Routine Lifts requiring the use of Overhead Travelling Cranes

or Tower Cranes may only be carried out under the direction of a Qualified Rigger where the load exceeds 3 Tonne or by a person trained in basic lifting operations where the load does not exceed 3 Tonne.

(iii) In the case of non-production related Routine Lifts requiring the use of Overhead

Travelling Cranes or Tower Cranes where the load is less than three Tonne, this lift may be carried out under the direction of a person authorised to carry out Basic Lifting Operations or a Qualified Rigger.

Remember: Nobody, including a Rigger or person authorised to carry out Basic Lifting

Operations may operate a crane under any circumstances unless he/she has been trained, found competent and is authorised in writing to operate the particular crane.

15.5 Risk Assessment and Lifting Plan requirements for Routine Lifts.

Standard site procedures developed for safe lifts carried out on a regular basis (without any deviations) may be used but remember: always do a pre-work HIRA to ascertain whether any new



hazards have arisen before obtaining a Clearance to Work Permit. Where there are no standard site procedures for safe lifts carried out on a regular basis, a procedure, specific to the required Routine Lift, must be developed as part of pre-work HIRA for the lift.

Remember: (i) If ever, you as the Rigger (or person authorised to carry out Basic Lifting

Operations) are assigned the task of a Routine Lift, no matter what the circumstances may be while conducting your pre-work HIRA, become unsure of how to perform any part of the Routine Lift safely, do not continue with the task but refer the problem to your Foreman / Supervisor for assistance.

(ii) If ever, you as the Foreman / Supervisor in charge of the aforementioned Rigger

(or person authorised to carry out Basic Lifting Operations) become in the least bit unsure of how to provide such assistance, do no allow the lift to proceed but refer the problem to the Responsible Engineer for a written instruction on how to proceed.

15.6 Rules applicable to Pick and Carry (Mobilift) type crane operations.

Pick and carry type mobile cranes are used as a convenient means of raising, transporting, lowering and placing relatively light loads. The cranes are therefore not equipped with outriggers and their operations are not intended to fall under the control of a rigger.

Load lifting could take place by means of grabs that close automatically or hooks that require manual load attachment. Although Pick and Carry cranes are usually constructed in accordance with a design for a specific operation i.e. mobilift, truck mounted cranes fall under the same category because they have no outriggers. Operations requiring the use of Pick and Carry cranes are specialised by nature and limited to the purpose for which the crane was designed. The responsibility to ensure that these operations are carried out safely invariably falls on the operator and his/her supervisor. The reason for including Pick and Cary crane operations into this course is to make sure that every person understands that loads may not be lifted using more than one Pick and Carry type cranes to lift the load. i.e. Many Fatal and serious accidents have occurred because Pick and Carry type cranes become

unstable when lateral loads, such as those created by tandem crane lifts, are applied to them. Because of this, Anglo Platinum has a ruling throughout its operations that loads may not be lifted under any circumstances using Pick and Carry type cranes in tandem.

Never involve yourself in a Lifting Operation where Pick and Carry cranes are being used in tandem to lift a load and if you ever hear any such lifting operation being planned, report the matter to your Foreman/Supervisor without delay.



APPENDIX 2: Typical Examples of Hooks Fitted with Safety Catches



APPENDIX 3: LIFT COMPLEXITY TABLE

Item Routine Lift Serious Lift Critical Lift Cranes and crane interactions

Number of cranes used 1 1 2 or more Interaction with other cranes or mobile equipment

No Yes, but not in the same lift

Yes

Load lifted Ratio of crane chart rated capacity 0 to 70 % 70 to 90 % Over 90 % Total mass of load if lifted by Overhead traveling crane

< 10 tons 10 to 50 tons Over 50 tons

Total mass of load if lifted by mobile crane

< 5 tons 5 to 20 tons Over 20 tons

Persons lifted No No Yes Lift of hazardous material No No Yes Proportion of liquids in lift mass None < 20 % > 20 % Centre of gravity position Well known Well known Difficult to

determine Centre of gravity near centre of load Yes No No Centre of gravity below sling attachments

Yes Yes No

Very large or flexible load No No Yes Strategically important, fragile or expensive load

No Yes Yes

Proximity of obstructions Proximity of overhead powerlines Well clear of any

powerlines Lift does not go over or between powerlines

Lift does go over or between powerlines

Proximity of fixed obstructions Well clear to sides, above and below

Crane boom or load can reach obstructions

Crane boom or load can reach obstructions

Limited headroom for Overhead traveling crane lifts

No Tight clearance, but no manipulation of load

Yes, requiring tilting or rotation of load

Slewing over plant, pipelines, conveyors or tanks that do not contain any dangerous substances, hazardous chemicals or gases

No Yes Yes

Slewing over plant, pipelines, conveyors or tanks that do contain dangerous substances, hazardous chemicals or gases

No No Yes

Visibility to Crane Operator Entire lift Part or none of lift

Part or none of lift

Number of Spotters required None 1 2 or more Outriggers and ground conditions

Ground soft or muddy No No Yes Outriggers fully extended Yes Yes No

Page 1 of 2 Pages



Item Routine Lift Serious Lift Critical Lift Outriggers close to steep embankment, large drains or other holes

No No Yes

General Straightforward lift with no complexities

Yes No No

Ease of slinging load No difficulty Difficult Difficult Effect of weather None Small Significant Access for lifting at lifting or placement positions

Straightforward Straightforward Awkward

Use of lifting beams or frames No Single beam only

Yes

Specific unusual risks identified No No Yes Any persons are required to be in the drop zone

No No Yes

Crane supported on structure on which it is not normally supported

No No Yes

Page 2 of 2 Pages



APPENDIX 4:

ROUTINE LIFT CHECKLIST (Pg. 1 of 2 pages)

SMELTER AREA TASK DESCRIPTION

SERIOUS ROUTINE LIFT CHECKLIST Yes No N/A THE LOAD

Do you know the weight? Have you included all the items to be lifted i.e. all items on or below the boom head? If you are using lifting lugs have they been properly designed? Are the lugs aligned with the slings so they are not bent?

If you are not using lifting lugs is the load attachment simple and clear? Is the load free of loose unsecured items and is it ready to lift, e.g. restraints removed? Will the lifting hook be directly over the centre of gravity of the load at pick up and placement? THE LIFTING EQUIPMENT

Have the SWL of the slings, shackles, etc been checked for the load to be applied? Have the sling angles and rigging method been considered in checking the capacity? Has all equipment been checked for correct capacity and up to date inspection and test certificates? Has the lifting equipment been inspected for defects and damage? Are the slings protected from any sharp edges? Is the lift within the specific limits of the relevant crane load charts for the configuration and radius? Have the pre and post start operational checks been completed? Are all the crane safety devices functioning correctly? If the crane is more than 10 tonne capacity, is the external rated capacity lighting functioning correctly? Have the ground conditions or structure been determined to be adequate? Is the crane set up with outriggers fully deployed and supported on the correct crane mats? Is there adequate ancillary equipment, e.g. boom lifts, scissor lifts, fork lifts? THE LIFT

Have you determined the lift complexity type? Is there a routine procedure, or have you done a risk assessment or prepared a lifting plan as appropriate? Does the lifting procedure include bringing equipment and loads to site, setting up equipment, lifting, moving and placing the load, and removal of equipment from site?

Are you using the procedure or lifting plan? Is there adequate guidance in the defined behaviours and rules for your site for this lift? Is the area of the lift free of operating plant, piping, live electrical lines and underground services? If not, have the risks associated with these been properly considered?

Has the radius been checked with a tape measure or surveyed using Engineering plans, etc? Has the area of the lifting operation been protected using barricades, tape and/ or spotters? If people are working at height, has a risk assessment been done and correct PPE sourced? Are environmental conditions safe for the lift e.g., not too windy, storms approaching? If there any chance of the load impacting the boom, or the crane body or boom impacting obstacles has a rigging study been done?

THE CREW

Does the Rigger or Responsible Artisan/Person have the appropriate statutory certification and certification by the site as being competent for a lift of this nature?

If the load is heavier or more complex than the Rigger or Responsible Artisan/Person normally handles does the Rigger or Responsible Artisan/Person have the Supervisor’s permission to lift?

Do the Operators of ancillary equipment have appropriate statutory certification? Have the Operators been assessed by the site as being competent to operate the equipment as per the site standards?

Has the Controller of the lift been identified and is he/she wearing an appropriately coloured reflective vest? Has the Crane Operator the appropriate statutory certification and been assessed by the site as being competent to operate this crane/ lifting equipment for this type of lift?

Have all members of the Lifting Crew been assessed as being medically fit for their tasks?



ROUTINE LIFT CHECKLIST (Pg. 2 of 2 pages)

Rigger or Responsible Artisan’s Name:…………………………………………………………………………………………………… Coy No:………………………………………………………………… Date:……………………………………………………………… Rigger or Responsible Artisan/Person’s Signature:…………………………………………………………………………………….. Note: The approval of your Foreman/Supervisor is required before proceeding with this Lift if any answer to the checklist

questions is NO. Approval (only required where the answer to any of the above questions is “NO”:

Approved: …………………………….Name ………………………………Signature (Responsible Eng. Foreman/Supervisor)

engineering learning guide for the safe use of lifting equipment and lifting tackle...

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