Procedure: Cranes and Lifting Equipment

DOCUMENT CODE: Revision: 01

Date: 2014-06-28
Prepared by: Tommy Febres
MPSA-SOP-07 Revised by: Dean Mills
Approved by: Nuccio Brunetto

Table of Content

1. Context and Purpose ............................................................................................................................... 3

2. Applicability/Scope .................................................................................................................................. 3

3. Roles and Responsibilities ..................................................................................................................... 3

3.1. Construction Manager: ............................................................................................................................ 3

3.2. Lifting Supervisor: ................................................................................................................................... 3

3.3. Health and Safety Manager: .................................................................................................................... 3

3.4. All Employees ....................................................................................................................................... 3

4. Definitions ....................................................................................................................................... 4

4.1. Competent Person ................................................................................................................................... 4

4.2. Lifting Equipment .................................................................................................................................... 4

4.3. Lifting Point ....................................................................................................................................... 4

4.4. Purpose Made Lifting Equipment ........................................................................................................... 4

4.5. Safe Working Load .................................................................................................................................. 4

4.6. Proof Load ....................................................................................................................................... 4

4.7. Gin Wheel ....................................................................................................................................... 4

5. General requirements .............................................................................................................................. 4

5.1. Equipment requirements ......................................................................................................................... 5

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5.2. Work area control .................................................................................................................................... 5

5.3. Maintenance / repairs of cranes and hoisting equipment. .................................................................. 5

5.4. Parking ....................................................................................................................................... 6

5.5. Selection of Operators ............................................................................................................................ 6

5.6. Recommendations for operators. .......................................................................................................... 6

5.7. Riggers ....................................................................................................................................... 6

6. Normal lifts ....................................................................................................................................... 6

7. Critical lifts ....................................................................................................................................... 7

7.1. Critical lift plans ....................................................................................................................................... 7

7.2. Crane supported personnel (work) platforms....................................................................................... 7

8. Inspection ....................................................................................................................................... 8

9. Communications. ................................................................................................................................... 10

10. Appendices ..................................................................................................................................... 12

Appendix A: Wire Rope Clip Spacing and Orientation (Not to be used for slings) ................................ 12

Appendix B: Wire rope removal and replacement criteria ........................................................................ 13

Appendix C: Minimum clearance from energized overhead electric lines .............................................. 14

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1. Context and Purpose

To establish the minimum requirements for Minera Panama to manage the safe and efficient use of cranes and
lifting equipment.

2. Applicability/Scope
The present procedure is applicable to all project activities performed by Minera Panama or their contractors
that involve use of cranes and lifting equipment.

3. Roles and Responsibilities

3.1. Construction Manager:
The Construction Manager is responsible to:
Ensure full compliance with the requirements of this procedure.
Approve the procedures for the use, maintenance and repair of lifting equipment.
Approve the procedures for the design and construction of any purpose made lifting equipment.

3.2. Lifting Supervisor:

Lifting Supervisors shall have the following accountabilities:
Be responsible for the safe installation and the proper operation, running and maintenance of all
machinery.
Be responsible for the safe erection and proper maintenance of all buildings, structures and tanks.
Be in charge of machinery.
Conduct risk assessment for tasks associated with this procedure and ensure the implementation of
controls.
Ensure employees are, provided with, educated in the use of, and wear the appropriate PPE when
performing activities associated with this procedure.

3.3. Health and Safety Manager:

Audit and monitor compliance with this procedure.
Identify remedial corrective actions required to meet this procedure.

3.4. All Employees

All employees shall have the following accountabilities:
Ensure that they are aware of the risks associated with the job.
Ensure compliance with this procedure.
Ensure that a Risk Assessment is filled out and all risk minimization measures are fully complied
with.
Ensure that equipment is not operated unless the operator is competent and tools / equipment
have been inspected prior to commencement of task.
Ensure that the correct equipment is selected, checked, maintained and used in accordance with
correct lifting techniques.

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4. Definitions
4.1. Competent Person
A person who has acquired through training, qualification, experience or a combination of these, the knowledge
and skill enabling that person to correctly perform the required task.

4.2. Lifting Equipment

Lifting equipment comprises all forms of lifting appliance and lifting gear such as the following:
Lifting appliance - is a machine or component which can raise, lower or suspend a load. Lifting
appliances include cranes, elevators / lifts for personnel and materials, forklift trucks, stacker trucks,
mobile working platforms, pulley blocks, gin wheels, runway beams with trolleys, davits, conveyors and
cherry pickers.
Lifting gear - components such as shackles, slings, hooks, chains and spreader beams used to connect
lifting appliances to one another or to connect lifting appliances to loads.

4.3. Lifting Point

Components or features of loads such as, lifting lugs, eyes and reinforcement pads designed for attachment or
bearing of lifting equipment.

4.4. Purpose Made Lifting Equipment

Lifting equipment not available as a standard or proprietary item, this is designed and manufactured for a
specific task or duty. This item can only be used if approved by the Competent Person and tested by a third party
approved company.

4.5. Safe Working Load

The maximum load that may be handled by a crane at a specific working radius and specific boom or jib length
without the strength and stability requirements being exceeded.

4.6. Proof Load

Test load applied to lifting equipment after manufacture or following any repair, replacement or modification of
any load bearing part. It is a specified load which is required to be withstood without the equipment showing
any defects on inspection following the proof load test. Proof loading shall be performed in a way which
accurately simulates in service loading.

4.7. Gin Wheel

A gin wheel is a simple form of tackle block, having one wheel, over which a rope runs and is used in conjunction
with scaffold to hoist light loads from one level to another by hand.

5. General requirements
- Before any crane or hoisting equipment is placed in use, it shall be inspected and tested and certified in
writing by a competent person to be in accordance with the manufacturers recommendations and the
requirements of this procedure.
- When the manufacturer's instructions or recommendations are more stringent than the requirements of this
procedure, the manufacturer's instructions or recommendations shall apply.
- The use of electronic equipment for entertainment purposes while operating equipment is prohibited.
- Mechanized equipment shall be shut down before and during refuelling operations. Closed systems, with an
automatic shut- off that will prevent spillage if connections are broken, may be used to fuel diesel powered
equipment left running.
- Riding on loads, hooks, hammers, buckets, material hoists, or other hoisting equipment not meant for
personnel handling is prohibited.
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- Lifting tackle will be stored or protected so as to prevent damage or deterioration when not in use.
- All types of lifting tackle used are to be clearly marked with the maximum mass load, which it is designed to
carry with safety and identification particulars.

5.1. Equipment requirements

- An operable fuel gauge;
- An operable audible warning device (horn);
- Adequate rear view mirror or mirrors;
- Non-slip surfaces on steps;
- A power-operated starting device;
- Seats or equal protection must be provided for the operator and all personnel required to be in/on
equipment;
- Whenever visibility conditions warrant additional light, all vehicles, or combinations of vehicles, in use shall
be equipped with at least two headlights and two taillights in operable condition;
- Glass in windshields, windows, and doors shall be safety glass. Cracked or broken glass shall be replaced;
- One (minimum) dry chemical or CO fire extinguisher with a minimum rating of 10B:C installed in the cab or
at the machinery housing;
- All self-propelled equipment, whether moving alone or in combination, shall be equipped with a backup
alarm.
- All guarding and safety devices shall be provided, used and maintained:
o All belts, gears, shafts, pulleys, sprockets, spindles, drums, flywheels, chains, or other
reciprocating, rotating, or moving parts of equipment shall be guarded when exposed to
contact by persons or when they otherwise create a hazard.
o All hot surfaces of equipment, including exhaust pipes or other lines, shall be guarded or
insulated to prevent injury and fire.
o Platforms, foot walks, steps, handholds, guardrails, and toe boards shall be designed,
constructed, and installed on machinery and equipment to provide safe footing and access
ways.
o Equipment shall be provided with suitable working surfaces of platforms, guardrails, and hand
grabs when attendants or other employees are required to ride for operating purposes outside
the operator's cab or compartment. Platforms and steps shall be of non-skid materials.

5.2. Work area control

When there are accessible areas in which the equipments rotating superstructure (permanently or temporarily
mounted) poses a risk of striking and injuring an employee or pinching/crushing an employee against another
part of the equipment or another object, employees shall be prevented from entering these areas (i.e.,
communication or risk, placement/maintenance of control or warning lines, railings or barriers)

5.3. Maintenance / repairs of cranes and hoisting equipment.

- Maintenance, including preventive maintenance and repairs shall be performed in accordance with the
manufacturer's recommendations. Records of maintenance and repairs conducted during the life of the
crane shall be made available.
- Replacement parts or repairs shall have at least the original design factor; replacement parts for load
bearing and other critical parts shall be obtained from the original manufacturer, (if possible) or certified by
a registered engineer knowledgeable in cranes.
- All equipment shall be shut down and positive means taken to prevent its operation while repairs or
manual lubrications are being done.
- All repairs shall be made at a location that will protect repair personnel from traffic.
- Cranes, hoisting equipment, or parts thereof that are suspended or held apart by slings, hoists, or jacks also
shall be substantially blocked or cribbed before personnel are permitted to work underneath or between
them.

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5.4. Parking
- Whenever equipment is parked, the parking brake shall be set.
- Equipment parked on an incline shall have the wheels chocked or track mechanisms blocked and the
parking brake set.
- All equipment left unattended at night, adjacent to a highway in normal use or adjacent to construction
areas where work is in progress, shall have lights or reflectors, or barricades equipped with lights or
reflectors, to identify the location of the equipment.

5.5. Selection of Operators

All crane operators shall have a certificate of competency that meets the requirements of legislation. In locations
where certification is not available, operators shall be tested against best practice available or other legislative
criteria. Training and assessment of crane operations shall be by holders of certificates of competency for specific
plant.
Crane and industry experience shall be checked prior to commencing on site.
An on-site assessment of operators competency for specific cranes shall be held. Training in specific project
procedures will be given.

5.6. Recommendations for operators.

- All Drivers/Operators shall be appointed and approved by the Construction Manager.
- If Driver/Operator does not adhere to rules and regulations his appointment shall be cancelled and he
shall not be able to carry on with his duty.
- No Driver/Operator shall be appointed without proof of training, drivers licence or letter of competency.
- No training of Drivers/Operators on Site.
- No passengers allowed on cranes.
- No eating or drinking allowed while operating equipment.
- No vehicle shall be left unattended with engine running or key in ignition.
- Cellular phones may not be used by drivers during operations.
- The operator shall respond to signals from the person who is directing the lift or an appointed signal
person. When a signal person is not used in the crane operation, the operator shall ensure he has full view
of the load and the load travel paths at all times the load is rigged to the crane and hoisting equipment;
- Each operator is responsible for those operations under his direct control. Whenever there is a concern as
to safety, the operator shall have the authority to stop and refuse to handle loads until a qualified person
has determined that safety has been assured.

5.7. Riggers
- The riggers must be certified by a competent person in the project.
- Rigger is responsible of inspection of all lifting accessories, and responsible on the verification of proper
capacity of these in according with the task.
- Two level of Riggers will be implemented in according with the weights of the loads
o Less than 20 tons
o 20 or more tons, in this case the rigger must have 3 years of experience.

6. Normal lifts
Is considered a normal lift:
- Lifts using of 70% of the nominal capacity of the crane and the load is of neutral type.
A lift planning must include:
- Weight of load and rigging, fly, hooks etc.
- Select appropriate load chart for crane configuration/proposed configuration.
- Confirm ground bearing pressure capacity.
- Check for underground services.
- Know required orientation at placement.

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- Provide for insulation between object and crane if object is to be welded.

- Consider pick up point and method of delivery of object to be lifted.
- Check for presence of power lines and isolate or provide mandatory clearance.
- Choose loaded crane slew path.
- Establish clear path of entry free of obstacles.
- Determine appropriate set up of crane for task.
- Allow sufficient headroom.
- Allow sufficient boom point elevation.
- Check that load wont become jib bound.
- Provide safe access for de-rigging.
- Prepare written JHA with work group - or
- Prepare lifting study and written JHA with work group.

7. Critical lifts
When using cranes or hoists, the following are identified as critical lifts requiring detailed planning and specific safety
precautions. Critical lifts are defined as:
- Lifts involving hazardous materials (e.g., explosives, highly volatile substances);
- Hoisting personnel with a crane or hoist;
- Lifts made with more than one crane;
- Lifts where the centre of gravity could change;

7.1. Critical lift plans

Before making a critical lift, a critical lift plan shall be developed:
- By a qualified person and shall include the crane operator, lift supervisor, and the rigger and signed by all
involved personnel prior to the lift;
- For a series of lifts on one project or job, as long as the cranes, personnel, type loads and configuration do
not differ;
- And shall include, as a minimum:
1. The specific make and model of the cranes, the line, boom, and swing speeds;
2. The exact size and weight of the load to be lifted and all crane and rigging components that add to the
weight. The manufacturer's maximum load limits for the entire range of the lift, as listed in the load
charts, shall also be specified;
3. The plan shall specify the lift geometry and procedures, including the crane position, height of the lift,
the load radius, and the boom length and angle, for the entire range of the lift;
4. Site drawing shall be included to identify placement/location(s) of crane, adjacent equipment and/or
facilities, etc.;
5. The plan shall designate the crane operator, lift supervisor and rigger and include their qualifications;
6. The plan will include a rigging plan that shows the lift points and describes rigging procedures and
hardware requirements;
7. The plan will describe the ground conditions, outrigger or crawler track requirements, and, if
necessary, the design of mats, necessary to achieve a level, stable foundation of sufficient bearing
capacity for the lift;
8. The plan will list environmental conditions under which lift operations are to be stopped;
9. The plan will specify coordination and communication requirements for the lift operation;
10. For tandem or tailing crane lifts, identify the requirements for an equalizer beam if applicable.

7.2. Crane supported personnel (work) platforms.

Crane supported personnel platforms are prohibited, except when the erection, use, and dismantling of
conventional means of reaching a work site, such as a personnel hoist, ladder, stairway, aerial lift, elevating
work platform or scaffold would be more hazardous or is not possible because of structural design or worksite
conditions.

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The work platform and suspension system shall be designed and certified by a Registered Professional Engineer
with knowledge in this area.
- The work platform (excluding fall protection systems) shall be capable of supporting, without failure, its
own weight and at least five times the maximum intended load.
- The suspension system shall be designed to minimize tipping of the platform due to movement of the
employees on the work platform.
- The system used to connect the work platform to the equipment shall allow the platform to remain within
10 degrees of level, regardless of boom angle.
- All welding of the work platform and its components shall be performed by a Certified Welder familiar
with the weld grades, types, and material specified in the platform design.
Crane supported work platforms shall meet the following requirements:
- The scaffold shall be of metal or metal frame construction with a standard guardrail system and shall be
enclosed at least from the toe board to mid-rail with either solid construction material or expanded metal
having openings no greater than inch (1.2 cm).
- A grab rail shall be installed inside the entire perimeter of the personnel platform.
- Access gates, if installed, shall not swing outward and shall be equipped with a device to prevent
accidental opening.
- Headroom shall be provided which allows employees to stand upright in the platform.
- In addition to the use of hardhats, employees shall be protected by overhead protection on the personnel
platform when the employee(s) are exposed to falling objects.
- The platform shall be conspicuously posted with a plate or other permanent marking that indicates the
weight of the platform and its rated load capacity or maximum intended load.

8. Inspection
The following equipment is to be inspected every three months:
- Chain slings and attachments.
- Wire rope slings and attachments.
- Synthetic fibre slings and attachments.
- Hand operated hoists.
- Air hoists and air winches.
- Plate clamps.
- Lifting hooks (which are an integral part of lifting equipment such as a chain block or lever hoist).

An appropriate colour coded tag shall be attached in accordance with the Project coding as follows:

January - March Green

April - June Red
July - September Blue
October - December Yellow

Lifting equipment shall be inspected at month intervals or as prescribed by legislation, and results recorded.
Inspection reports shall include the date, condition of the equipment, corrective actions required and the name of
the inspector and organisation.

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Crane & derrick inspection frequency

When to inspect Type of Inspection

(a) Initial inspection
Prior to initial use - all new cranes
(b) Initial inspection
Prior to use - all altered cranes
(c) Periodic inspection
Prior to initial use on project
Monthly after initial use on a USACE Periodic inspection
project
Prior to every operation (shift) Start-up inspection
Before using a crane that is not in use on a regular basis and
that has been idle for more than 1 month, but less than 6
months (d) Frequent inspection

Before using a crane that is not in use on a regular basis and

(d) Periodic inspection
that has been idle for more than 6 months

(e) Frequent inspection

Standby cranes, at least semi-annually
(f) Frequent inspection
Standby cranes, prior to use

Notes:
(a) Performed by the manufacturer.
(b) Altered is defined as any change to the original manufacturers design configuration, that is, replacement
of weight handling equipment parts and components.
(c) Initial use refers to (1) the first time takes possession of and assembles a crane, or (2) whenever a Contractor
brings a crane onto a job site and assembles the crane.
(d) This requirement is in addition to the requirement for a periodic inspection.
(e) Standby cranes are those cranes that are not used on a regular basis but are available - on a standby basis -
for emergencies; requirements for frequent inspections of standby cranes are in addition to the requirement for
a periodic inspection.
(f) In addition to the semi-annual frequent inspection, a frequent inspection shall be conducted prior to use

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9. Communications.
A standard signal system shall be used on all cranes and hoisting equipment (by hand, voice, audible or comparable
signals). Manual (hand) signals may be used when the distance between the operator and signal person is not more
than 100 ft (30.4 m). If using hand signals, Standard Method must be used.
Radio, telephone, or a visual and audible electrically- operated system shall be used when the distance between
operator and signal person is more than 100 ft or when they cannot see each other.

Crane hand signals (ANSI/ASME B30)

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10. Appendices
Appendix A: Wire Rope Clip Spacing and Orientation (Not to be used for slings)

Number of clips and the proper torque necessary to assemble wire rope eye loop connections with a probable
efficiency not more than 80%

Rope Torque to be applied

Nominal size of Number of
diameter to nuts of clips (ft-
clips (in/cm) clips
(in/cm) lb/N-m)

5/16 (0.7) 3/8 (0.9) 3 25 (33.9)

3/8 (0.9) 3/8 (0.9) 3 25 (33.9)
7/16 (1.0) 1/2 (1.2) 4 40 (54.3)
1/2 (1.2) 1/2 (1.2) 4 40 (54.3)
5/8 (1.5) 5/8 (1.5) 4 65 (88.2)
3/4 (1.9) 3/4 (1.9) 5 100 (135.7)
7/8 (2.2) 1 (2.5) 5 165 (223.9)
1 (2.5) 1 (2.5) 6 165 (223.9)
1 1/4 (3.1) 1 1/4 (3.1) 7 250 (339.3)
1 3/8 (3.4) 1 1/2 (3.8) 7 375 (508.9)
1 1/2 (3.8) 1 1/2 (3.8) 8 375 (508.9)
1 3/4 (4.3) 1 3/4 (4.3) 8 560 (760.0)

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Appendix B: Wire rope removal and replacement criteria

# OF
# OF BROKEN BROKEN
WIRES WIRES IN
IN RUNNING STANDIN
ROPES G ROPES

At end connection

At end connection
In one rope lay

In one rope lay

In one strand
Standard Equipment
Not
ASME/B30.2 Overhead & gantry cranes 12** 4 N/S
Specified

ASME/B30.4 Portal, tower, & pillar cranes 6** 3 2 3 2

Running ropes 6** 3 2 3 2

Mobile &
ASME/B30.5 locomotive 2 randomly distributed broken wires in
cranes Rotation-
6 rope dia.or 4 randomly distributed
resistant ropes
broken wires in 30 rope dia. **
ASME/B30.6 Derricks 6** 3 2 3 2

ASME/B30.7 Base-mount drum hoists 6** 3 2 3 2

ASME/B30.8 Floating cranes and derricks 6** 3 2 3 2

Not
ASME/B30.16 Overhead hoists 12** 4 N/S
Specified
ANSI/A10.4 Personnel hoists 6** 3 2 2** 2
Not Not
ANSI/A10.5 Material hoists 6**
Specified Specified

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Appendix C: Minimum clearance from energized overhead electric lines

All dimensions are distances from live part to employee.

Voltage (nominal, kV, Minimum

alternating current) rated clearance
Up to 50 10 ft (3 m)
51 200 15 ft (4.6 m)
201 350 20 ft (6 m)
351 to 500 25 ft (7.6 m)
501 - 650 30 ft (9.1 m)
651 800 35 ft (10.7 m)
801 950 40 ft (12.2 m)
951 1100 45 ft (13.7 m)
Clearance values calculated using: (Initial kV-50kV) x (4 in/10
kV) x (1 ft/12 in) = increased distance (ft) over 10 ft. Add this
value to 10 ft to yield minimum rated clearance

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