Ames Procedures
Ames Procedures
Ames Procedures
and Guidelines
APR 8715.1
COMPLIANCE IS MANDATORY
Appendix A: Definitions
Appendix B: Acronyms
Appendix C: Daily Inspection Form
Appendix D: Inventory Form
Appendix E: Lift Determination Form
Appendix F: Critical Lift Plan Form
Appendix G: Non-Critical Lift Plan Form
Appendix H: Periodic Inspection Chain Hoist Form
Appendix I: Periodic Inspection Come-a-long Form
Appendix J: Periodic Inspection Lifting Beams Form
Appendix K: Periodic Inspection Lifting Clamp Form
Appendix L: Periodic Inspection Master Links Form
Appendix M: Periodic Inspection Shackle Form
Appendix N: Periodic Inspection Swivel Hoists /Rings Form
Appendix O: Periodic Inspection Synthetic Web Form
Appendix P: Periodic Inspection Turnbuckle Form
Appendix Q: Periodic Inspection Wire Rope Sling Form
Appendix R: Periodic Inspection Wire Rope Form
Appendix S: Emergency Procedures Checklist
17.1 Responsibilities
a. All personnel, including contractors, working with or around lifting devices shall follow the
requirements of this chapter, Occupational Safety & Health Administration (OSHA),
American Society of Mechanical Engineers (ASME), NASA-STD-8719.9 (Standard for
Lifting Devices and Equipment) and all other applicable regulations.
b. Signatures
1. Designate in writing at least one person and one or more alternates as the Ames
Lifting Device Equipment Manager (LDEM) with appropriate background in lifting
devices, lifting operations, lifting equipment industry standards and an
understanding of lifting safety.
2. Designate in writing at least one representative and alternate from each Directorate
that uses lifting devices to be an active member of the Lifting Device Equipment
Committee.
1. Upon request, review and evaluate Critical Lift Plans and associated documents.
2. Document nonconformance, noncompliance, and corrective action tracking in
applicable electronic databases, such as the Ames Continuous Improvement Action
System (CIAS).
3. Support and evaluate hazard analysis on lifting device equipment used for critical
lifts as specified in NASA-STD-8719.9 (Standard for Lifting Devices and
Equipment).
1. Determine the process to identify type of lift using the Lift Determination form in the
appendix.
2. Ensure that all lifts are conducted in accordance with NASA policies and all
applicable regulations.
3. Include in contracts the appropriate requirements for safety performance and
written safety plans, such as those in NASA Specification Section 01 35 26,
(General Safety Requirements).
4. Ensure that the "Lift Plan" for critical lifts is not issued until an engineer approves
the lifting plan in writing. The evaluation must include specifications and
calculations of all lift hardware and loads at a minimum.
5. Appoint an individual (NASA or contractor) who shall be present as the Safety Lift
Observer (SLO) during each critical lift and designated as responsible for the safety
of the operations. That person may be the LDEM or a safety professional, a
supervisor, an engineer or a task leader, provided he or she has appropriate
training and background in lifting operations with an understanding of lifting safety.
6. Submit lift plan for approval prior to conducting crane lifting activities or all critical
lifts (includes forklift, manlift, all other lifting devices and equipment).
7. Inform the LDEM of any installations, maintenance, and/or other improvements to
any lifting devices and equipment at Ames Research Center within six (6) months of
purchase.
8. Notify the LDEM and Safety, Health & Medical Services division of all planning
meetings when a critical lift plan has been received.
9. Ensure that a lifting procedure and safety hazard analysis are developed for all
critical lifts including the lifting of personnel. Provide copies to the LDEM and the
Safety, Health & Medical Services Division prior to the critical lift review meeting.
10. Ensure that a safety meeting is held with in 5 business days prior to each lift.
11. Revew each non-critical lift to determine if an engineer is needed to approve the
specifications of all lift hardware and loads prior to conducting a lift.
12. Ensure that all mobile crane lifts have an engineering load evaluation as part of the
approval process. The evaluation must include specifications and calculations of all
lift hardware and loads at a minimum.
13. Be appointed by the supervisor within each directorate, organization or program
office for an individual lift. The Lift Project Manager can be a Civil Servant or
Contractor.
1. Require that all contracts for mobile crane services include a copy of NASA-STD-
8719.9 (Standard for Lifting Devices and Equipment).
2. Inform the LDEM of any installations, maintenance, and/or other improvements to
any lifting devices and equipment at Ames Research Center within six (6) months of
purchase.
3. Invoke the "Suspension of Work" provision of the contract should the Contractor or
subcontractors refuse or fail to ensure prompt corrective action of any noted safety
deficiencies.
a. Maintain oversight of the Alternate Lifting Device Equipment Manager activities and
responsibilities.
b. Promptly report to the Center Director when any ORG with lifting devices does not have
a representative assigned to the Lifting Device Equipment Committee for a period of
more than thirty (30) days.
c. Participate as a member of the Lifting Device Equipment Committee providing Ames'
position on lifting devices and equipment safety issues.
d. Serve as the chair of the Lifting Device Equipment Committee.
e. Have joint responsibility for the enforcement of the Ames lifting device and equipment
program, including Powered Industrial Trucks, Mobile Aerial Platforms, and Jacks with
the Ames Safety, Health & Medical Services Division.
f. Ensure that annual inspection, documentation and certification of cranes has been
completed.
g. Provide technical coordination and relative support with regards to cranes, critical and
non-critical lifts, lifting operations, qualification of operators and supervisors, reviews
safety variances.
h. Assist in the training qualification process for crane operators, riggers & signal persons
through the Ames Health, Safety & Medical Services Division training program.
i. Submit Lessons Learned information to the NASA Ames Lessons Learned Administrator
within thirty (30) days after conclusion of investigation for mishap or close calls to be
published in the NASA HQ Lessons Learned system. See the Lessons Learned section
in this chapter for additional information.
j. Manage an inspection program for lifting equipment, using an inventory status report
provided by equipment owners and organizations using lifting equipment.
k. Establish and maintain records in the Ames Management System to include procedures
for the maintenance and calibrating of equipment that is used to load test lifting devices
and equipment. These records will be kept on file for the life of the lift equipment or
device.
l. Document proof and load tests of overhead cranes and maintain associated calibration
records for the life of the crane.
m. Maintain oversight responsibility for program through monthly documented program
audit to ensure annual inspection and periodic load test have been conducted. (see the
Maintenance & Inspection Program section for additional information)
n. Provide an annual report to the Lifting Device Equipment Committee on the status of
each organization that owns lifting devices and equipment in efforts to inventory and
provide records regarding the tagging and inspection of each critical and non-critical
lifting device in accordance with NASA-STD-8719.9 (Standard for Lifting Devices and
Equipment). These records will be on file for the life of the lifting equipment and/or
device.
o. Manage the Maximo or system and document the process.
p. Ensure non destructive testing (NDT) of overhead cranes is conducted and documented
when it is required for the periodic load test.
q. Ensure that all lifts are conducted in accordance with NASA policies and all applicable
regulations.
r. Maintain rigging hardware periodic load test reports for a minimum of two test cycles.
1. Develop a charter for the NASA Ames Research Center (ARC) Lifting Device
Equipment Committee to ensure this chapter and NASA-STD-8719.9 (Standard for
Lifting Devices and Equipment) is understood and applied across other
organizations at NASA Ames.
2. Meet to discuss specific center requirements and/or needs such as variances or
pick plans.
3. Provide a forum to resolve to any issues and exchange information.
4. Have representation for each organization within NASA Ames that are responsible
for and/or involved with lifting device equipment.
5. Keep meeting minutes, an attendance sign-in sheet and submit minutes for
publication on the Lifting Device Equipment Committee web page within thirty (30)
days.
6. Meet to discuss and develop Lessons Learned from close calls and mishaps at
NASA Ames.
a. A supervisor or appointed designee who manages overhead cranes, mobile cranes and
derricks, hoists and winches, hooks, hydra-sets and load measuring devices, mobile
aerial platforms, powered industrial trucks, and jacks used to lift or support flight
hardware and employees who operate such devices or equipment shall:
a. Contractors who operate cranes or other lifting devices covered by this chapter shall:
8. Meet the criteria of the National Commission for the Certification Crane Operators
(NCCCO) requirements for certification and qualification status.
9. Notify the LDEM and Safety, Health & Medical Services Division of all planning
meetings.
1. Inspect then document daily and periodic inspections of cranes, hoists, winches,
hooks and all rigging hardware using the approved NASA forms.
2. Ensure immediate administrative locking of crane if any deficiencies are identified
during inspection. See section (Standard Lockout/Tagout System) of this document.
3. Ensure that supervisor takes custody of rigging hardware to secure (or destroy if
appropriate) when deficiencies are identified during inspection.
4. Maintain inspection documents at a conspicuous location at/near the lift and/or
equipment.
5. Maintain operator's certification at the Qualified level when performing overhead
crane, rigging and signal person duties.
6. Complete a medical evaluation for cranes before operating a crane or performing
rigging and signal duties to be in good standing and to remain a Qualified lift
equipment operator.
7. Conduct all lifting actions in a manner that meets the requirements of this
document, NASA-STD-8719.9 (Standard for Lifting Devices and Equipment), the
Occupational Safety and Health Administration (OSHA) and ASME B30 series.
8. Inform the LDEM of any installations, maintenance, and/or other improvements to
any lifting devices and equipment at Ames Research Center within six (6) months of
purchase.
17.2 Training
a. General training requirements for lifting devices and equipment
1. Includes Forklift, Manlift and Overhead Cranes.
a. Attend the NASA Ames Training course or an equivalent (as published in the
Ames Training Catalog) provided by an industry recognized trainer, training
center, or locally developed training program which meets or exceeds industry
and OSHA training requirements.
b. Complete annual review given by your supervisor during the month of January.
This will be done through PowerPoint presentations available to your supervisor
via the QH Training Homepage. The supervisor will verify that all currently
trained participants for Forklift, Manlift, Overhead Crane Operators, Riggers and
Signal Persons have completed the annual review. The supervisor will submit
the code QH Annual Lifting Devices and Equipment Training Review Form to
the QH Training Coordinator by February 1st of each year for documentation.
a. For Qualified Overhead Crane Operators & Riggers there are two levels of proficiency
(Critical and Non-critical). Qualified Operator cards are marked with the words
“Restriction: Non-critical Only” unless they are authorized for critical lifts and the
operator has demonstrated a higher level of proficiency.
a. To become a qualified rigger and signal person the following shall be addressed:
3. Examinations:
4. On-the-job training:
3. Examinations:
4. On-the-job training:
b. Training cards will indicate specific crane types for which the holder is qualified to
operate.
c. Training will be due at least every two (2) years.
2. Examinations:
3. On-the-job training:
b. Training cards will indicate specific aerial lift types for which the holder is qualified to
operate.
c. Training will be due at least every two (2) years.
2. Examinations:
3. On-the-job training:
b. Training cards will indicate specific forklift types and size for which the holder is qualified
to operate.
c. Training will be due at least every two (2) years.
a. A representative from the Health, Safety & Medical Services Division may revoke a
license or certification card by collecting the card in person or contacting the card
holder in writing for acts of negligence, violations of safety requirements or failure to
meet medical standards. The supervisor is to be notified of the revocation in writing.
1. Disseminate Crane mishap and close call lessons learned information to the Lifting
Device Equipment Committee.
2. Disseminate Crane mishap and close call lessons learned information to the Safety,
Health and Medical Services Division Training Program Manager for inclusion in the
training course curriculum.
3. Disseminate Crane mishap and close call lessons learned information to the Ames
Lessons Learned Administrator for inclusion in the NASA HQ Lessons Learned
system.
a. Hardhats are required for all personnel during mobile crane lifts.
b. Hardhats are required for all personnel during overhead crane lifts where the
load is to be lifted above shoulder height.
14. Contact the LDEM and receive specification approval prior to procurement of
rigging hardware.
Table 1: Minimum Design Factors for Rigging Hardware
a. Have a permanently affixed red colored tag identifying the Maximo database
thirteen digit tracking number that has been issued through the LDEM.
b. Have the WLL listed on the tag. For Synthetic rope slings, list the WLL at fifty
(50) percent of the manufacturer's rated load and the type of material.
c. Have the next periodic load test expiration date listed on the tag. See Table 3
for Periodic Load Test Factors.
d. For alloy steel chains also list size, grade and reach or length on the tag.
4. Proof load testing is required before use, for new hardware, when extensively
repaired or modified at two-hundred (200) percent of rated load. Proof load tests
performed by the manufacturer prior to delivery are acceptable, if the necessary
load test papers are provided to verify the extent and thoroughness of the test on
the specific item.
5. Operational testing is required prior to use on an annual basis.
a. Have a permanently affixed tag identifying the Maximo database thirteen digit
tracking number that has been issued through the LDEM .
b. Have the WLL listed on the tag.
c. Have the next periodic load test expiration date listed on the tag. See Table 3
for Periodic Load Test Factors.
4. Proof load testing is required before use, for new hardware, when extensively
repaired or modified at two-hundred (200) percent of rated load. Proof load tests
performed by the manufacturer prior to delivery are acceptable, if the necessary
load test papers are provided to verify the extent and thoroughness of the test on
the specific item.
5. Operational testing is required prior to use on an annual basis.
a. Check for defects such as cracks, deformations, gouges, galling, kinks, crushed
areas and corrosion.
b. Check for proper configuration (lifting assembly and associated hardware, as
proof load tested).
c. For inspection forms, see Appendix.
2. Periodic Inspections - At least once a year. The need to replace or repair all rigging
hardware is determined by a certified or otherwise qualified person based on an
evaluation of inspection results.
a. For inspection criteria, see NASA-STD-8719.9 (Standard for Lifting Devices and
Equipment) section 10.4.5 (Periodic Inspections).
b. For inspection forms, see Appendix.
c. Complete inspection forms on an annual basis before their expiration date and
submit to the LDEM. The Maximo system will generate the reminder a minimum
of thirty (30) days before the inspection is due.
c. The Lifting Device Manager (LDEM) is responsible for oversight of the program and
recordkeeping which shall include:
2. A ten (10) percent random spot check with a representative from the Health, Safety
and Medical Services division.
d. The Maximo system is used for tracking and documentation of equipment and lifting
hardware.
a. Before first use, unless noted below, all new, extensively modified, repaired, or altered
slings and rigging equipment shall undergo a proof load test at two (2) times the rated
load (except for structural slings may be tested at one hundred twenty-five (125)
percent of the rated capacity if specified by design, due to material characteristics,
geometry, design factors, etc.) Proof load tests performed by the manufacturer prior to
delivery are acceptable, if the necessary load test papers are provided to verify the
extent and thoroughness of the test on the specific item. The proof load test papers are
sufficient documentation until next periodic load test is scheduled. See Table 2 for
Proof Load Test Factors.
b. Proof load test may be substituted at the time of purchase if manufacture test papers
suggest a load test of one hundred and twenty-five (125) percent of the working load
limit has been completed. This documentation must be maintained by the user group.
1. Establish and maintain safe zones (areas not to be entered by personnel during the
lift unless authorized and necessary to perform assigned duties) before lifts begins
and place appropriate barriers in place.
2. Prevent anyone from becoming under a suspended load, become trapped, crushed
or pinched.
3. Know the weight of the load.
4. Test holding brakes for weights above seventy-five (75) percent of rated capacity,
according to NASA-STD-8719.9 (Standard for Lifting Devices and Equipment).
5. Test radio communications. If communications are lost, stop all operations until
restored.
6. Establish written emergency procedures which are to be communicated to
everyone involved in the operation. See the Operating Procedures for Emergencies
section of this chapter for additional information. (7). Meet prior to lift for a safety
briefing that covers the following at a minimum:
a. Hardhats are required for all personnel during overhead crane lifts where the
load is to be lifted above shoulder height.
10. Ensure that outdoor hoisting operations do not take place if winds are above 20
knots (23 mph) steady state or gusts exceed 35 knots (40 mph). Weather will also
be a consideration before lift operations occur such as rain or lightening.
11. Document any deficiency found during the pre-operational check and remove from
service using administrative locking until steps are taken to correct deficiency.
12. Ensure that all overhead crane activities follow a written operational procedure. The
operational procedure is a document that defines the scope of the project and lists
step by step procedures to accomplish the lift. The operational procedure is in
addition to the Lift Plan.
a. Critical lifts are lifts where failure/loss of control could result in loss of life, loss of or
damage to flight hardware or lifts involving special, such as spacecraft, one-of-a-kind
articles, or major facility components whose loss would have serious programmatic or
institutional impact. Critical lifts also include the lifting of personnel with a crane, lifts
where personnel are required to work under a suspended load and operations with
special personnel and equipment safety concerns beyond normal lifting hazards.
b. All personnel involved in critical lifting operations shall:
1. At least five (5) days prior to the lift, complete the Lift Determination form in the
appendix to determine the type of lift (critical or non-critical) requirements with the
input of facility, program, user and safety and mission assurance personnel.
2. Obtain approval & signatures required on the form.
3. Distribute approved form:
1. Ensure that a meeting takes place with all required personnel to discuss planned
lifting operations, inviting the LDEM, the facility FSM, the crane operator, the owner
(or owner's representative) of the items to be lifted, and representatives from the
Health, Safety & Medical Services Division (QH).
2. Ensure the crane operator presents an outline of the lift plan at this meeting.
3. Present a Lift Determination form (see Appendix) in conjunction with a Hazard
Analysis of the proposed lift at this meeting.
4. Create an official record of this meeting with action items and general notes then
distribute to all parties present.
17.4.1.3 Safety Analysis and Documentation of Cranes Used for Critical Lifts
a. A recognized safety hazard analysis such as fault tree analysis, FMEA, Operating and
Support Hazard Analysis (O&SHA), shall be performed on all cranes used for critical
lifts and meet the following requirements:
a. non-critical lifting operations involve routine lifting and are governed by standard industry
rules and practices. All personnel involved in non-critical lifting operations shall:
1. Not have personnel located under suspended or moving loads unless the operation
adheres to the OSHA-approved NASA Alternate Standard for Suspended Load
Operations NASA-STD-8719.9 (Standard for Lifting Devices and Equipment).
a. Before first use and after installation, all new, extensively repaired, extensively
modified, or altered cranes shall undergo a proof load test with a dummy load
as close as possible to, but not exceeding 1.25 times the rated capacity of the
crane.
a. Each crane shall be tested at least once every 4 years with a dummy load equal
to the crane's rated capacity. Cranes used for critical lifts shall be load tested at
least once per year.
3. Operational tests:
a. Performed in conjunction with proof load and periodic load tests, the operational
test typically moves the load through a full range of movement to determine if
the equipment (limit switches, emergency stop controls, brakes, etc.) is
functioning properly.
b. The proof load tests and operational tests are to be performed prior to first use for new
cranes and for existing cranes that have had modifications or alterations performed to
components in the load path. Repairs or alterations to nonlifting, secondary lifting, or
holding components such as suspension assemblies, electrical system, crane cab, etc.,
do not require a load test, although a functional check should be performed to
determine if the repairs or alternations are acceptable.
c. All load and operational tests are to be performed by qualified personnel according to
written (specific or general) technical operating procedures. An inspection of the crane
and lifting components will be performed after each load test and prior to the crane
being released for service to ensure there is no damage. Surface or volumetric
nondestructive testing (NDT) of critical components is used to validate the existence or
absence of cracks or other load test effects indicated by this inspection. The periodic
load test requirement may be fulfilled by a concurrently performed proof load test.
d. There are three types of inspections for cranes.
1. Daily inspections:
e. After each formal inspection by an outside agency, qualified authorized personnel of the
agency are to prepare written, dated and signed inspection reports. These reports will
include a reference to the inspection procedure and adequacy of the crane and crane
components. Inadequacies are to be documented and, if determined to be a hazard,
corrected prior to further use. These reports are to be filed and be made readily
available by the organizational element responsible for crane inspection.
a. The Lifting Device Equipment Manager (LDEM) shall ensure that cranes have a
permanently affixed tag (red for critical lift use and for non-critical) with the following
information:
1. Thirteen digit equipment part number that has been assigned through the MAXIMO
database.
2. Next certification due date taking into account critical or non-critical use.
3. Rated capacity of crane (WLL - Working Load Limit).
4. Are plainly marked on both bridge and/or trolley sides of the crane and correspond
with the operator station or pendant control. Should the crane have multiple hoisting
units, each unit load blocks will be clearly marked, visible from the floor and
operators view.
a. The tag will state the discrepancy or issue, date, person applying the tag and
contact information.
b. The tag will be applied to the electrical disconnect or breaker in a durable
manner.
c. The only tag used is to be yellow colored and read "Caution, Special Condition”.
d. A lock is to be used in addition to the tag however it may not be red in color.
e. If the item or equipment will not receive a lock, a tag may be used alone and
must be securely attached with a one-piece, all-environment-tolerant nylon
cable tie in a manner so it cannot be inadvertently or accidentally detached.
f. Administrative locking and/or tagging will not be used as a means of protection
during a servicing, maintenance, or modification procedures, and is not a
substitute for lockout and/or tagout. See the NASA Ames Health & Safety
Manual Chapter 31 (Lockout/Tagout) for specific procedures to follow.
2. The crane is not used until the original discrepancy causing application of the
administrative locking has been resolved.
a. Records such as proof tests, load tests, operational tests, inspections, and audits of the
lifting safety program shall be maintained in accordance with APR 1440.1, NASA Ames
Research Center Records Management Program Requirements and the NASA
Records Retention Schedule.
b. Formal inspection records are kept on file with the Lifting device Equipment Manager
(LDEM).
c. Non-Formal inspection records are kept and made readily available by the organizational
element responsible for crane inspection.
a. These procedures may be part of the lift plan or a separate document such as in the
Emergency Procedures checklist found in the Appendix.
b. All lifts shall follow the procedures below at a minimum:
1. Power Loss.
2. Brake failure.
3. Other Emergencies.
a. Call 911 from an Ames phone or 650-604-5555 from a cell phone and report the
emergency.
b. Suspend all outside crane operations during thunderstorms.
a. For DOT packaged explosives, Safety personnel will be made available. Barricades and
warning signs will be erected to control access.
b. Explosives and EEDs that are not within DOT approved containers will be handled in
accordance with approved hazardous operations procedures. In addition to system
configuration controls, these procedures shall address:
1. Voltage checks on crane hooks that will handle explosives or EEDs will be
performed prior to the start of operations; including when crane is in motion.
2. The grounding of the crane hook prior to connecting to explosives or EED's for
static sensitive systems. If a ground connection will be disconnected to facilitate
operations, an alternate ground should be connected prior to disconnecting the
existing ground. The final attachment/detachment will need to be at least 10 feet (3
m) from exposed propellant grain, explosives, or EEDs.
3. The danger potential for radio transmissions near explosives will be evaluated prior
to the operation.
4. Personnel limits, protective clothing, warning signs and barricades.
5. Safety surveillance and inspections will be established as requirements.
b. Should significant issues or problems arise during the lift, a debriefing will be held to
discuss the problems and lessons learned. See the Lessons Learned section in this
chapter for additional information.
c. Personnel working with Mobile Cranes, Derricks, Hoists & Winches will complete the Lift
Determination form from the Appendix to determine if the lift is classified as critical or
non-critical five (5) days prior to the lift and then submit to the Construction Project
Manager.
d. Personnel working with Mobile Cranes, Derricks, Hoists & Winches will prepare a written
lift plan using the Non-Critical Lift Plan form found in the Appendix five (5) days prior to
the lift and then submit to the Construction Project Manager.
1. Ensure that ropes are not handled on a winch head without the knowledge of the
operator.
2. Ensure that while a winch head is being used, the operator is within convenient
reach of the power unit control lever.
1. Mobile cranes are required to receive an annual periodic load test and an
operational test the day of the lift. Rigging used for the lift are also required to
receive an annual load test.
c. Holding Brakes:
1. Two (2) holding brakes are required, each capable of bringing a rated load to zero
speed and holding it. The brakes are to be designed so that they can be tested as
required in paragraph 5.3.3.f of NASA-STD-8719.9 (Standard for Lifting Devices
and Equipment). This may be accomplished by the following means:
a. When brakes and clutches are used to control the motion of the hoist drum, two
independent means of braking are required to be provided which are a service
brake and an emergency brake. The service brake is to be capable of
functioning with power, and the emergency brake is to be set in the event of a
power failure.
b. For load hoists equipped with a mechanically linked hydraulic motor/brake
combination, the use of a counterbalance valve that locks the hydraulic fluid
when the valve is in the neutral position is an acceptable braking means. If a
free fall clutch is present in the hoist design between the hydraulic motor and
planetary disc, then a second independent holding or control brake is required.
d. Operational Tests:
1. The operational test for a modified crane/derrick can be tailored to test only those
portions of the equipment that were modified, only if the periodic load and
operational test interval has not expired. After a boom change on a crane/derrick
used for critical lifts, the operational test does not have to include verification of
each brake if it has been less than a year since the brakes were tested with a load
equal to or greater than the maximum capacity of the crane/derrick with the new
boom.
1. Cranes and derricks used for critical lifts are to be load tested at least once per
year. A periodic load test is to be performed after each boom change (when boom
disassembly/assembly is required) if the crane or derrick is to be used for critical
lifts.
f. Operation:
1. The load is not to exceed seventy-five (75) percent of the rated capacity for the
crane or derrick.
1. Each day of a Critical Lift, a Pre-Lift Safety meeting will be held with all lift
participants. For pre-planned multiple lifts, a safety meeting is to be performed prior
to each individual lift. The purpose of the meeting is to review the procedure, the
hazards, the responsibilities of each team member, and the Critical Lift
requirements. The following requirements are to be addressed:
a. That Lift Plan will be followed as approved.
If changes are made in real time, the Lift Project Manager may approve
changes in writing.
b. Lift items will have tag lines at both ends for controllability.
c. Hardhats and steel-toed boots are mandatory for all individuals.
d. No unauthorized personnel may enter the exclusion zone.
e. Gloves will be used as necessary, i.e., for holding tag lines.
f. Personnel will not be located under suspended or moving loads unless the
operation adheres to the OSHA-approved NASA alternative Standard for
Suspended Load Operations. (See NASA-STD-8719.9 (Standard for Lifting
Devices and Equipment), appendix A).
g. Lifts over seventy-five (75) percent of the rated capacity of a mobile crane are
not allowed for critical lifts.
i. Documentation:
4. Complete the Lift Determination form from the Appendix to determine if the lift is
classified as critical or non-critical five (5) days prior to the lift and then submit to the
Construction Project Manager.
5. Prepare a written lift plan using the Critical Lift Plan form found in the Appendix five
(5) days prior to the lift and then submit to the Construction Project Manager.
17.5.4 Load Test and Inspection Requirements for Mobile Cranes and Derricks
a. There are three types of load tests required for mobile cranes and derricks.
a. Before first use, all new, extensively repaired, extensively modified, or altered
cranes and derricks are to undergo a proof load test. Mobile cranes and
derricks are to be tested at the minimum practical working radius (and
maximum working radius for new cranes and derricks only), without interfering
with crane structure with a load as close as possible to, but not exceeding 1.10
times the rated load at the given radius. The load is to be lifted slowly and in an
area where minimal damage will occur if the crane/derrick fails.
3. Operational Test:
a. Performed in conjunction with proof load and periodic load tests, the operational
test typically moves the load through a full range of movement to determine if
the equipment (limit switches, emergency stop controls, brakes, etc.) is
functioning properly.
b. The proof load tests and operational tests are to be performed prior to first use
for new, extensively repaired, or altered cranes and derricks. This applies only
to those components directly involved with the lifting or holding capability of a
crane and derrick that has been repaired or altered. Repairs or alterations to
nonlifting, secondary lifting, or holding components such as suspension
assemblies, electrical system, or crane cab do not require a load test, although
a functional check should be performed to determine if the repairs or alterations
are acceptable.
c. All load and operational tests are to be performed by qualified personnel
according to written (specific or general) technical operating procedures. An
inspection of the crane or derrick and lifting components is to be performed after
each load test and prior to the crane or derrick being released for service to
ensure there is no damage. Surface or volumetric NDT of critical components is
required to validate the existence or absence of cracks or other load test effects
indicated by this inspection. The periodic load test requirement may be fulfilled
by a concurrently performed proof load test.
a. There are three types of inspections required for mobile cranes and derricks.
1. Daily Inspections:
a. These inspections are to be performed and documented prior to first use each
day the crane or derrick is used, and kept on file in the area.
1. Mobile crane operators shall provide the following documentation at the lift site for
verification:
a. All operators of mobile cranes and riggers shall be trained and certified by a recognized
certification organization that normally performs this function.
b. Critical lifts require a more rigid operator certification program than those operations that
involve routine lifts.
a. All personnel working with chains and winches for critical lift use shall follow the
requirements of NASA-STD-8719.9 (Standard for Lifting Devices and Equipment)
section 6.2.7 i.
b. A powered industrial truck is considered unattended if out of the operators' view or the
operator is MORE than 25 feet away regardless of being in the operators' view.
c. Perform a safety hazard analysis such as fault tree analysis, FMEA, O&SHA for
industrial trucks that are used for lifts where failure/ loss of control could result in loss or
damage to flight hardware. The safety hazard analysis it to include at a minimum:
1. Determine potential sources of danger.
2. Identity failure modes and recommended resolutions with a system of risk
acceptance for those conditions found in the hardware-facility-environment-human
relationship that could cause loss of life, personal injury and loss of/or damage to
the powered industrial truck, facility or load.
d. Critical lifts are lifts where failure/loss of control could result in loss of life, loss of or
damage to flight hardware or lifts involving special, such as spacecraft, one-of-a-kind
articles, or major facility components whose loss would have serious programmatic or
institutional impact. Critical lifts also include the lifting of personnel, lifts where
personnel are required to work under a suspended load and operations with special
personnel and equipment safety concerns beyond normal lifting hazards.
a. Three types of tests are required for Powered Industrial Lift Trucks:
1. Proof load test: prior to first use, all new, extensively repaired or altered powered
industrial lift trucks in accordance with the manufactures instructions and applicable
AMSE standard.
2. Periodic load test: conducted annually with a load equal to the rated load. See
Table 3 for Periodic Load Test Factors.
3. Operational tests: conducted simultaneously with proof test with a dummy rated
load unless otherwise specified.
a. Three types of inspections are required for Powered Industrial Lift Trucks:
b. All Powered Industrial Lift trucks shall have a legible data plate showing the capacity in
English or Universal weight measurements.
c. Document any deficiency found during the pre-operational inspection and remove from
service using administrative locking until steps are taken to correct deficiency.
a. Minimum operational and design features for lift trucks (on road and off road) shall
include:
1. A load backrest will be so installed to prevent loads from falling back and to cradle
loads when traveling.
2. Overhead guards will be installed to protect against falling objects hitting operators.
3. Attachments have to be treated as part of the load and authorized by the
manufacturer.
1. Proof load test: prior to first use, all new, extensively repaired or altered mobile
aerial platforms in accordance with the manufactures instructions and applicable
American National Standards Institute/Scaffold Industry Association (ANSI/SIA)
standard.
2. Periodic load test: conducted annually with a load equal to the rated load.
3. Operational tests: conducted simultaneously with proof test and a dummy rated
load unless otherwise specified.
a. The following practices shall be followed for mobile aerial platform operations:
a. For lines rated 50kV or below, minimum clearance between lines and any part
is to be ten (10) feet.
b. For lines rated over 50kV, minimum clearance between lines and any part is to
be ten (10) feet plus 0.4 inches for each 1kV over 50kV, or twice the length of
the line insulator but never less than ten (10) feet.
10. Outdoor use is prohibited in winds above 20 knots steady (23mph) or if gust exceed
25 knots (29mph) or as recommended by manufacturer.
11. Considerations will be made to weather conditions such as lightening and rain
before beginning work.
12. PPE is available and worn to include: gloves, hard hats, safety glasses, safety
shoes or other PPE as required.
13. Use a full body harness with an adjustable lanyard or Self Retracting Lifeline (SRL)
connected to an approved anchor point in the basket while working.
17.7.2 Inspections
17.8 Jacks
a. All personnel working with Jacks shall:
1. Ensure that a job hazard analysis is performed and that PPE is available and worn
to protect against the identified hazard.
a. Only high quality off the shelf OEM type equipment will be used if it is maintained,
designed and operated to the requirements in NASA-STD-8719.9 (Standard for Lifting
Devices and Equipment).
b. Critical lifts are lifts where failure/loss of control could result in loss of life, loss of or
damage to flight hardware or lifts involving special, such as spacecraft, one-of-a-kind
articles, or major facility components whose loss would have serious programmatic or
institutional impact. Critical lifts also include operations with special personnel and
equipment safety concerns beyond normal lifting hazards.
c. c. All personnel involved in critical lifting operations shall:
1. Ensure that Jacks clearly indicate the items below which can be painted on the
Jack or listed on the thirteen digit tag from the Maximo database tracking system:
a. The rated load capacity or WLL.
b. Hydraulic or air pressure force.
c. Type of hydraulic fluid to be used.
2. Ensure that jacks used to lift or support flight hardware is labeled and tagged as
specified in NASA-STD-8719.9 (Standard for Lifting Devices and Equipment).
3. Ensure that jacks used to lift or support flight hardware shall be operated or used as
specified in this chapter, OSHA 1926.1400, OSHA 1910.179, OSHA 1910.184,
ASME B30 series, Ames Safety Chapter 27 (Construction Safety Management) and
NASA-STD-8719.9 (Standard for Lifting Devices and Equipment).
a. Each formal inspection,the qualified personnel will complete a written, signed and dated
report. All noted discrepancies are documented and if determined to be a safety hazard
will be corrected prior to use of the jack. These reports will be filed and made readily
available by the organization element responsible for the jack inspection.
b. Inspections include the following:
1. Proof Load test: before first use, all new, or extensively repaired, altered jack will
undergo a proof test of one hundred twenty (120) percent of the rated load and
operated to it full length of travel in accordance to the manufactures instructions
and ASME B30.1.
2. Periodic load test: annual for all jacks.
3. Daily: prior to first use.
c. Document any deficiency found during the pre-operational inspection and remove from
service using administrative locking until steps are taken to correct deficiency.
Appendix A: Definitions
Lifting Devices and Equipment: Devices such as overhead and gantry cranes (including top
running monorail, underhung, and jib cranes), mobile cranes, derricks, hoists, winches,
special hoist supported personnel lifting devices, hydra-sets, load measuring devices,
hooks, slings and rigging, mobile aerial platforms, powered industrial trucks and jacks, used
for lifting and lowering.
Lifting Devices and Equipment Manager (LDEM): Person responsible for overall
management of the installation lifting devices and equipment program, coordinating with
appropriate personnel at their installation on lifting issues and providing their installations
position on lifting devices and equipment safety issues.
Lift Project Manager: The individual appointed by the supervisor within each directorate,
organization or program office for an individual lift to be the single point of contact. Lift
Project Manager’s can be a Civil Servant or Contractor and are responsible for all aspects of
coordinating, planning, and execution of a lift within the designated project area.
Load: The total load, including the sling or structural sling, below the hoisting device hook,
being raised or moved.
Load Measuring Device: A measuring device below the hook that is part of the load path for
lifting operations.
non-critical lift: A lift involving routine lifting operations governed by standard industry rules
and practices except as supplemented with unique NASA testing, operations, maintenance,
inspection, and personnel licensing requirements contained in this standard.
Operational or Working Load: A value representing the weight of the load actually being
handled plus the weight of the attaching equipment (slings, Hydra-set, spreader bars, etc.).
Operational Test: A test to determine if the equipment (limit switches, emergency stop
controls, brakes, etc.) is functioning properly.
Periodic Load Test: A load test performed at predetermined intervals with load greater than
or equal to the rated load, but less than the proof load.
Proof Load: The specific load or weight applied in performance of a proof load test and is
greater than the rated load.
Proof Load Test: A load test performed prior to first use, after major modification of the load
path or at other prescribed times. This test verifies material strength, construction, and
workmanship and uses a load greater than the rated load. Proof load test, as used in this
standard, is equivalent to the OSHA rated load test.
Rated Load or Safe Working Load or Rated Capacity: An assigned weight that is the
maximum load the device or equipment can operationally handle and maintain. This value is
marked on the device indicating maximum working capacity. This is also the load referred to
as "safe working load" or "working load limit". If the device has never been downrated or
uprated, this also is the "manufacturer's rated load."
Record: an electronic, written, or printed object that provides evidence of what was done or
has occurred in the past
Safety Lift Observer (SLO): Individual designated during each critical lift as responsible for
the safety of the operations. That person may be the LDEM or a safety professional, a
supervisor, an engineer or a task leader, provided he or she has appropriate training and
background in lifting operations with an understanding of lifting safety.
Single Failure Point: A single item or component whose failure would cause an undesired
event such as dropping a load or loss of control.
Sling: A lifting assembly and associated hardware used between the actual object being
lifted and hoisting device hook.
Standby Lifting Device: Lifting device that is not in regular service but used occasionally or
intermittently as required. Intermittent use is defined as a lifting device which has not been
used for a period of one month or more, but less than 6 months.
Appendix B: Acronyms