Crane Operation Plan and Safety Measures

Project: Detailed Design, Rehabilitation and Construction
of Bridges (Bridge No.1-35) Between Lae Nadzab and

Henganofi
No: NPC 2020-50 (BCW1)
Metallurgical
Title: Crane Operation Plan and Safety Measures Date:06/3/2024
corporation of china ltd
CRANE OPERATION PLAN AND

ENVIRONMENTAL, HEALTH AND
SAFETY MEASURES
INSERT PICTURE
REVISION HISTORY
Revision Date Prepared MCC Reviewed by Description
by Approval for of Change
Release by
0 06/03/2024 Junior Kare Mr Zang New
(MCC HSE) Meng -
Project
Manager
1
Henganofi
No: NPC 2020-50 (BCW1)
Metallurgical
Contents
1. INTRODUCTION.............................................................................................................................4
2. SCOPE............................................................................................................................................4
3. PURPOSE........................................................................................................................................4
4. ROLES AND RESPONSIBILITY..........................................................................................................4
4.1 Project Manager....................................................................................................................4
4.2 Construction Manager...........................................................................................................4
4.3 Site Engineer..........................................................................................................................4
4.4 Safety Manager......................................................................................................................5
4.4.1 Safety Officer.................................................................................................................5
4.5 Environmental Manager........................................................................................................5
4.5.1 Environmental Officer/Specialist...................................................................................5
4.6 Supervisor..............................................................................................................................5
4.7 Leading Hand.........................................................................................................................5
5. DETAILED WORK AND LIFTING PLAN.............................................................................................5
6. RISK ASSESMENT AND SAFETY MEASURES....................................................................................5
6.1 Potential Hazards and Risk Control/Safety Measures............................................................6
7. CRANE AND EQUIPMENT INSPECTION AND CERTIFICATION.......................................................15
8. COMMUNICATION AND EMERGENCY RESPONSE PLAN..............................................................15
8.1 Communication...................................................................................................................15
8.2 Emergency Response...........................................................................................................15
8.2.1 Emergency Wardens....................................................................................................16
9. ENVIROMENTAL PROTECTION MEASURES..................................................................................16
9.1 Environmental Conditions That Impact Crane Safety..........................................................16
9.1.1 Power Lines..................................................................................................................16
9.1.2 Ground conditions.......................................................................................................17
9.1.3 Weather.......................................................................................................................17
10. TRAFFIC MANAGEMENT..........................................................................................................17
Henganofi
No: NPC 2020-50 (BCW1)
Metallurgical
10.1 General Objectives...............................................................................................................19
10.2 General Principles................................................................................................................19
10.2.1 Planning Ahead............................................................................................................19
10.2.2 Safety of Workers........................................................................................................20
10.2.3 Check the Signs Carefully.............................................................................................20
10.2.4 Fix the Signs Properly...................................................................................................20
10.2.5 Provision for Pedestrians.............................................................................................20
10.2.6 Keeping the Site Tidy...................................................................................................20
11. COMPLIANCE MONITORING....................................................................................................21
11.1 Environmental Monitoring...................................................................................................21
11.2 Safety Monitoring................................................................................................................23
12. REPORTING..............................................................................................................................23
13. APPENDIX.................................................................................................................................24
13.1 Appendix 1: WORKING ENVIRONMENT (SITE) CHECKLIST...................................................24
Henganofi
No: NPC 2020-50 (BCW1)
Metallurgical
1. INTRODUCTION
BCW1 Contractor, Metallurgical Corporation of China (MCC) was awarded the Contract No:
NPC 2020-50 for the Detailed Design, Rehabilitation and Construction of Bridges (Bridge
No.1-35) between Lae Nadzab and Henganofi. This is part of a larger program of works, the
Sustainable Highlands Highway Investment Program (SHHIP). The BCW1 project is located
within the provinces of Morobe and Eastern Highlands, Papua New Guinea.
The BCW1 section of the project has a total length of 210 KM, starting from Nadzab Junction
turnoff in Lae, Morobe province and ending at Kamontina River Bridge in Henganofi, Eastern
Highlands Province.
2. SCOPE
For the BCW1 section, the construction works includes a total of eleven (11) bridges to be
reconstructed at existing locations, three (3) bridges to be relocated at new locations and 21
bridges to be repaired or reinforced, altogether, a total of 35 bridges for BCW1 contractor.
3. PURPOSE
This operation plan includes safety measures, risk analysis and assessments, environmental
impact assessment and mitigation measures, communication and emergency response plan
and reporting procedures to ensure control, assurance and compliance during crane operations
in the 14 bridge construction areas.
4. ROLES AND RESPONSIBILITY
4.1 Project Manager

The Project Manager is directly responsible to the Engineer in ensuring the
implementation of this Operation Plan. This is to ensure crane operation works are done
in safe and sound manner and in accordance with the approved Health and Safety, Traffic
Management Plan and the CEMP. He reports to the Engineer on the progress and conduct
of the works.
4.2 Construction Manager

The Construction Manager shall be directly responsible to the Project Manager in
ensuring that the works are done in a safe and timely manner and in accordance with good
and sound engineering practices. He shall oversee the overall conduct of the field works
in terms of compliance to the quality, safety, social and environmental aspects.
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Metallurgical
4.3 Site Engineer
The Site Engineer shall be responsible for ensuring that the crane operation works are
done in accordance with this management plan and other sub plans for compliance.
4.4 Safety Manager

The safety manager will communicate with the construction manager with regard to all
safety aspects of the operation and will directly report to the project manager. He will
direct the safety officer on ground on whatever necessary tasks to attend
4.4.1 Safety Officer

The safety officer will be responsible for monitoring and reporting to the safety
manager
4.5 Environmental Manager

The Environmental Manager will work closely with the Construction Manager, Site
Engineer and the Safety Manager to ensure that the works are done with minimal effects
to the environment and shall institute mitigating measures to lessen the impacts of
construction to the environment. He shall have the power to effect changes to the
Contractor’s construction practices that adversely affect the environment.
4.5.1 Environmental Officer/Specialist

The Environmental Officer/Specialist is responsible for monitoring during
operation of the crane to ensure all works are done in an environmental friendly
manner and in compliance. He reports to the Environmental Manager.
4.6 Supervisor
Plan and obtain required manpower and resources in coordination with the Site Engineer.
Carry out all activities as per the planned schedule to achieve target dates. Coordinate
with respective disciplines of work and liaise with the site engineer for day to day
activities. Inform Discipline Engineer regarding site inspections when it is ready. Ensure
pre-task briefing is to be conducted prior to start of work at each session.
4.7 Leading Hand

Works shall be executed as per direction of Supervisors/Foremen for all activities as per
the planned schedule to achieve target. Coordinate with respective disciplines of work
and liaise with the Supervisors/Foremen for day to day activities. Ensure pre-task briefing
is conducted prior to start of work at each session.
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No: NPC 2020-50 (BCW1)
Metallurgical
5. DETAILED WORK AND LIFTING PLAN
6. RISK ASSESMENT AND SAFETY MEASURES
Risk management is a systematic process of Hazard Identification, Risk Assessment and Risk
Control with the aim of providing healthy and safe conditions for workers. The bridge works,
in this case the crane operations with its associated activities/works requires an effective risk
management to be implemented so as to achieve the HSE targets of the Contractor. MCC
adopts a ZERO Incident approach.
6.1 Potential Hazards and Risk Control/Safety Measures

There are potential hazards in crane operations which can be mitigated and/or avoided
and these measures must be adhered to at all times.
Table 1: Potential Hazards and Safety Measures
1. GENERAL POTENTIAL HAZARDS AND RISK CONTROLS

A GENERAL HAZARDS RISK CONTROLS & GENERAL PRECAUTIONS
A1 Unintended movement of When driving or operating the machine, do not wear
plant due to clothing getting clothing with dangling parts, which might catch on
caught or tangled in control control levers or mechanical parts. Wear appropriate
levers and mechanical parts. personal protective equipment as necessary.
A2 Unintended movement of Do not operate the crane when you are excessively
plant from operating wrong fatigued or unwell.
controls or errors in judgment.
Read the Operators Manual & Risk Assessment (“this
manual”) thoroughly, familiarizing yourself with all
controls before you start operating the crane.
Follow instructions and warnings in this manual and

on plates and stickers mounted on the machine. If there
is something you do not understand, have it explained
to you. If the manual is lost, or a warning label is
illegible, replace it.
A3 Fire and emergency response. Carry a fire extinguisher and first aid kit in the crane.
Learn how to use the fire extinguisher before an actual
emergency situation arises.
A4 Fire from handling chemicals Do not smoke or use fire near fuel, oil, antifreeze,
batteries or other chemicals, which could ignite.
Extinguish all fires and potential sources of ignition

when handling these flammable materials.
Before refuelling the crane, switch off the engine and

check that there are no fires or potential sources of
ignition nearby.
After refuelling securely fasten all fuel and oil caps

Henganofi
No: NPC 2020-50 (BCW1)
Metallurgical
and wipe off any spillage.
Refuel and change oil in a well-ventilated work area.

B GENERAL HAZARDS – RISK CONTROLS & GENERAL PRECAUTIONS
WORKING PROCEDURES
B1 Unfamiliarity with site Plan for Pick & Carry crane operations as early as
conditions or scope of work possible. Planning should involve inspection of the
site, consultation with all persons involved in the work
such as the principal contractor, crane hirer, energy
suppliers, employer, dogman, spotter, site foreman and
crane operator.
B2 Not observing instructions on Observe all instructions on the warning labels. Ensure
warning labels could cause that all warning labels are clean and legible. If the
operation beyond limitation of warning labels are damaged or illegible replace them.
plant.
B3 Collision with people or Before starting work, check the work area for the
objects in work area. presence of roads, overhead power lines, nearby
structures, other cranes, aerial hazards and other
obstructions.
Isolate the work area by using witches hats, temporary

barriers or fencing. People, vehicles, etc. should be
prohibited from entering the isolated area.
Consult the principal contractor, site supervisor, the

other crane operators and everyone involved with the
work and prepare a safety plan for the job.
Always be aware of your surroundings and the hazards

while you work.
B4 Collision with other plant and When operating a Pick & Carry crane, consider
structures. hazards such as overhead power lines, nearby
a. During articulating or structures, other cranes, high obstructions and other
reversing mobile equipment within the crane working area.
b. From dirty windows and
mirrors a. When you need to articulate or reverse in areas of
c. From poor lighting. restricted visibility, place a guide or use a spotter and
d. From adverse follow their instructions.
b. Keep the cab windows, mirrors, wipers and working

lamps clean.
c. When working in areas with poor lighting switch on

the lights. If required use additional illumination
(mobile lighting can be hired from equipment hire
places).
d. When visibility is bad due to fog, snow, rain, or

other adverse
B5 Collision with people or other When working on public roads, position a guide and
vehicles when working on erect fences, witches hats, etc.
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No: NPC 2020-50 (BCW1)
Metallurgical
public roads
Observe all the traffic rules and safety regulations and
laws of the Country or State where the crane is being
used
B6 Collision with objects and Discuss your requirements with the site supervisor. If
people working in the work you consider that the people and equipment in the area
area. has to be removed before you operate the crane,
discuss it with the site supervisor so the necessary
arrangements can be made.
B7 Electrocution from live Take the following precautions when working near
overhead conductors. If you power cables.
are working close to power a. Contact the managing company in advance and
cables you can also receive a arrange for electricity to be switched off (if
shock even if the crane does possible),or arrange for cables to be fitted with
not physically contact the protective devices.
cables. b. Keep a safe distance between the machine and
the power cables. Consult the electricity
authorities on the location and voltage of
cables on the site and the minimum isolation
distance.
c. Use a spotter and follow their instructions.
B8 Electrocution from lightning If thunderstorms are approaching, lower the boom, turn
strikes. A crane with a long off the crane and get out of the crane. Resume work
boom is prone to lightning when the thunderstorm ceases.
strikes.
B9 Inadvertent movement from Work according to signals. Choose one person to be
poor signalling. If the signaller the signaller. Before starting the job the controller, the
does not signal appropriately signaller, the sling handler and other workers should
with the sling handler and confer on signal procedures in order to work safely
other workers there could be under the direction of the signaller.
an accident.
B10 Collision between two cranes Determine signals for joint operations in advance. If
working together. two or more cranes are working together on a site
ensure that all parties involved discuss the work plan
and clearly define the lines of communications.
B11 The crane could tip over due a. Stop work in strong windy conditions. If the
to: wind has a gust speed of 10m/s or more retract
the boom, turn off the crane and get out of the
a. Strong windy machine. Resume work when the gust speed is
conditions. Loads with below 10m/s.
large volumes or b. Check that the ground conditions are stable
surface areas have and level over the entire intended path of
larger wind forces travel. Do not operate the crane on unstable
acting on them. The ground.
wind forces and the c. Articulate the crane slowly and smoothly.
loads from the
suspended objects act
on the crane and could
cause the crane to tip
over.
b. Poor ground
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No: NPC 2020-50 (BCW1)
Metallurgical
conditions.
c. Rapid articulation.
C HAZARDS – PRE- RISK CONTROLS & GENERAL PRECAUTIONS
OPERATIONS
C1 inadvertent operation of Keep the area of the operator's cabin and seat clean and
plant due to poor tidy. Do not leave parts, tools or other objects in the area
housekeeping of the operator's seat. These can cause unexpected
accidents while you are working.
C2 Stress and tiredness from Adjust the operator's seat so that you can sit comfortably
poor sitting position and with good posture, and all control levers are within easy
posture. reach without having to lean or strain your body. Check
that you can reach the foot pedals comfortably with your
back resting against the back of the seat.
C3 Accidental operation of Before and during work, nobody other than the operator
plant if operated by more should sit in the operator's seat or climb onto the crane.
than one operator.
Passengers may collide
with obstructions or be
thrown off the machine, or
they may cause a hazard by
obstructing the operator's
field of view
C4 Slips, trips and falls when Take the following precautions when you get in and off
getting on or off the plant. the crane.
a. Check that all guards and covers on the machine
are fastened correctly. Tighten any loose bolts or
repair any damage.
b. Wipe off any mud, oil or snow on the steps before
you start work.
c. Do not jump onto or off the machine.
d. Do not hold onto the seat, control box, control
levers or anything other than the hand- grips
provided when you get on or off the machine.
e. Do not get on and off the machine while it is
moving.
C5 Dropping of load Check safety devices. Pick & Carry cranes are fitted with
various safety devices which should be checked before
starting work.
C6 Crane overload or tip over Check the operation of the crane computer / Load
in adverse working Moment Indicator (“LMI”) according to the pre-
configuration operational check procedure described in the Operators
Manual (this manual should be kept in the crane cabin).
C7 Failure of controls and/or Before operating the crane check the machine according
mechanical parts of plant. to the pre-operational checking procedure detailed in this
manual. Check the operation of the control levers while
the crane is not carrying any load.
Allow the crane to warm up before carrying full load.
Ensure that the crane is serviced regularly in accordance

with this manual.
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No: NPC 2020-50 (BCW1)
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C8 Dropping of load Check all safety and warning devices. Pick & Carry
cranes are fitted with various safety devices, which should
be checked before starting work.
Carry out regular servicing of the crane in accordance

with the recommendations in this manual.
C9 Falling objects (during Erect and maintain effective barricades around the mobile
erecting and dismantling crane. Only allow persons who are directly involved Pick
activities) could damage & Carry crane operations inside the area.
property and present a risk
of injury to workers and Schedule the erecting and dismantling of the crane to
members of the public. occur when the movement of other persons and mobile
plant at the workplace is at a minimum.
2. OPERATIONAL POTENTIAL HAZARDS & RISK CONTROLS
A HAZARDS - STARTING RISK CONTROLS & GENERAL PRECAUTIONS
THE ENGINE
A1 Fire from spills Keep the engine and surroundings clean. Do not leave
tools, rags, or anything else in the engine compartment.
After inspection and maintenance wipe off any spilled oil
or fuel. Check that flammable material is not scattered
about or piled up near the engine.
A2 Accidental movement of Only start the engine when seated in the operator’s seat
the crane.
A3 Operating the crane when it Always attach warning tags on control levers of the
is being serviced or machine when it is being serviced or repaired. Isolate the
repaired. machine where possible.
A4 Collision with people and Check for people and objects near the crane before you
objects start the engine. Concentrate on the job and always be
aware of people and equipment approaching the crane.
Erect temporary barriers around the crane if necessary.
A5 Unintended movement of Before starting the engine check that all levers, pedals and
the crane on start up. switches are in their neutral or OFF positions
B HAZARDS WHEN RISK CONTROLS & GENERAL PRECAUTIONS
OPERATING THE
CRANE
B1 Structural failure or tip over Do not exceed the lifting capacity of the crane. If unsure
of the crane during of the lifting capacity, always check the rated lifting
operation. capacity chart. Lifting capacity varies with the boom
length and working radius.
Always check that all safety devices and warning systems

are functioning properly. Do not operate a crane if any of
the safety devices or warning systems are faulty.
B2 Collision from swinging Avoid sudden movement or violent operation of the
load or reduced stability of crane. Operate the levers and pedals smoothly. Start,
the crane. accelerate, decelerate, articulate and stop the crane
smoothly and securely.
When lifting long loads tie a guide rope to each end of the
load. This will prevent the load from swinging whilst it is
being lifted.
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Metallurgical
Compound operations, such as combining winch hoisting

or lowering, articulating, luffing and telescoping will be
slower than the individual operations. When switching
from compound to single operation, work the controls
slowly and smoothly with no sudden change in speed or
direction.
B3 Collision if operator is not Do not operate the crane if you are tired or cannot
concentrating on the job concentrate on the job.
Always be alert and watch that the boom or the suspended

load does not collide with people or buildings and the
load does not collide with the boom.
B4 Operating the crane by Only operate the crane while seated in the operator’s seat
reaching in through the
door or window. (The
operator is not in full
control of the crane and
could cause the crane to
collide with people,
buildings and other
objects).
B5 Dropping of the load from Never leave a suspended load on an unattended crane.
an unattended crane. When leaving the crane, always lower the load to the
ground, switch off the engine, lock the crane and take the
keys with you.
B6 Dropping of load, damage Carry out the following checks before lifting a load.
or tip over of the crane due a. Check that the total weight of the load (including
to overloading or unstable the weight of slings, hook and attachments) is
load. below the rated capacity of the crane.
b. Check that the number of parts of line on the
winch rope is a standard number according to the
rated lifting capacity.
c. Check that the slings are properly positioned to
lift the load above its centre of gravity.
d. Check that the winch rope is hanging vertically.
When the load just leaves the ground pause until it stops
swinging. Confirm that the load is stable before
continuing to hoist.
B7 Dropping of load from To prevent the load from falling off or slipping out of the
insecure slings or hook. slings, pay attention to the following points when
arranging the sling.
a. The slings or chains should be of the right
capacity and in good condition.
b. Arrange the slings so that they do not get tangled
with each other.
c. The hook is fitted with a retainer to prevent the
slings from slipping out. Check that the hook is in
good condition and the retainer is operating
correctly.
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d. Place a protector (some soft material) to prevent
the rope from damage where it comes into contact
with the corner of the load, and elsewhere where
the sling is prone to damage
B8 Damage to the crane or When lifting a load the boom flexes and increases the
reduced stability when working radius. This is more noticeable with a very heavy
working with a heavy load load or long boom. Allow an extra margin below the rated
and long boom. lifting capacity to compensate for the increased working
radius.
B9 Overload due the increased Lift the load off the ground carefully. Hoist the load
flexure of the boom when vertically and pause briefly when the load is just off the
the load is lifted suddenly. ground to confirm the sling and that there is no overload.
Then resume hoisting.
B10 Damage to crane or Never lift the load off the ground by luffing or extending
reduced stability if the load the boom. Wait until the load is just off the ground before
is lifted off the ground by luffing or extending the boom.
luffing or extending the
boom.
B11 Damage or injury caused Before moving the load sideways check that it is safe to
by personnel under the load do so. The path of the load or crane should be clear of
when articulating. people or obstructions.
B12 Collision or dropping of Do not move the suspended load above people’s head
load on people.
B13 Damage or injury caused Read and understand the Operators manual regarding
by loss of stability due to operation on sloping ground. The rated capacity of the
operation on sloping machine should be reduced when lifting on or traversing
ground sloping / uneven / out of level terrain.
Do not operate the machine on sloping ground outside the

limits described in this manual and the machine load
chart.
Plan lifts carefully when operating on uneven terrain.
Operators must be able to perform a manual calculation to

reduce the safe working load of the machine if a lift plan
is unavailable.
Some Pick & Carry cranes may be fitted with crane

computers which can perform a reduction in rated
capacity. Refer to the operators’ manual to check if this
function is available on the machine in use.
B14 Collision with obstacles If the wire rope becomes entangled with an obstacle,
from entanglement of wire carefully disentangle it without further hoisting or
rope during hoisting or slewing. Place the load back on the ground and check that
articulating. the wire rope is not damaged before resuming
B15 Overload and tip over of Lower the load to the ground using the winch. Avoid
the crane by sudden raising sudden raising and lowering of the boom as it makes the
or lowering of the boom. crane prone to tipping over.
B16 Damage to the boom or tip Never drag a load sideways, hoist it diagonally or drag it
over of the crane if the load towards the crane. Luffing or hoisting to drag the load
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is not lifted from a position sideways or lift it diagonally subjects the crane to forces it
above its centre of gravity. was not designed for. These additional forces will damage
the boom or cause the crane to tip over.
Follow the signaller and lift the load vertically.

B17 Impact from falling objects
If there is an earthquake when the crane is operating, the
during an earthquake. vibrations feel greater and more alarming from the
elevated position of the operator’s seat. Stop work
immediately and respond to ground deformation or falling
objects as follows:
a. Lower the load to a safe place.
b. Articulate away from the danger of falling or
toppling objects and then lower the boom.
c. Stop the engine.
d. To avoid being thrown out of the cab (by the
vibrations caused by the earthquake) fixes you in
position with your hands and feet until the
earthquake stops. If the door is open close it and
secure it.
To resume work after the earthquake has ceased and there
is no likelihood of further tremors, thoroughly check the
ground conditions. Look for damage to any part of the
crane, check the operation of the crane computer and
check hooks and slings for any abnormalities. Inspect the
load for signs of movement of damage.
B18 Cabin noise when operating Refer to the Db ratings on the noise certificate in the
the crane. (An operator Operator’s Manual, and Occupational Health and Safety
subjected to high noise guidelines (for noise levels and the time an operator can
levels over a prolonged be safely subjected to these noise levels without adversely
period of time can become affecting his or her health) in your state or country. If the
temporarily or permanently noise levels and period of exposure are high, use
deaf) appropriate hearing protection.
3. POST-OPERATIONAL POTENTIAL HAZARDS AND RISK CONTROL
A POST OPERATION RISK CONTROLS & GENERAL PRECAUTIONS
HAZARDS
A1 Inadvertent or unauthorised Take the following precautions:
operation of crane can a. After finishing work, stow the crane and lock it.
cause accidents. b. Do not leave the crane in its working position –
this can cause accidents
A2 Collision from crane rolling Take the following precautions:
down a slope a. Park the crane in a safe and level location. If there
is no level location to park on, and the crane has
to be parked on an incline, place chocks under the
wheels to prevent the crane from moving.
b. Ensure that the parking brakes are engaged.
A3 Collision of parked crane Take the following precautions:
with passing vehicles. a. If possible park the crane off the road.
b. If the crane has to be parked on a road, park it in a
safe and level location. Avoid parking around
bends, just after the crest of a hill and where an
approaching driver’s vision is obscured.
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c. Observe the safety regulations and laws of the
state or country where the crane is being used.
A4 Mechanical failure of the Ensure that the crane is maintained in accordance with the
crane. manufacturer’s requirements. After operating the crane,
check the crane for damage or signs of failure. Repair or
replace damaged or worn parts. Replenish greases and
oils as required.
A5 Damage from unauthorized When the machine is not being used, lock the doors and
use of the crane. take the keys away.
4. INSPECTION AND MAINTENANCE POTENTIAL HAZARDS AND RISK
CONTROL
A INSPECTION AND RISK CONTROLS & GENERAL PRECAUTIONS
MAINTENANCE
HAZARDS
A1 Failure of controls or If there is a breakdown or malfunction of a control or
mechanical parts of the crane component or part, repair or replace it immediately.
crane. Do not, under any circumstances, start a crane, which
requires repairs.
A2 Equipment malfunctions Always keep the crane in good state of repair and serviced
from incorrect tuning. regularly. Use authorized Terex dealers or service agents
to keep the crane in top operating condition. Terex
authorized dealers and service agents thoroughly
understand the Terex cranes, and are trained and equipped
to ensure that you get the best possible returns from your
investment.
A3 Collision from a run-away When inspecting and maintaining the crane, park on level
crane if not parked on level ground and always engage the parking brakes. Also place
ground. chocks under the wheels for additional safety.
A4 Inadvertent operation of the Always place warning signs on the crane when it is being
crane during inspection and services or repaired. Whenever possible, stop the engine
maintenance. and remove the keys. Isolate the crane where possible.
A5 Mechanical failure through When topping up or replacing fuel or hydraulic oil, take
corrosion from oils care to avoid the entry of water or other contaminants.
contaminated with water. Ensure that the oils are changed regularly according to the
instructions in the crane service schedule.
A6 Environmental hazards Drain waste oil from the crane into a proper container
from waste oil. designed for the purpose. Dispose the waste oil in
accordance with the regulations of the state or country.
Never allow waste oil or other contaminants to get into
the storm water system, streams, rivers or wetlands.
A7 Fire from flammable Do not weld, solder or heat with a torch on or near
vapours generated by hydraulic equipment or pipes. Heat applied on pressurized
heating the hydraulics. pipes or rubber hoses could cause them to rupture. Cover
the pipes and hoses with fire-resistant materials before
applying heat near or on them.
A8 Crushing from dropping Use the winch rope for the crane. Check that the wire is
load or parts of plant due to not damaged before operating the crane
broken wire ropes.
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7. CRANE AND EQUIPMENT INSPECTION AND CERTIFICATION
8. COMMUNICATION AND EMERGENCY RESPONSE PLAN
8.1 Communication
The channel of communication is specified in Section 4 and its Sub Sections. The
most common method of communication to be used will be the use of mobile
phones.
8.2 Emergency Response

The contractor has its approved emergency response plan in case of emergencies.
Table 2: Emergency Response Team
PERSON’S RESPONSIBILITIES
EMERGENCY CONTROLLER (EC) Shall be in co-ordination with Incident
(Project Manager) controller, Emergency coordinator and
assess the emergency situation.
INCIDENT CONTROLLER (IC): Shall be in co-ordination with
Civil/Site Engineers emergency controller and emergency
coordinator.
Ensure all works are stopped, assess the
situation and follow the emergency
plan.
Ensure all employees are evacuated
immediately from the scene.
EMERGENCY COORDINATOR: Shall be in co-ordination with
Health & Safety Officer emergency controller and emergency
coordinator.
Alternate Member: Public Relations Ensure all works are stopped, assess the
Officer situation and follow the emergency
plan.
Ensure all employees are evacuated
immediately from the scene.
LOGISTICS COORDINATOR: MCC Shall be in coordination with emergency
Administrator coordinator and extend the service of
vehicles for evacuation / transport of
Alternative Member: MCC Asst. victims as and when required.
Administrator Coordinator shall ensure that spare
vehicle is readily available to response
to emergency events. Also vehicles shall
be adequately maintained and have
enough fuel.
Source: MCC SHHIP BCW1 Emergency Response Plan
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No: NPC 2020-50 (BCW1)
Metallurgical
8.2.1 Emergency Wardens
Shall be in coordination with Emergency coordinator and activate manual
emergency alarms as directed and will assist all employees for safe
evacuation and direct them to assembly point. This is to ensure all
employees are safely evacuated by cross-checking the assigned areas.
Table 3: Emergency Wardens
EMERGENCY WARDENS
NAME/
S MOBILE
ALTERNATE DESIGNATION RESPONSIBILITIES
I NUMBER
MEMBER
Project Manager/ Area Site
1 Zhang Meng 79340007 Emergency Controller
Manager
2 Dai Liwen 73782480 Planning Manager Incident Controller
Emergency
3 Zhang Daihong 71866583 Safety Manager
Coordinator
4 Yang Tinghui 73245017 Construction Manager Logistic Coordinator
5 Wang Huigang 74284309 Environmental Manager Emergency Wardens

6 Junior Kare 72557528 HSE Specialist Emergency Wardens
7 Brian Purari 70174920 Safety Officer Emergency Wardens
Source: MCC SHHIP BCW1 Emergency Response Plan
9. ENVIROMENTAL PROTECTION MEASURES
9.1 Environmental Conditions That Impact Crane Safety

Cranes vary in size and load capacity; they all have to be operated with care and
caution to protect workers and the public. And before any work can take place, it’s
important to ensure proper ground and environmental conditions.
9.1.1 Power Lines

In the planning stages and before any work can begin, those in charge need
to request that utility owners and/or operators provide them with voltage
information of power lines in the vicinity. They must also consult with
utility companies before performing work in close proximity to power
lines
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No: NPC 2020-50 (BCW1)
Metallurgical
9.1.2 Ground conditions
Given the size and weight of the majority of cranes, it’s vital to monitor
ground conditions on the worksite. The controlling entity (usually the
contractor or employer) is responsible for ensuring that the conditions are
sufficient for crane assembly.
The ground needs to be firm, drained and graded, and able to support the
crane (in conjunction with blocking, mats, etc.). In addition, the
controlling entity must inform the crane operator of known underground
hazards such as utilities, and provide them with all other information
known about ground conditions.
9.1.3 Weather
The importance of weather when performing crane assembly and
operations cannot be overstated. Various weather conditions can affect
ground stability, visibility, workers’ performance and grip and, in extreme
circumstances, even lead to a crane overturning.
This is why it’s so important to include weather in the employer’s work

plans. Additionally, weather should also be one of the topics discussed at
each safety meeting. Although people working with cranes are regularly
exposed to the elements and working in the rain or scorching heat is
nothing new, sometimes it might be wise to consider if certain conditions
are worth the risk.
Due to the nature of their job, cranes need to be assembled and

disassembled at various different locations and environments. This is why
considering all the conditions that could have an impact on the crane’s
performance and safety need to be considered. Ground conditions,
electrical safety and the weather are the usual suspects, but it’s worth
considering anything and everything that could affect the stability and
performance of the crane and the performance of the crew, including
human factors and work processes that may inadvertently increase the risk
of a crane-related incident.
10. TRAFFIC MANAGEMENT

The Contractor shall give careful attention and manage the flow of traffic on the
existing road throughout the construction stages of the work. Measures shall be made
to minimize any inconvenience to the riding public and shall facilitate construction
with minimal obstruction. Equipment shall be deployed to any areas to remove any
breakdown vehicle to prevent obstruction to the passing traffic.
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No: NPC 2020-50 (BCW1)
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Figure 1: Traffic Management Plan
Source: PNG DOW Field Guide (Safe Traffic Controls at Road Works & MCC BCW1 Traffic
Management Plan
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No: NPC 2020-50 (BCW1)
Metallurgical
10.1 General Objectives
For the effective and smooth passage of vehicles and equipment during the whole
construction period, the Contractor will give careful attention and will manage the
flow of traffic on the existing road. The Contractor will minimize any
inconvenience to pedestrians, motorists and the public and will facilitate execution
of the Works with minimal obstructions.
Without limiting the generality of the foregoing, the Contractor will provide and
install appropriate warning signs and barriers at conspicuous places clearly visible
to pedestrians, motorists and construction operatives for their proper guidance and
safety during the whole construction period.
Traffic Control Aides will be assigned at work sites where construction activities
will affect the flow of traffic particularly but not limited to structure and other
sites where detour roads may have to be provided during construction. The
Traffic Control Aides will be provided up to 24 hours a day or as long as
necessary to ensure the safety of the public and the works.
Where necessary to facilitate the construction of major work items, the Contractor
will provide diversion or detour roads in accordance with the guidelines of
Government Authorities. On completion of the phase of work, such temporary
access or detour roads will be removed and the site will be reinstated to its
original condition.
10.2 General Principles

The Contractor will ensure that the works are safe and will not cause traffic
problems, which means that all road works will be properly signed. The
following discussions will demonstrate how this will be done.
4.1.1 Provision of Signs
The Contractor will provide the necessary warning signs to warn the road
users that there is a hazard ahead so that they can be ready to take action.
The signs will inform them the things to expect so that they will know
what maneuver or action to make and will direct them how to pass through
a hazard in a safe manner. The signs will also protect the road workers
and keep traffic delays to a minimum.
10.2.1 Planning Ahead
With the help of this Traffic Management Plan, the Contractor will
determine what signs and cones are needed before the work starts. Police
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No: NPC 2020-50 (BCW1)
Metallurgical
assistance will be obtained in difficult and tight situations or where
necessary. Permission from highway authorities will be obtained where
required.
10.2.2 Safety of Workers

All persons working on or near the road will be made to wear brightly
colored clothing, preferably an orange or yellow waistcoat.
10.2.3 Check the Signs Carefully

The signs will be checked carefully so that the road users will understand
exactly what is happening and what is expected of them. The signing will
be altered as the work proceeds so that it is always consistent with the
work in progress.
10.2.4 Fix the Signs Properly

The signs will be fixed properly. They will be mounted off the ground,
either on upright posts or frames. In order to ensure that the signs cannot
be blown over or dislodged by moving traffic, additional weight will be
placed on the base. The signs will be checked regularly to see that they are
in place and will be cleaned when necessary.
10.2.5 Provision for Pedestrians

Where the works will obstruct a footway, a safe and clearly marked
alternative route for pedestrians will be provided.
10.2.6 Keeping the Site Tidy

The Contractor will take up as little road space as possible, and store
construction materials and equipment off the road if possible. When work
is completed, the road surface will be reinstated and any dangerous holes
or trenches will be filled. The road will be cleared of any construction
debris or excess construction materials.
Table 4: Basic Traffic Control Signs
Signs Description
The Road Works Ahead sign is the first sign to be
seen by the driver, so it will be placed before the
work site (refer to Table 1). The sign will be put in a
location where it can be seen from a distance. For
example, if the works are just after a bend, the sign
will be placed before the bend
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No: NPC 2020-50 (BCW1)
Metallurgical
A line of Traffic Cones will be placed to guide traffic
past the works. See Table 2 for details of sizes and
spacing. Some space will be left between the line of
cones and the work area to provide a safety zone for
the workers. The cones shall have white reflective
sleeves if they are going to be used at night, and on
main roads, amber flashing lights will be added. An
alternative to the use of cones is to string reflective
barrier tape between upright metal rods that have
reflectors on them.
Where there is less than 5.5m width of carriageway
left unobstructed the road will not be safe for 2-way
working, so cones will be used to reduce the
carriageway to a width of not more than 3.5m.
Unless there is very little traffic, traffic will be
controlled manually using STOP/GO signs or else
portable traffic signals may be used.
Source: MCC BCW1 Traffic Management Plan
The Contractor shall take any and all measures to ensure the safety of all persons
entitled to be on site and shall ensure that the works are carried out in a safe manner.
Reasonable precautions shall be taken to protect the members of the public and road
users from any activity under its control. Barriers, fencing and lighting around the
working areas when and where necessary shall be provided and maintained for the
safety of the public and road traffic. First aid equipment shall be provided where
appropriate.
Provision and enforcement of the utilization of appropriate safety equipment, where

appropriate, for all workmen and staff employed directly or indirectly. Such safety
equipment shall include, as appropriate, safety helmets, eye protectors, hearing
protectors, etc.
11. COMPLIANCE MONITORING

Compliance monitoring is to ensure operations are done within set guidelines as
stipulated in the management plans and sub plans relating to this specific works.
11.1 Environmental Monitoring

The environmental monitoring programme shall be included Performance
monitoring and Monitoring of Environmental Impacts.
This monitoring plan includes mitigation measures, monitoring parameters,

location, method and frequency shall be prepared.
Table 5: Environmental Monitoring and Mitigation Measures

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Mitigation Measures Monitoring Location Method Freq
Parameters
1. Emission and Dust
Dust suppression by water Dust rising from the Construction sites Visual Daily
spraying. project area. I.e. Bridge Assessment
construction area Interview local
people and by
Using In-situ-
equipment
(Pm10/Pm2.5)
Crane exhausting emissions Air pollution by the Construction Visual Daily

will undergo immediate crane Sites, Camp sites Assessment
servicing
2. Noise and Vibration

Install a temporary Noise from Crane Construction sites Visual Daily
construction site sound barrier Assessment
near a noise source. Transportation Interview local
Avoid night-time construction routes people
in residential neighbourhoods. Use sound level
Locate stationary construction Camp sites meter to
equipment as far as possible monitor noise
from noise-sensitive sites. level.
Monitor and maintain
equipment to meet noise
limits.
Work far from vibration Vibration from crane Construction sites Visual Daily
sensitive areas, like Kassam works Assessment
Pass area or near schools. Or
to work cautiously taking into
consideration the risk of the
area of concern.
3. Ecological Management
Water quality should be Protection of Aquatic Construction sites Assessment Weekly
maintained. Work away from Ecosystem
the riverbed.
4. Disposal of Debris and Site Drainage Systems
Dispose all wastes onto agreed Spoils Disposal Construction site Visual Daily
dumping stations or on land as Assessment
requested (in writing) by Interview local
landowners. people
Dispose on stable areas.
Avoid disposal onto sensitive
receptors
5. Demolition of Existing Infrastructures
Clear the demolition area from Existing Infrastructures Construction site Visual Daily
workers and the general public marked to be Assessment when
Carry out demolition demolished require
cautiously. d
(Manda
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tory)
11.2 Safety Monitoring

The Occupation Health and Safety Programs will verify the effectiveness of the
prevention and control strategies. The selected indicators will be representative of
the most significant occupational, health and safety hazards and the
implementation of prevention and control strategies. The occupational health and
safety will include;
o Safety Inspections -This should include regular inspection and testing of

all safety features and hazard control measures focusing on engineering
and personal protective features, work procedures installations, equipment,
and tools used. The inspection will verify that issued PPE continues to
provide adequate protection and is being worn as required.
o Surveillance of the working environment – MCC safety officers will do

routine safety inspections of the working environment during working
hour s to ensure all safety requirements are met.
o Surveillance of Workers health - When extraordinary protective

measures are required (for example, against hazardous compounds),
workers will be provided appropriate and relevant health surveillance prior
to first exposure, and at regular intervals thereafter
o Training - training activities for employees will be adequately monitored

and documented (curriculum, duration and participation). Emergency
exercises, including fire drills, should be documented adequately.
Accidents and diseases monitoring:
12. REPORTING
MCC emphasis on the importance of reporting of any issues or work progress/need
during construction works. This includes incidents/near miss etc. whether it is
environmental, safety or social issues. This is to ensure smooth flow of work and that
safety and well-being of the workers and the nearby communities is maintained so as
to be in compliance and to produce good feedbacks during reporting.
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13. APPENDIX
13.1 Appendix 1: WORKING ENVIRONMENT (SITE) CHECKLIST
WORKING ENVIRONMENT (SITE) CHECKLIST

Before commencing work at a site, it is recommended that the user should carry out a
risk assessment for the worksite. This checklist is provided for guidance only. Due to
the variety of working environmental conditions, this checklist is not exhaustive. If
there are other hazards, please list them on a separate sheet, and decide on the risk
control measures to be introduced.
Site Address/Bridge Name:

Site Conditions that May Increase Are the Risk Improvements
Risk of Accident Control Measures Required
Adequate?
YES NO
1 Is the ground stable?
2 Is the ground slope excessive?
3 Is the weather too windy, wet or
foggy, or near thunder clouds?
4 Are there buried water mains, gas
mains, electrical cables,
undetonated explosives or any
other objects?
5 Is the working area controlled
(from pedestrians and other
traffic)?
6 Is visibility of work area
adequate?
7 Are there overhead power lines or
high-power electromagnetic wave
emitters near working area?
8 Is the working area too close to
drops and road shoulders?
9 Others?
Site Assessed by:

Name:
Date:

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Project: Detailed Design, Rehabilitation and Construction

of Bridges (Bridge No.1-35) Between Lae Nadzab and

CRANE OPERATION PLAN AND

4. ROLES AND RESPONSIBILITY

4.1 Project Manager

4.2 Construction Manager

4.4 Safety Manager

4.4.1 Safety Officer

4.5 Environmental Manager

4.5.1 Environmental Officer/Specialist

4.7 Leading Hand

6. RISK ASSESMENT AND SAFETY MEASURES

6.1 Potential Hazards and Risk Control/Safety Measures

Table 1: Potential Hazards and Safety Measures

1. GENERAL POTENTIAL HAZARDS AND RISK CONTROLS

Follow instructions and warnings in this manual and

Extinguish all fires and potential sources of ignition

Before refuelling the crane, switch off the engine and

After refuelling securely fasten all fuel and oil caps

Refuel and change oil in a well-ventilated work area.

Isolate the work area by using witches hats, temporary

Consult the principal contractor, site supervisor, the

Always be aware of your surroundings and the hazards

b. Keep the cab windows, mirrors, wipers and working

c. When working in areas with poor lighting switch on

d. When visibility is bad due to fog, snow, rain, or

Allow the crane to warm up before carrying full load.

Ensure that the crane is serviced regularly in accordance

Carry out regular servicing of the crane in accordance

Always check that all safety devices and warning systems

Compound operations, such as combining winch hoisting

Always be alert and watch that the boom or the suspended

Do not operate the machine on sloping ground outside the

Plan lifts carefully when operating on uneven terrain.

Operators must be able to perform a manual calculation to

Some Pick & Carry cranes may be fitted with crane

Follow the signaller and lift the load vertically.

8. COMMUNICATION AND EMERGENCY RESPONSE PLAN

8.2 Emergency Response

Table 3: Emergency Wardens

5 Wang Huigang 74284309 Environmental Manager Emergency Wardens

9. ENVIROMENTAL PROTECTION MEASURES

9.1 Environmental Conditions That Impact Crane Safety

9.1.1 Power Lines

This is why it’s so important to include weather in the employer’s work

Due to the nature of their job, cranes need to be assembled and

10. TRAFFIC MANAGEMENT

Figure 1: Traffic Management Plan

10.2 General Principles

10.2.1 Planning Ahead

10.2.2 Safety of Workers

10.2.3 Check the Signs Carefully

10.2.4 Fix the Signs Properly

10.2.5 Provision for Pedestrians

10.2.6 Keeping the Site Tidy

Table 4: Basic Traffic Control Signs

Source: MCC BCW1 Traffic Management Plan

Provision and enforcement of the utilization of appropriate safety equipment, where

11. COMPLIANCE MONITORING