020-T001-100 Crane Lifting Operations Rev5 PDF

McConnell Dowell Corporation
MCD Management System
CRANE AND LIFTING OPERATIONS

MMS No: 020-T001-100
Revision History
Rev Date Details Author Reviewer Approver
1 14Jun2012 Added Section 6.11.18 Crane Free fall R Brown J Phillips
2 22Jul2013 Full Review D Woods J. Phillips
3 20Oct2014 Updated Section 6.7.1, Definitions of High Risk Work licence T Knight K. Rolls M. Collins
responsibilities for licensed Basic, Intermediate and Advanced
Rigger classes.
4 11 Aug 2015 Revision of 6.4.1 to include requirements of pick and carry M Collins M Collins M Collins
operations with side slopes >2.50
5 6 Oct 2015 Updated section 6.1.8b Inclination Factors. N. Kidd M Collins M Collins
This document remains the property of McConnell Dowell Corporation. Its contents are confidential and shall not be reproduced,
destroyed or given away without the express, written permission of McConnell Dowell Corporation. The electronic version of this
document in MMS Database on designated server(s) is the Master Copy and is a controlled document. Unless specifically noted
thereon, other copies of this document are uncontrolled. Based on MMS Template# 010-J011-000 Rev3 2Oct2014
COMMERCIAL-IN-CONFIDENCE
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
TABLE OF CONTENTS
1 PROCESS SUMMARY .................................................................................................................... 6
2 OBJECTIVES .................................................................................................................................. 6
3 DEFINITIONS .................................................................................................................................. 6
4 RESPONSIBILITIES ........................................................................................................................ 6
4.1 Project Manager (PM) ............................................................................................................... 6
4.2 Senior Project OHS representative (SPOHSR) .......................................................................... 6
4.3 Superintendents and Supervisors (S) ........................................................................................ 7
4.4 McConnell Dowell and subcontractor personnel ........................................................................ 7
4.5 Contracts and Procurement Personnel ...................................................................................... 7
4.6 Crane Lift Supervisor ................................................................................................................ 7
5 PROCESS DESCRIPTION .............................................................................................................. 7
5.1 Plan the Job .............................................................................................................................. 7
5.1.1 Review legislation, standards, other related MCD SOPs and Project Risk Register ............. 7
5.1.2 Select lifting equipment that is fit for purpose ...................................................................... 8
5.1.3 Identify licence or competency requirements for crane and lifting personnel ....................... 8
5.1.4 Select Plant operators ........................................................................................................ 9
5.1.5 Initial inspection and approval to bring plant on site ...........................................................10
5.1.6 Report defects...................................................................................................................10
5.1.7 Statutory plant inspections ................................................................................................10
5.1.8 Develop a plant maintenance schedule .............................................................................11
5.1.9 Arrange maintenance and refuelling ..................................................................................11
5.2 Do the Job ...............................................................................................................................12
5.2.1 Plan the lift ........................................................................................................................12
5.2.2 Daily plant inspections.......................................................................................................12
5.2.3 Report defects...................................................................................................................12
5.2.4 Prepare work area and evaluate weather ..........................................................................13
5.2.5 Conduct the lift ..................................................................................................................13
5.3 Supervise and Monitor Lifting Operations .................................................................................13
5.3.1 Supervise the lifting operation ...........................................................................................13
5.4 Take action when safety risks are identified..............................................................................13
5.4.1 Report and Take Action.....................................................................................................13
6 TECHNICAL STANDARDS .............................................................................................................14
COMMERCIAL-IN-CONFIDENCE PAGE 2 OF 50
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
6.1 Crane Selection and Planning ..................................................................................................14

6.1.1 Pre-Mobilisation ................................................................................................................15
6.1.2 Crane location planning – vicinity, visibility ........................................................................15
6.1.3 Ground Support ................................................................................................................16
6.1.4 Cranes on Suspended Surfaces ........................................................................................16
6.1.5 Weather Conditions...........................................................................................................17
6.1.6 Marine Conditions .............................................................................................................17
6.1.7 General Operation of Cranes on Floating Barge ................................................................17
6.1.8 Guidelines for Crane De-rating and Tie Down/securing......................................................18
6.1.9 Crane Tie Down ................................................................................................................18
6.2 Crane Operation ......................................................................................................................19
6.2.1 General Safe Use requirements ........................................................................................19
6.2.2 Competency......................................................................................................................19
6.3 Communication ........................................................................................................................20
6.3.1 Hand Signals ....................................................................................................................20
6.3.2 Radio Communication .......................................................................................................20
6.4 Lift Categories..........................................................................................................................22
6.4.1 Travelling Loads (Pick and Carry)......................................................................................22
6.4.2 Multiple hoist or crane operation ........................................................................................22
Requirements for multiple crane hoisting .........................................................................................22
Planning for multiple crane hoisting .................................................................................................23
Synchronisation of the crane and crab motions ...............................................................................23
Pick and Carry (Multiple Cranes) .....................................................................................................23
6.4.3 Controls ............................................................................................................................23
6.4.4 Crane Lift Plans ................................................................................................................24
6.5 Maintenance, Inspection and Repair - Cranes ..........................................................................24
6.5.1 Maintenance .....................................................................................................................24
6.5.2 Inspections........................................................................................................................25
6.5.3 Periodic inspections ..........................................................................................................25
6.5.4 Major inspection to assess a crane for continued safe operation. .......................................26
6.6 Repairs ....................................................................................................................................26
6.6.1 Assessment for repair procedure .......................................................................................26
6.6.2 Management of repairs. ....................................................................................................26
6.6.3 Repair work.......................................................................................................................27
6.6.4 Welding repair examination ...............................................................................................27
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
6.7 Rigging and lifting ....................................................................................................................27

6.7.1 Competency......................................................................................................................27
6.7.2 Equipment Selection & Planning........................................................................................28
6.7.3 General requirements- Lifting Equipment...........................................................................28
6.7.4 Chains ..............................................................................................................................29
Care................................................................................................................................................29
Use .................................................................................................................................................29
6.7.5 Steel Wire Rope ................................................................................................................30
6.7.6 Synthetic Slings ................................................................................................................30
6.7.7 Lifting Hardware ................................................................................................................31
Shackles .........................................................................................................................................31
Eye Bolts ........................................................................................................................................32
Lifting Beams ..................................................................................................................................32
Sundry Equipment ..........................................................................................................................33
6.8 Lifting the Load ........................................................................................................................33
6.8.1 Slinging the Load ..............................................................................................................33
6.8.2 Executing the Lift ..............................................................................................................33
6.8.3 Management of change during a lift ...................................................................................34
6.9 Inspection, Repair and Modification ..........................................................................................34
6.9.1 Inspection .........................................................................................................................34
6.9.2 Repair and Modification.....................................................................................................35
7 OTHER EQUIPMENT USED FOR LIFTING ....................................................................................36
7.1 Earthmoving Equipment Used For Lifting..................................................................................36
7.1.1 General requirements for lifting with earth moving equipment ............................................36
7.1.2 Requirements for rated capacity at maximum reach/radius ................................................37
7.1.3 Controlled lowering devices ...............................................................................................37
7.1.4 Stability .............................................................................................................................37
7.1.5 Rated hydraulic capacity ...................................................................................................38
7.1.6 Quick-hitches ....................................................................................................................38
7.1.7 Marking and Labelling .......................................................................................................38
8 RECORDS......................................................................................................................................38
9 REFERENCES ...............................................................................................................................39
10 APPENDICES .............................................................................................................................40
Appendix A – Licences To Perform High Risk Work ............................................................................40
Appendix C – Communication Signals and alarms ..............................................................................42
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
Appendix D – Working near overhead power lines - No go zone .........................................................43

APPENDIX E – Free Fall Features on Cranes ....................................................................................44
APPENDIX F – Typical Adverse Weather Guidelines ..........................................................................45
APPENDIX G - Commonly used Terms and Alternative Names ..........................................................47
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
1 PROCESS SUMMARY
To manage crane and lifting operations in order to minimise or eliminate the risk of injuries, fatalities and
incidents
This Safe Operating Procedure addresses the following MCD Golden Rules:
“Never be under a suspended load.”
2 OBJECTIVES
This procedure applies to all crane and lifting activities conducted on land within McConnell Dowell
controlled sites and activities, and to all McConnell Dowell employees, contractors and visitors when
involved in crane and lifting operations.
3 DEFINITIONS
Competent Person – A person, who has through training, qualification, experience, or a combination of
these, has the knowledge and skill enabling them to correctly perform the required tasks.
Lifting equipment – Any equipment or device used or designed to be used directly or indirectly to
connect a load to a crane and which does not form part of the load e.g. Wire rope slings, chain slings,
synthetic fibre slings, hooks, fittings, swivels, shackles, eye bolts, rigging screws, wedge sockets, plate
clamps and lifting beams.
SWL – Safe Working Load
WLL – Working Load Limit
4 RESPONSIBILITIES
4.1 PROJECT MANAGER (PM)
• Ensure that this procedure is communicated to relevant Project personnel.

• Ensure that all relevant aspects of this procedure are implemented by McConnell Dowell and
contractor personnel.
4.2 SENIOR PROJECT OHS REPRESENTATIVE (SPOHSR)
• Assist the Project Manager, Superintendents, Supervisors and Contractor Representatives to

implement this procedure
• Modify this procedure to meet any project specific contractual and legislative requirements
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• Monitor compliance with the procedure and report noncompliance to the Project Manager
4.3 SUPERINTENDENTS AND SUPERVISORS (S)
• Prepare and supervise crane and lifting operations in accordance with this procedure
• Ensure that sufficient resources are available to conduct a safe lift
4.4 MCCONNELL DOWELL AND SUBCONTRACTOR PERSONNEL
• Comply with all relevant aspects of this procedure
4.5 CONTRACTS AND PROCUREMENT PERSONNEL
• Make sure that all purchased or hired-in lifting equipment to be used on MCD projects, complies
with the relevant standards of the country, and is fit for purpose.
• All contracts awarded comply fully with the requirements and intent of this procedure.
4.6 CRANE LIFT SUPERVISOR
• Review all technical details and plans for lifts
5 PROCESS DESCRIPTION
5.1 PLAN THE JOB
5.1.1 Review legislation, standards, other related MCD SOPs and Project Risk Register
WHAT HAS TO BE DONE WHEN WHO INFORMATION
Review the Project OH&S Legal & Other Start of project SPOHSR Project OH&S Legal &
Requirements to identify any legislation that is Other Requirements
relevant to this procedure
Refer to Compliance with
Legal & Other
Requirements
(MMS # 000-D004-000),
and Project Compliance
with Legal & Other
Requirements
(MMS # 300-E012-100).
Identify any Standards, Codes of Practice etc Start of project SPOHSR

relevant to this operation
Review MCD SOPs to identify any that are relevant Start of project SPOHSR SOP MMS# 020-T005-100
to this operation Height
SOP MMS# 020-T009-100
Overhead Power Lines
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
SOP MMS# 020-T003-100

Workbox Use
Plan works using the HSE Risk Register. (Create Start of project SPOHSR Project Risk Register will
Construction Execution Procedures, JSEA/SWMS and ongoing Project identify phases in the
and ITPs, or refer to existing risk assessments and Manager project where this SOP is
documents). Construction applicable.
Manager Refer to procedure
HSE Risk Management
(MMS # 020-D012-100)
5.1.2 Select lifting equipment that is fit for purpose
Select crane Commencement Project See section 6.1 cranes

of project and Manager (below) for selection criteria
ongoing Project Where possible employees
Engineer undertaking lifting
Supervisor operations should be
consulted.
Select rigging and lifting equipment Commencement Project See section 6.7.1 rigging
of project and Manager and lifting equipment
ongoing Project (below) for selection criteria
Engineer
Lifting
Supervisor
Supervisor
5.1.3 Identify licence or competency requirements for crane and lifting personnel
Once the types of cranes to be used on the project Commencement SPOHSR Crane operators must hold
are known, the specific licence requirements to of project and appropriate certification or
operate these vehicles are identified. ongoing license for the country state
Record the licence and competency requirements throughout project or region relevant to the
project
See Appendix A –
Certificates of Competency
(below) for Australian
competency tickets
Record any licence
requirements in Project
Training Plan – Legislation
Compliance
Identify the specific licence requirements for the Commencement SPOHSR See Appendix A –
range of persons assisting crane operations of project and Certificates of Competency
Record the licence and competency requirements ongoing (below) for Australian
throughout project competency tickets.
Identify whether any additional training is required to Commencement SPOHSR Difficult site conditions may
operate the plant of project and mean that operators need
ongoing additional training even
throughout project though they have the
requisite licenses.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
Record any additional

training requirements in
Project Training Plan
(use MMS # 030-J008-100).
5.1.4 Select Plant operators

Employ crane operators and other personnel and Commencement SPOHSR See 6.2.2 Training and
check their licence and training. of project and Competency below for
ongoing selection criteria.
throughout project HR to arrange a fitness for
work medical examination
as part of the employment
process.
Photo copy operator
licences and competency
tickets and record in the
appropriate project
Operator Competency
Registers:
File the photo copies of
licenses etc in the
employee personal file.
Arrange training and/or test competency Commencement SPOHSR Plant Operator
of project and Assessment (MMS # 030-
ongoing F047-100) or
throughout project Assessment by external
training organisation
Record competencies of each plant operator. Commencement SPOHSR Competency Register
of project and (MMS # 030-F044-100, and
ongoing Competency Register –
throughout project By Person
MMS # 030-F045-100).
Notification of loss of license or onset or medical Immediately the Or mobile Supervisor to be
condition that could make it unsafe to operate employee plant operators immediately notified of the
mobile plant becomes aware. expiry or loss of license by
any person.
12 monthly fitness It is the responsibility of a
for work medical plant operator to notify their
examination. Supervisor if they have a
medical condition that may
affect their ability to operate
plant safely, or if any
medication has been
prescribed that may affect
their ability to operate plant
safely.
Rescind the authority to operate plant As soon as Supervisor Where there is a medical
management SPOHSR condition the issue is to be
becomes aware discussed with the
employee before any
decision is made.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
5.1.5 Initial inspection and approval to bring plant on site
Initial inspection and approval to bring plant on site

Carry out an inspection of all lifting equipment When plant arrives Lifting Incoming Plant Inspection
before commencement of work. on site Supervisor Checklists (MMS # in the
For external hires, service records, inspection SPOHSR number sequence 045-
records, log books etc. must be checked Fnnn-100).
For items supplied internally by [McConnell Dowell
entity], obtain and review inspection & service
records.
Record approval of cranes. Once lifting Supervisor Plant & Equipment
equipment has SPOHSR Register (MMS # 045-
been inspected F136-100 or equivalent).
5.1.6 Report defects
Write-down all defects and damage in the inspection As required Plant operator Mobile Equipment Daily
report. Inspection Report
If the defect requires immediate attention or (MMS # 045-F030-100).
endangers the safety of employees, phone the
supervisor immediately.
If plant is unsafe to operate tag with an ‘Out of Immediately Supervisor Refer to procedure Tagging
Service’ tag. and Locking (MMS # 020-
E015-100)
Arrange for repairs. As required Supervisor
5.1.7 Statutory plant inspections
Identify any statutory requirements for Plant At project SPOHSR See 6.5 Maintenance,
inspection or any requirements listed in relevant commencement Lifting Inspection and repairs –
Standards Supervisor Crane (below) for MCD
requirements
See 6.9 Maintenance,
Inspection and repairs --
Rigging and lifting
Equipment (below) for MCD
requirements.
Record any statutory
inspection requirements in
Project Legal & Other
Requirements (MMS #
020-J004-YYYY and MMS
# 025-J001-YYYY)
Schedule inspections on the project plant At project SPOHSR Project plant maintenance
maintenance and inspection schedule commencement and inspection schedule
Arrange inspections See schedule SPOHSR Record completed
inspections in the project
plant register
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
5.1.8 Develop a plant maintenance schedule

Develop a project plant maintenance and inspection Commencement Plant Manager See 6.5 Maintenance,
schedule that complies with legal requirements of project and Inspection and repairs –
MCD requirements and manufacturers’ ongoing Crane (below) for MCD
recommendations for all cranes and lifting throughout project maintenance and repair
equipment requirements
See 6.9 Maintenance,
Inspection and repair -
Rigging and lifting
Equipment (below) for MCD
maintenance and repair
requirements
Project plant maintenance
and inspection schedule
5.1.9 Arrange maintenance and refuelling
Arrange maintenance and refuelling

Source Plant maintenance and refuelling suppliers. Project Project Refer to Storage
commencement Manager Maintenance & Refuelling
and ongoing Plant Manager of Machinery
(MMS # 025-L007-100).
Potential suppliers are to
provide information on safe
operating procedures for
tasks such as refuelling,
plant isolation systems,
elevated work, qualifications
of maintenance personnel
etc.
Potential suppliers must
provide evidence of being
able to meet the
environmental conditions of
the project
Maintenance companies
are to provide a written
assurance that all work is
performed by appropriately
trained and competent
persons and that all work is
done in accordance with
any relevant legislation or
standards.
Modification to lifting Equipment
Ensure that all modifications to lifting equipment if As required Project See 6.9 (below) for MCD
required are designed and carried out by a Manager requirements on
competent Engineer and in accordance with the modification of lifting
relevant legislation and standard. equipment
Obtain the engineers certification before returning As required Supervisor
any modified lifting equipment to service
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
5.2 DO THE JOB
5.2.1 Plan the lift

Review the work pack When planning the Lift Supervisor
lift
Inspect the work site When planning the Supervisor Check for issues such as
lift overhead services
existing structures.
proximity to excavations
Underground services
other cranes and mobile
plant etc in the vicinity.
Develop the lift plan. When planning the Supervisor See section 5.11(below) for
lift MCD lift plan requirements
Obtain the Ground Load Bearing Capacity When planning the Supervisor See section 6.13 (below) for
Calculations for Outrigger placement lift MCD requirements
Identify additional equipment required When planning the Lift Supervisor
lift
Develop Safe Work Method statement (SWMS) Prior to the lift Supervisor
Communicate SWMS to workgroup Prior to the lift Supervisor
Set up crane and inspect crane and all lifting Prior to the lift Lift Supervisor See section 6.1 (below) for
equipment inspection requirements
after crane has been
mobilised.
Lift and place the load Supervisor See sections 6.8 (below) for
Rigger MCD requirements on
executing the lift.
5.2.2 Daily plant inspections

Carry out and record daily pre-start checks of all Daily or at start of Plant operator Mobile Equipment Daily
lifting equipment. Submit check sheets to the each shift. Inspection Report
project office weekly. (MMS # 045-F030-100).
Pre-start checks are to be performed when taking
over from another operator..
5.2.3 Report defects

Write-down all defects and damage in the inspection As required Plant operator Mobile Equipment Daily
report. Inspection Report
If the defect requires immediate attention or (MMS # 045-F030-100).
endangers the safety of employees, phone the
supervisor immediately.
If plant is unsafe to operate tag with an ‘Out of Immediately Supervisor
Service’ tag.
Arrange for repairs. As required Supervisor
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
5.2.4 Prepare work area and evaluate weather

Identify and barricade ‘no-go’ zones. Prior to the lift Supervisor Traffic controllers may be
required where loads are
lifted over access roads
Check weather forecast and current wind speeds 4 hours prior to the Supervisor Check manufacturers
lift manual for safe wind
speeds.
Notify other workgroups in the immediate area Prior to the lift Supervisor
5.2.5 Conduct the lift

Check that slings, ropes chains etc are correctly Immediately Lift Supervisor See section 6.8 (below) for
attached to the load. before the lift Rigger MCD requirements on safe
lifting.
General Safe Use
requirements
Executing the Lift
5.3 SUPERVISE AND MONITOR LIFTING OPERATIONS
5.3.1 Supervise the lifting operation
Observe the lifting operations of both MCD Ongoing Supervisor Monitor compliance with this
employees and contractors Rigger standard.
Conduct regular inspections of lifting operation Weekly Lift Supervisor Check that a JSEA/SWMS
Supervisor has been completed for the
Rigger job. Stop the job if no
JSEA/SWMS is available.
SPOHSR
Refer to HSE Inspections
and monitoring (MMS #
020-D010-100).
5.4 TAKE ACTION WHEN SAFETY RISKS ARE IDENTIFIED
5.4.1 Report and Take Action
Report any defective equipment to the supervisor. Immediately All employees

Turn off the equipment Immediately Supervisor
Fix an “Out of Service” tag to the suspect Immediately Supervisor Refer to procedure Tagging
equipment. and Locking (MMS # 020-
E015-100)
Send the equipment for repair. Immediately Supervisor
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
Report inappropriate or unsafe operations involving As required All site Complete hazard report
crane use and lifting operations management form
and
employees
Stop the job if unsafe Immediately on Supervisor

the identification HSR
of unsafe activity
SPOHSR
Initiate disciplinary action were required. As required Project Disciplinary action may
Manager include suspension of
authority to operate plant for
a period of time, retraining,
termination of employment
etc
6 TECHNICAL STANDARDS
6.1 CRANE SELECTION AND PLANNING
Before selecting a crane for service, the following criteria are to be taken into account:
• The result of an appraisal of an existing crane, if applicable.
• The maximum permitted forces on the supporting structure.
• Power supply.
• Rated capacity of the crane.
• Classification of the crane taking into account the application, including;
- type of loads to be lifted;
- mass of loads to be lifted;
- speed of lifts; and
- frequency of lifts.
• The maximum load that will be imposed on the crane.
• The maximum load moment that will be imposed on the crane.
• The nature of the rigging or slinging to be used.
• The position from which the load is to be lifted.
• The position in which the load is to be placed.
• The movement limitations of the crane and the load.
• Other limitations of the crane.
• Multiple crane lifting.
• Working environment including hazardous gases, corrosive atmospheres and high ambient
temperatures including full speed operation against in-service wind load.
• Projected upgrades of plant.
• The provision of additional crane capacity to cater, where necessary, for changes in the site
environment, for example, increases in lifted load mass due to manufacturing tolerances, rapid
changes in weather conditions.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
6.1.1 Pre-Mobilisation
The following planning activities are to be carried out by a competent person(s):
• Selection of cranes
• Lightning protection
• Earthing for the conditions – e.g. static build up due to EMR, wind etc
• Site access and crane siting
• Safety of personnel and public entering into the site and the lift area
• Procedures for setting up of the crane
• Procedures for lifting operations
• Procedures for dismantling of the crane
• Selection of the personnel
• Communication systems(s)
• Weather conditions
• Ground conditions
• Proximity of excavations
• Selection of lifting gear to the appropriate standards
• PPE requirements
• Emergency procedures
• Procedures for non-routine lifts – Multiple Lifting Operations
• For multiple crane lift MCD Insurance underwriters require notification
• Night Operations
• Parking & Storage facilities for crane components
• Marking of crane and ancillary equipment e.g. rated capacity, safety signs
• Access for servicing
• Interface with existing plant and traffic
• Obtaining of approvals from statutory authorities or other relevant parties
• Appraising an existing crane for suitability for use, and ensuring that the appraisal is carried out by
a competent person.
• Suitable equipment is available for the installation, maintenance, operation and dismantling of the
crane.
• Condition monitoring of the crane and associated equipment.
• The maintenance, inspection and safe operation of the crane and associated equipment.
• The preparation, availability and maintenance of instructions for the assembly, operation,
maintenance and inspection of the crane.
6.1.2 Crane location planning – vicinity, visibility
Assess the risks of the following:

• Overhead Power Lines
• Underground services
• Wind loading is to be taken into account, including increased funnelling effects between adjacent
buildings or structures.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• Nearby structures or other cranes

• Excavations
• Fixed hazards – (Trees, poles, protruding objects)
• Personnel movement within the crane working area/s
• Mobile equipment movement within the crane working area/s
• Public access areas including roadways, railways, rivers and aircraft flight paths
• Effects of EMR (e.g. busbars, strobe lights, welding) on radio, infra-red or electronic controls
• The vicinity of airfields (High operating Cranes) maybe required warning lights and jibs painted high
visibility colours.
• The crane should be sited so that the crane operator has optimum visibility
• Precautions should be taken against the effects of noise, exhaust gases, hydraulic fluids, lubricants,
fuel, dust and other environmental pollutants emitted by the crane.
6.1.3 Ground Support
• For Heavy Lifts, e.g. Bridge Beams; Tilt-up Panels and other lifts where the load is 50 tonnes or
more, certification of the ground bearing capacity must be obtained from a geo-technical engineer
before performing a lift.
• A competent person must make sure that loads imposed by the crane can be sustained by the
ground or any other means of support and that the crane can operate within the levels and other
parameters specified by the manufacturer.
• Where the crane is required to work in the vicinity of an excavation or an embankment, the
possibility of slip or collapse of the supporting surface is to be evaluated by a competent person –
and where applicable the embankment or excavation is to be reinforced.
• Loads are not to be imposed on any new concrete supporting structure until the structure has
reached sufficient strength.
6.1.4 Cranes on Suspended Surfaces
• An assessment should be carried out by a structural engineer when planning to position a crane
on a suspended surface. A suspended surface could include but not limited to the following;
suspended concrete slabs, wharfs, jetties, barges or any other instance where the surface integrity
or rating is unknown.
• The assessment should ensure that the supporting surface is capable of supporting loads imposed
by the crane, and the loadings it would apply to the supporting surface during its proposed
operation.
• The structure needs to be assessed during various stages of the job, including driving to the set up
location on the structure, set up, use and, if different or the structure is changed during the job,
dismantling and removal of the crane.
• Where there is a requirement to use a propping system for the supporting structure, a structural
engineer must advise of the correct location and ensure the design considers all loading factors
that will be imposed upon it. A competent site representative is to ensure the propping system is
functioning and maintained in line with the engineer’s advice.
• If the crane cannot be set up in the planned location than full assessment is to reoccur.
• Assessment items to address, but are not limited to the following include;
- Crane model
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
- Crane configuration
- Any crane de-ratings
- Maximum outrigger loadings
- Type of dunnage to be placed under outriggers
- Principal Contractor details and representative
- Structural Engineer completing assessment
• The crane operator has the right to refuse to operate, where the above assessment cannot be
validated and provided on site.
6.1.5 Weather Conditions
Prior to commencing crane and lifting operations the Crane Operator is to review the prevailing weather
conditions (wind speed and direction, visibility, etc.). Crane and lifting operations shall not commence if the
weather or environmental conditions are likely to jeopardise the safety of the activity – refer to Appendix F
Adverse Weather Guidelines, for a comprehensive guide to the effects of varying wind speeds on land and
water.
6.1.6 Marine Conditions
Crane and lifting operations occurring in a marine environment may be subject varying conditions (such as
swell or unexpected wave action) which have potential to shock or dynamic load lifting plant and equipment,
particularly when loading or unloading equipment to and from barges or vessels.
If a load suddenly comes onto the lifting equipment, or if a load being lowered is suddenly stopped, the
weight of the load borne by the equipment is effectively increased. The movement of the vessel and the
hoist motion of the crane can combine to produce severe dynamic loading of up to three times the static
weight of the load.
Shock loading is not only experienced by the crane: the lifting accessories between the load and crane will
also be subject to increased loading and, in the case of chains, shackles, etc. this may result in deformation
known as permanent set.
Twist may be induced in lifting equipment leading to the whole lifting assembly becoming tangled and
shackles becoming jammed in their attachment points. Such deformation prevents the shackles being
pulled into line with the sling and they become loaded in the wrong direction.
In addition, the length of the slings can become uneven, causing unequal load distribution.
The inherent risks associated with lifting operations in a marine environment, including the dynamic loading
described above, mean that agreed requirements in the risk assessment are adhered to.
6.1.7 General Operation of Cranes on Floating Barge
Crane lifting operations on floating barges and vessels are inherently dangerous activities and McConnell
Dowell requires the highest standards of planning and operation when these activities are being
performed.
The requirements of all relevant local legislation and regulations are to be complied with in all
circumstances
The crane manufacturers’ requirements for operating their specific cranes on floating barges and vessels
must always be followed.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
Cranes will be tied down in all conditions except within smooth water limits, and only where site specific
conditions permit. In such situations a documented risk assessment must be undertaken. The risk
assessment is to fully describe the particular activity or lift to be performed and when and how the crane
can be used without the tie downs.
Cranes on barges shall be appropriately de-rated for all conditions.
Where a project specific assessment shows that an amendment to the guidelines below is warranted,
such an amendment is to be considered for that project only.
6.1.8 Guidelines for Crane De-rating and Tie Down/securing
Cranes on floating barges shall be de-rated as follows:

a) Dynamic Factors
All loads to be lifted shall be factored as indicated and the factored load shall be used when checking
against the crane’s current applicable load chart, including any de-rating as derived below.
1. All lifts in Smooth Waters – 1.1;
2. All lifts in Partially Smooth Waters with wave heights ≤1m – 1.35;
3. All other cases, but wave height ≤3m – 2.4;
4. Where wave heights exceed 3m, no lifts shall be performed.
b) Inclination Factors
Manufacturers Crane Maximum Load Charts shall be derated as applicable to the heel and trim
inclinations derived in the vessel’s stability booklet that applies to the barge/crane combination intended
to be used and for the lift/no lift condition being contemplated. Manufacturers Crane Maximum Load
Charts shall be derated as applicable to the heel and trim inclinations derived in the vessel’s stability
booklet that applies to the barge/crane combination intended to be used and for the lift/no lift condition
being contemplated. Unless a rigorous crane/barge combination stability analysis has been performed
and using specific inclination crane capacity data provided by the crane manufacturer, the following
factors shall be adopted:
1. For inclinations < 1% - no change;
2. For inclinations >1% and <1° - 20% de-rating applies;
3. For inclinations >1° and <2° - 35% de-rating applies;
4. For inclinations >2°- do not lift or operate the crane.
Note: the manufacturer’s recommendations may vary from these requirements and, if more
stringent, they must be followed.
6.1.9 Crane Tie Down
The tie down system for a crane shall be designed for the following loads:-
1. Smooth Waters – 0.1g lateral force in any direction;
2. Partially Smooth Waters - 5° heel, 2.5° trim, 0.1g heave, 0.1g lateral force in down
heel/trim direction;
3. Other areas – special analysis is required by independent certified naval architect.
Friction between the crane and the barge is not to be taken into account to mitigate these forces.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
These provisions do not apply to any coastal or ocean tow, any tow longer than 4 hours in duration, any
extreme environmental event (e.g. cyclones) or any operations outside of Inshore Operational Areas. Tie
downs/sea fastenings are to be specifically designed for such tows.
Refer to USL Code of Australia for definitions.
6.2 CRANE OPERATION
6.2.1 General Safe Use requirements
• The crane will only be operated within the rated capacity and design classification
• Power supply is compatible with the crane requirements (Gantry Cranes)
• Clear safe and defined pathways for cranes operated by pendant or wireless control is to be
provided and maintained (Gantry Cranes)
• All cranes are to be kept clean
• Tools and loose objects are to be stowed and secured
• The crane is to be inspected in accordance with the Operations and Maintenance Manual and/or
local regulatory requirements
• The crane is to be inspected daily by the crane operator to identify maintenance or repair items that
may affect the efficient or safe operation of the crane.
• The SWL is to be stencilled on the crane.
• All cranes be fitted with “Christmas Tree Lights”
• No repair work or maintenance or refuelling is to be carried whilst the crane is operating.
• Only one competent person (certified dogman/ rigger or local equivalent) is to give signals to the
crane operator.
• Persons entering a crane operating area must make contact and be acknowledged by the person
in charge of the area prior to entering the area. Crane operators should never be approached
directly.
• Barricades or guarding may be required where necessary.
• The crane is not to be left unattended in the operating mode.
• The crane driver is to be familiar with any electrical power cables or conductors in the lift area and
any other potential hazard.
• Clearances are to be maintained and procedures developed to prevent unplanned contact between
any parts of cranes working in the same site (refer to AS 1418 or AS 2550)
• The crane driver is not to use a mobile telephone whilst operating the crane.
• When travelling a crane without a load, all chains and slings must be removed from the hook unless
it is either tied to the crane to ensure it cannot bounce or twist: or independently tied back to the
hook in such a way that any possible dislodgement caused by the movement of the jib is prevented.
6.2.2 Competency
• The crane operator is to hold a valid license and/or certification, specific to the type and size of the
crane and/or lifting equipment that is been used.
• All operators who operate any crane are to be familiar with the following:
- Safe operation of the particular crane
- Locations and operation of all safety backup systems
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
- Reading and understanding of load charts

- Capabilities of the machine
- Any peculiarities pertaining to that particular crane
- Safe operation near overhead power lines.
Appendix A Licensing Persons Performing High Risk Work lists the Certificates of competency relevant
to the crane industry - Australia Only.
Project management is to identify the specific local licensing/certification requirements for persons
undertaking crane operations.
6.3 COMMUNICATION
At all times, there is to be adequate communication between all personnel involved in the lifting operation.
Either hand signals or radio equipment appropriate for the relevant lifting operation is to be used.
6.3.1 Hand Signals
Crane Operators and dogman/ riggers or local equivalent must be familiar with the system of signalling
being used for the operation. The signals presented in Appendix C are recommended for adoption in
Australia. The local equivalent should be consulted when operating outside of Australia.
The Crane Operator must:
• Ensure that the signalling system to be used is clearly agreed between the crane crew prior to
commencing any crane and lifting activities.
• Only respond to signals given by the dogman/ rigger or local equivalent or ‘STOP’ when given a
signal by other persons in an emergency situation.
• Maintain visual contact with the dogman/ rigger or local equivalent at all times.
• Cease lifting operations if contact is lost and only recommence when a clear line of communication
is re established.
• Cease crane operations if inclement weather or darkness impairs the ability to see the dogman/
rigger or and operations cannot continue safely.
6.3.2 Radio Communication
The Crane Operator is to reach a clear understanding with the dogman/ rigger or local equivalent before
lifting operations begin on the protocols to be used.
If there is any interruption to the communication (e.g. third-party transmission) the Crane Operator must
STOP the lifting operation immediately, only resuming when communication with the dogman/ rigger or
local equivalent is re-established.
Radio checks shall be carried out prior to the start of the lifting operation. When directing the load,
instructions shall be clear and precise.
Where appropriate, a communication method can be used whereby the signaller gives a continuous signal
to continue the movement. The equipment operator shall stop immediately if he does not receive the signal.
During periods of no radio communication, all lifting operations should be reviewed with suitable controls
identified and agreed by personnel involved to enable safe execution of the operation.
The following protocol is recommended for radio communication during lifting operations:
• Call signs should be set up and adhered to.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• Call signs must be used at all times to establish the authenticity of commands or directions.
• At the end of an instruction or enquiry the transmitting operator should indicate the end of the
message by the command ‘over’.
• The receiving operator should indicate understanding of any dialogue through the response ‘roger’.
• Under no circumstances should the transmitting operator assume understanding without
acknowledgement (‘roger’) from the receiving operator.
• If the receiving operator is unsure regarding a message, the operator must not acknowledge but
should repeat the message as he understands it and ask for confirmation or simply request the
transmitting operator to repeat.
• At the close of communication the transmitting operator should indicate the end of the transmission
with the command ‘over and out’.
• For single function operations the dogman/ rigger or local equivalent should relay to the Crane
Operator using terminology such as: ‘up on the hoist’, ‘Boom up’, ‘Slew right’, etc. Where it is
necessary to carry out an operation slowly the dogman/ rigger or local equivalent should instruct
the Crane Operator accordingly. To stop a function the dogman/ rigger or local equivalent should
instruct the Crane Operator to ‘Stop’. To stop all operations the dogman/ rigger or local equivalent
should instruct the Crane Operator with ‘All stop’.
• For simultaneous function operations the dogman/ rigger or local equivalent should relay to the
Crane Operator using terminology such as: ‘Come up on the load and boom down’, etc. To stop a
function the dogman/ rigger or local equivalent should instruct the Crane Operator to ‘Stop on the
boom, slew right only’, etc. To stop all operations the dogman/ rigger or local equivalent should
instruct the Crane Operator with ‘All stop’.
• Under no circumstances should profane language be used while transmitting.
• Should the radio antenna become damaged exposing the central core, the antenna must
immediately be replaced in order to maintain not only optimum performance but to ensure user
safety.
• Radio messages should reflect work requirements only; general conversation should not be carried
out over the air waves.
• Always ensure that you fully depress the transmission button before speaking into the microphone.
Speak clearly at all times and do not release the button until a few seconds after completing your
message.
• When directing the crane, ensure that any accompanying colleagues’ radios are switched off – if
more than one radio is switched on in close proximity interference and distortion of the signal will
take place when an instruction is transmitted.
• During blind lifts when the load is being hoisted or lowered for a long time do not maintain the
transmission button in the depressed position for the duration of the lift – the dogman/ rigger or
local equivalent should give the initial instruction and then talk to the Crane Operator as required
to reassure the Operator that the line of communication is still active and that the lift remains under
control.
• During high winds, ensure that the area of the microphone you speak into is not exposed to the
wind as background noise created may distort the transmission.
• Ensure that the radio microphone is not exposed to rain. If a plastic carrying case offering full
protection of the radio is not available, a simple precautionary measure such as a small plastic bag
or a piece of cling film around the microphone will ensure that it remains dry.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• Do not carry the radio in a pocket always ensure that they are carried on the body by either a belt
clip or protective holster. Consider using the protective holster when working at height or climbing
ladders to ensure that the radio does not become a dropped object if dislodged.
6.4 LIFT CATEGORIES
6.4.1 Travelling Loads (Pick and Carry)
• No person is to walk between the load and the crane whilst the load is being carried on site roads
or within any work area.
• Dogman/ Riggers are to escort the cranes when travelling with loads on site, and must not travel in
the crane cab under any circumstances.
• Use of tag lines to tie load to crane at >2.5o side slope gradients is prohibited.
• When travelling without a load, the hook block is to be secured to prevent swinging and damage to
boom sections. Where this is impractical the hook block should be held fast against the boom head.
• Loads are to be kept as close to the ground as possible when travelling.
• If unstable ground conditions or obstructions in travel path are present, the control methods for
these hazards are to be included in a specific JSEA.
Pick and Carry cranes shall be de-rated as follows:
• 0.0 – 0.6 o manufacturer approved load charts and specifications apply.
• >0.6 – 2.5 o de rate in line with manufacturer approved load charts and specifications.
• >2.5 - <5.0 o de rate by a full 60% of normal SWL capacity, regardless of boom position and
length*.
• >5.0 o the activity is to cease and be reassessed to identify another means of load lifting or
transportation.
* Additional MCD safety factor exceeding manufacturer’s instructions
6.4.2 Multiple hoist or crane operation
Requirements for multiple crane hoisting
• All multiple crane lifts are to comply with the relevant Australian Standard as a minimum
• Other than for designed lifts, lifting operations using two or more cranes will use cranes of the same
type.
• The following minimum capacity requirements for each crane is to apply (where hoisting operation
is not designed):
• For 2 cranes - 20% greater than the calculated share of the load.
• For 3 cranes - 33% greater than the calculated share of the load.
• For 4 or more cranes- 50% greater than the calculated share of the load.
• Where load is suspended from more than one hoist line the load must be handled in such a way
that:
- The rated load for each line is not exceeded
- The load being handled does not exceed the rated capacity of the crane.
- Supervision is to be provided by a competent person, who is not one of the crane operators.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
Planning for multiple crane hoisting
When planning, determine:

the accurate proportion of the load to be carried by each crane
how the proportioning is to be maintained
whether each crane has appropriate additional capacity over the portion of the load to be lifted
the operating characteristics of the cranes e.g. speed of hoisting.
The allowance that should be made for manufacturer’s tolerances (if the load information is taken from
technical drawings)
The mass and distribution of the lifting gear on cranes and crabs
Manitowoc and Grove cranes require the weight of any wire below the head sheave to include in the total
load weight.
Weather conditions, and access the prevailing conditions (such as wind) before commencement of and
during the multiple hoisting operations.
Synchronisation of the crane and crab motions
• Crane and crab motions are to be synchronised or one crane placed in free slew mode
• To allow for the probability of the motions of the cranes or crabs not being accurately synchronized,
particularly if the cranes or crabs have dissimilar operating characteristics, the operation must be
performed at slow speeds with extreme care being exercised to maintain the hoist ropes as close
to vertical as possible.
• NOTES:
- 1. The rated capacity of a crane is calculated on the assumption that the load will be raised and
lowered in a vertical plane. The crane structure will have been designed to withstand any lateral
loads imposed by accelerations in the various crane and crab motions, but it is unsafe to rely
on this lateral strength to withstand horizontal components of non-vertical lifts.
- 2. In practice, there will always be some variation due to differences in response to the
activation of the motion controller and the setting and efficiency of the braking system
Pick and Carry (Multiple Cranes)
• In pick and carry operations, the axis of both or all cranes or crabs is to be kept aligned in the same
direction where possible. The possibility is that once out of alignment especially during cornering;
the movement of one crane or crab may push or pull either the other crane(s) or crab(s) and cause
loss of stability. Load chart limitation during articulation is to adhered to
• NOTE: Instruments are available to monitor constantly the angle of the load, and the verticality and force in
each hoist rope throughout the lifting operation. Their use is recommended.
• Tag lines must be used on loads when in pick and carry operations with the exception of dual crane
operations
• Cranes will not pick and carry loads on a fly or with a fly in the un-stowed position
• Dual crane pick and carry is a critical lift requiring a lift study
6.4.3 Controls
• All lifts require JSEA/SWMS to be completed and reviewed by the Crane Crew and responsible
Supervisor prior to commencing the activity.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• Lifting of persons in workboxes (Refer MMS Safe Operating Procedure # 020-T003-100 Workbox
Use).
• Working near overhead power lines (Refer MMS Safe Operating Procedure # 020-T009-100 –
Overhead Power Lines)
• Documentation specific to the operation being carried out should accompany the Crane Lift Plan.
This includes items such as erection sequences, relevant drawings, fixings etc.
6.4.4 Crane Lift Plans
Crane Lift Plans are to show weight, radius, crane capacity and % of SWL and a drawing showing the plan
view of the crane and load.
Crane Lift Plans (MMS # 600-F003-100) are required to be completed when any of the following conditions
apply:
• The client requires one or the crane operator requests one;

• The total suspended load including rigging equipment exceeds 85% of available crane capacity
(refer to crane load chart);
• The load is 50 tonnes or more;
• A Bridge Beam is to be lifted during bridge installation work;
• A Tilt-up Panel is to be lifted;
• Pre-cast Concrete Panels are to be erected;
• A Tower Crane is to be erected;
• A Mobile Crane is to used on a Barge;
• Lifting large pressure vessels or tanks
• More than one crane is to be used - either in shared lift configuration or when one of the cranes is
to be used as a `tailing' crane;
• The suspended load passes over any operating facility, or passes over or within 6 meters of any
electrical installation such as transformers and substations. In addition, lifting activities near
overhead aerial conductors are to comply with SOP MMS # 020-T009-100;
• Drawings of existing facilities at the site show that the movement of the crane or any operation of
the crane may damage underground services.
• Singapore - All lifts (Refer to WSH Operation of Cranes Regulations 2011)
6.5 MAINTENANCE, INSPECTION AND REPAIR - CRANES

Maintenance, inspection and repairs are to be carried out by a competent person in accordance with the
requirements listed below and as identified in AS.2550.1 or its local equivalent.
6.5.1 Maintenance
• A preventative maintenance program will be established giving consideration to the manufacturer’s

recommendations. It will be based on the working environment and the frequency and severity of
use of the crane.
• Ensure all subcontractor contracts include maintenance schedules
• When parts and components are replaced, replacements will be identical or equivalent to the
original equipment parts and components.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• Where past experience has shown particular problems with a crane, a specific rectification program
will be instigated and documented.
• All malfunctions and problems will be corrected before the crane is returned to service.
• Maintenance is to be carried out in accordance with the Manufacturer’s recommendations.
• A documented record is to be maintained for any maintenance completed.
• Routine inspections should take place at intervals not exceeding those shown in the operator’s
handbook.
6.5.2 Inspections
The following items should be checked for compliance with manufacturers’ specifications and safe
operation as part of a pre-operational inspection of a crane:
• Check the oil levels, fuel level and lubrication of all moving parts.
• Check the ropes, rope terminal fittings and anchorages, rope drums and sheaves for any damage
and wear.
• Check that all water is drained from air reservoirs.
• Check the crane for any loose or damaged structural component including supports and outriggers
where fitted. Loose joints may be readily noticed by flaking or marking on the paint surface or by
rust marks. Similarly, cracks may often be detected by rust runs.
• Visually inspect structural members and other critical components such as brakes, gears,
fasteners, pins, shafts, wire ropes, sheaves, locking devices and electrical contacts.
• Check the security of the counterweight. Where this is in the form of removable weights, check that
the weights correspond to those shown on the counterweight chart for the operating condition in
use.
• Check that the load moment system where fitted is correctly set or fitted (or both) with the program
appropriate to the boom or jib length, and fly-jib lengths and falls or parts of rope.
• Check that the indicator appropriate to the boom, jib or fly-jib length is fitted.
• Check that the crane cabin is in a tidy condition and free from grease and oil, rags, tools and
materials other than those for which storage provision is made.
• Check the pneumatic systems and hydraulic systems including their safety devices.
• Check the operation of the crane through all motions with particular attention to brakes.
• Check the operation of all limit switches or cut-outs, emergency and safety devices.
• Exercise caution in making the checks in the event of non-operation.
• Check that, where radio communications are being used, the calling signal is functioning and any
messages may be clearly heard.
• Check signage, including warning signs and control markings.
• Check that fire extinguishers are in place and satisfactory for use.
• Additional items nominated in the manufacturer’s instructions or operator’s handbook.
6.5.3 Periodic inspections
• Inspection is to include all items specified by the manufacturer for annual inspection along with all
routine inspection and maintenance items.
• As the result of a periodic inspection, a competent person may recommend a major inspection.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• For details of inspections for particular types of cranes, refer to relevant Part of the AS 2550 series.
• Where the crane has a non-positive lifting attachment, (vacuum, magnetic etc) suitably qualified
personnel are to carry out maintenance according to the manufacturer’s recommendations. If such
recommendations are not available, then twice-yearly maintenance is to be carried out. Permanent
and electro-permanent lifting magnets are to undergo a yearly residual magnetism check of the
magnet core. Where vacuum lifting attachments are used, the frequency of inspection is to be twice
daily to ensure no seal damage the machines continue to function as designed.
• Vacuum and magnetic devices are to be fitted with failsafe devices where available
6.5.4 Major inspection to assess a crane for continued safe operation.
• All cranes are to be inspected and repaired as per AS2550.1

• Where third-party inspections are conducted, the following requirements apply:
- As part of this inspection, the maintenance records of the crane must be reviewed prior to the
inspection. After the inspection, a report on the condition of the crane is to be compiled on the
current condition of the crane. The usage of the crane must be verified for compliance with the
design classification.
- The inspection is to include checking electrical, mechanical and structural components for safe
condition and function. Opening of cover plates and removal of guards is to be as considered
necessary by the inspector due to the existing condition. Particular attention must be paid to
any component with a recent or existing history of repeated failures.
6.6 REPAIRS
Any part of a crane that becomes worn beyond manufacturer’s tolerances, damaged as to constitute a
hazard, impairs the operation of the crane, or constitutes a hazard before the next routine inspection, must
be repaired or replaced. The repairs and parts must comply with the manufacturer’s recommendations and
specifications, or the recommendations of a competent person, taking due cognizance of the Standard to
which it was designed and must be carried out by competent persons under competent direction and
supervision. The repairs are to be appropriately tested. All repairs are to be adequately documented and
recorded.
6.6.1 Assessment for repair procedure
• A competent person is to make an assessment of the defects and damage requiring repair based
on the manufacturer’s tolerances and in accordance with AS 2550.1. The assessment is to be
recorded and form a report. The report should contain the following:
• Details of how the incident happened or circumstances leading to the discovery of the defective
parts.
• Nature and extent of the damage and defects.
• Proposed action based on the manufacturer’s recommendations.
6.6.2 Management of repairs.
Following the review of the competent person’s report, the equipment may only be repaired or scrapped.
Where any component is scrapped, arrangements should be made to dispose of the damaged component
in a manner that ensures it remains unusable as a load-carrying component.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
Where it is decided to implement the manufacturer’s recommendations, instructions incorporating such

recommendations will be prepared. Such instructions must be followed.
Following repairs, the crane will undergo the load and operational tests specified in the appropriate part of
AS 1418 to an extent commensurate with the type of alteration or repair.
6.6.3 Repair work
• The repairer selected to carry out the work must be acceptable to the competent person. Repair
work is to be carried out according to the following:
• Personnel with the necessary qualifications and experience will be engaged on the work.
• Work instructions will be provided.
• All work is to be in accordance with manufactures recommendations
• Sign off line manufacturers prior to work commencing
• All work to be managed by ITP, SMP, QMP, QC checklists.
• All work will be conducted in accordance with relevant Australian Standards or other applicable
national or international Standards.
• All final non-destructive testing will be conducted by a competent person.
• A records management system is to be established for the documentation produced by repairers
and received from other bodies for transfer to the owner.
6.6.4 Welding repair examination
• The examination of welding repairs must be carried out in accordance with the manufacturer’s
repair procedure, or the appropriate weld inspection Standard.
• Preapproval for the welding procedures and qualifications of welders is required.
6.7 RIGGING AND LIFTING
6.7.1 Competency
The slinging method is to be determined by a person who is competent in load slinging in accordance
with local Safety Regulations.
Project management is to identify the specific local licensing requirements for persons undertaking lifting
operations.
Within Australia the Riggers licence capabilities are defined as;:
Dogging – consists of the application of slinging techniques to move a load (including the selection and
inspection of lifting gear) and/or the directing of a crane/hoist operator in the movement of a load when the load
is out of the view of the crane/hoist operator.
Basic rigging – consists of dogging and rigging work involving:

• Movement of plant and equipment
• Steel erection
• Hoists (including mast climbing hoists)
• Placement of pre-cast concrete
• Safety nets and static lines
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• Perimeter safety screens and shutters, and Cantilevered crane-loading platforms.

Intermediate rigging – consists of all basic rigging work including rigging work involving:
• Cranes, conveyors, dredges and excavators
• Tilt slabs
• Hoists with jibs and self-climbing hoists
• Demolition
• Dual lifts
Advanced rigging – consists of all intermediate rigging work including rigging work involving:
• Gin poles and shear legs
• Flying foxes and cableways
• Guyed derricks and structures
• Suspended and fabricated hung scaffolds
Australia Only
Appendix A Licensing Persons Performing High Risk Work lists the Certificates of competency
relevant to the crane industry -.(Refer to National Standard for Licensing Persons Performing High
Risk Work.)
6.7.2 Equipment Selection & Planning
Before selecting any rigging and lifting equipment, the following should be taken into account;
• Load
• Headroom
• Frequency of use- life of sling
• Type of load – Steel, Machinery, timber, crates, shipping container etc
• Current inspection certificate
• Cost versus efficiency
• Length of sling
• Method of slinging
• Environment – corrosion, heat etc
• Storage requirements
6.7.3 General requirements- Lifting Equipment
• A visual inspection will be conducted prior to use of rigging and slinging equipment.
• Never combine different types of slings.
• Shackles are to be used where slings are attached to eyebolts or lugs.
• Shackle diameter must not be less than sling diameter.
• Multiple individual slings are to be shackled together on the hook.
• All hooks are to be supplied with devices to prevent load movement.
• Lifting clutches are to be proof load tested at least at twelve (12) monthly intervals, with a record
kept on site to verify such testing.
• Inspections must be conducted by a competent person and be recorded by that person.
• All rigging and lifting equipment either purchased or hired on a project, must have all certifications
relevant to the item in accordance with the relevant local standard.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• Items to be kept include but not limited to records from the manufacturer or supplier, identifying that
the equipment has passed all relevant testing and has been supplied in accordance with the
relevant local standard. Items include equipment such as; slings, shackles, eyebolts, lifting
clutches, chain blocks etc.
• All rigging and lifting equipment certification and inspection/test records are to be maintained and
readily available.
• Suitable storage arrangement available for the particular types of equipment – typically hung up off
the ground in a covered, dry, clean, well ventilated place, away from direct sunlight.
• If one or more of the defects, listed in Error! Reference source not found. is identified, the item
is to be removed from service immediately, tagged out and condition fully assessed prior to being
discarded.
6.7.4 Chains
Care
• Compliance certificate for chains should be available in project files.

• Store chain slings in a clean dry place, preferably on A-frames or wall racks.
• Lightly oil chains before prolonged storage.
• Never heat treat alloy chain or fittings.
Use
• Minimum size chain for lifting purposes is to be 6mm.

• Alloy steel chain Grade (T) 80 or higher is to be used for lifting.
• Always visually inspect that a chain sling is free from damage or wear before use.
• Ensure the weight of the load is known and is evenly distributed on the sling legs.
• Ensure that the chain is free of twists and is protected from any sharp corners on the load.
• Avoid crushing the chain.
• Do not use a chain in a manner that will exceed the WLL of the chain for the particular conditions
of use.
• The user should seek advice from the manufacturer regarding a reduction in WLL, where chain is
to be used at temperature hotter than 200°C or colder than -10°C.
• Commence the lift slowly, taking up the slack gradually. Avoid shock loads.
• When lowering, avoid the possibility of crushing the chain by ensuring the load does not land on it.
Use packing, timber or similar.
Inspection
• Clean the chain thoroughly.
• Lay the chain out on a clean surface or hang it up in a well lit area.
• Every chain link should be individually inspected for any signs of wear, twisting, stretching, nicks,
or gouging and any worn link measured to determine degree of wear using vernier callipers.
• Master links and hooks should be inspected for any sign of wear at their load bearing points and
for any signs of distortion, such as widening of hook throat opening.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• Coupling links should be inspected for any signs of wear at their load bearing points, for excessive
play of the load pin within the body halves and for impaired rotation of the body halves around the
load pin.
• Chain links or fittings having any defects should be clearly marked to indicate rejection and the
chain sling should be withdrawn from service until properly repaired and retested prior to returning
to service.
Remember - Every link must be examined
6.7.5 Steel Wire Rope
Care and Use

• Minimum size wire rope for lifting purposes is to be 8mm
• Continuous wire rope slings with large diameter soft eyes must not be used. Wire rope slings with
a ferrule secured thimble eye are acceptable
• All slings must be visually inspected prior to each lift.
• A thorough inspection of all slings in use must be made at regular intervals.
Inspection
Inspections must be conducted by a competent person who will inspect for the following:
• Broken Wires (refer to Australian Standards for quantity breaks).
• Corrosion (rust).
• Kinks
• Crushed or flattered sections.
• Bird-caging and high stranding.
• Damage to Wire Rope Terminations such as; sockets, wire rope grips, thimbles, ferrules, swage
buttons, cable stockings etc.
• Stretching or extended lay.
• >33% wear on individual wires.
• Adjacent broken wires.
• Heat damage.
• Other obvious damage.
If in your opinion a sling has sufficient damage of any type, don’t use it report it!
6.7.6 Synthetic Slings
Round Sling – an endless sling comprising a load-bearing core of high-tenacity continuous-multifilament

yarn that is completely enclosed in a woven cover, with or without fittings or coupling components.
Flat Webbing Sling – a sling made of flat woven synthetic-fibre webbing, which may incorporate end fittings
complying with AS 3585 or AS 3776 or local equivalent for the lifting and handling of loads.
Care and Use
• Never overload equipment
• Do not use if WLL tag is removed or illegible.
• Inspect sling for damage prior to use.
• Do not use if there is any sign of cut webbing, snagging, heat or chemical damage, excessive wear,
damaged seams, any other defects or presence of grit, abrasive materials or other harmful matter.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• Do not tie knots in sling webbing.

• Protect sling webbing from sharp edges. Use protective sleeves.
• Do not expose sling to temperatures above 90°C.
• Do not allow abrasive or other damaging grit to penetrate fibres.
• Consult with manufacturer’s recommendations before immersing a sling in a chemical solution.
• Keep away from strong alkalis and phenolic compounds.
Note: A nylon sling loses 15-18% of its strength on wetting with water, but regains that loss of strength after
drying out.
Inspection
Synthetic slings should be inspected for the following prior to use:
• One major disadvantage of woven webbing slings is that when used to lift loads such as concrete
slabs, grit can penetrate the sling causing internal fibre damage, which is not always obvious.
• Internal wear, caused by repeated flexing, particularly where particles of grit have penetrated into
the fibres.
• Damage to a fixed protective coating or sleeve can allow abrasive grit easy access to the sling
fibres.
• Melting or shrinkage of fibres due to exposure to high temperatures. Remember that high
temperatures can result from friction as well as from a hot environment.
• Prolonged exposure to ultra violet light, generally from sunlight, will weaken synthetic fibres - this
may be indicated by powdering of the outer layer.
• Chemical attack may also cause fibres to break down and soften. Surface fibres may be plucked
or rubbed off and there may be local stiffening of the sling.
6.7.7 Lifting Hardware
Shackles
Shackles are used for interconnecting components in lifting, tensioning and staying systems. A shackle
consists of a body, a removable pin and any applicable locking device.
• All shackles are to be Alloy steel shackles of grade S or better
• Commercial grade shackles are not to be used for lifting purposes.
• Stainless steel shackles are not to be used for lifting purposes.
• All shackles are to have the SWL cast or stamped into the shackle body
• Compliance certificate for the batch supplied is to be available in the Project plant files
• Ensure that all markings are clearly legible.
• Ensure pin is the correct type. Never replace the pin of a shackle with a bolt.
• The threads of the pin and body are undamaged and the pin screws freely into position.
• The body and pin is not unduly worn and free from distortion, nicks, gouges, cracks and excessive
wear and corrosion.
• The pin is screwed tightly with the collar and the pin is bedded evenly on the surface of the shackle
eye.
• The correct type of pin is used for the application.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• A bolt type shackle has a split cotter (safety pin) attached correctly.
• Shackles should not be heat treated as this may affect their working load limit.
• Never modify, repair or reshape a shackle by welding, heating or bending as this will affect the
working load limit.
Eye Bolts
• Eyebolts of 12mm or smaller should not be used in general lifting, staying or tensioning purposes.
• Commercial grade eyebolts are not to be used for lifting purposes or to support loads.
• Stainless steel eyebolts are not to be used for lifting purposes.
• Eyebolts should be screwed down fully to the face of the load to be lifted.
• WLL markings are clear and suit the application.
• Conduct a visual inspection for deformation and cracking.
• Conduct a visual inspection of the inside eye for wear.
• Conduct a visual inspection and check for damaged threads.
• Ensure the thread centre is aligned with centre of eye.
• Ensure the eyebolt’s thread form and the thread form in the corresponding hole or nut is
the same.
• Avoid excessive tightening of eyebolts.
• Metric and imperial eyebolts that conform to the Australian Standard have a safety factor of 6:1.
• When using eyebolts in pairs, it is essential that care be taken to properly align them. Eyebolts
must not be forced into alignment as overstress will cause a reduction in the WLL.
• A continuous sling should not be used with pairs of eyebolts. When lifting with pairs of eyebolts
supported by slings, always use slings with individual lengths.
Eyebolts should be inspected periodically by a competent person as per AS2317 or local equivalent.
Lifting Beams
There are three (3) types of lifting beams:

Lifting Beam - a lifting beam that is placed in bending by the applied load(s).
Spreader Beam or Bar - a spreader beam or bar that is placed in axial compression
by the applied load.
Combination Beam - a beam that combines both bending and axial compression
loads in the one beam.
• All spreader and lift beams are to comply with AS.4991 or the local equivalent.
When using lifting beams, the following shall be observed:
• The method by which the load is attached to the beam.
• The method by which the lifting beam is attached to the crane.
• Checking the security of the attachment of the load to the lifting beam.
• Alignment of the centre of gravity of the load to the lifting means.
NOTE: Open sections (UB, UC, PFC) are relatively flexible in torsion and care should be taken to avoid twisting these
components by eccentric loading.
• Checking the security of the attachment of the lifting beam to the lifting means, e.g. crane hook.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
Sundry Equipment
• All sundry rigging equipment is to fully comply with the relevant Australian standard or local
equivalent as a minimum.
6.8 LIFTING THE LOAD
6.8.1 Slinging the Load
• The slinging method is to be determined by the shape, size and weight of each load.
• Slings are to be positioned over flat surfaces not over sharp edges or corners.
• Use protective padding when using any sling around sharp corners.
• Secure the lifting area from unauthorised entry.
• Tag lines of 16mm natural fibre rope or equivalent are to be used as necessary to control load
sway.
• For large or long loads (12m+) attach 2 taglines and controllers or more if required
• Dual crane lifts do not require tag lines
• Loads are to be balanced.
• Ensure no part of the load can slide or fall out during lifting.
• Don’t stand between the load and other obstructions.
• Keep hands and feet well clear of pinch points.
• Loads are not to be lifted over personnel.
6.8.2 Executing the Lift
While undertaking the lift, the operator and the dogman/ rigger must:
• Coordinate the lift with other operations in the area

• Confirm wind speeds immediately prior to the lift
• Refer to the cranes load chart for load-reach relationship, working within the crane’s lifting capacity
at all times
• If the weight of the load is unknown, do not guess, but seek further advice
• No loads in excess of the safe working load shown on the load chart are to be lifted
• The load chart is to be kept in the cab of the machine at all times
• Never switch off or override the lift computer during a lift
• The crane driver is responsible for the overall safety of the lift and must discuss the lift with the
dogman/ rigger prior to commencing the lift. The crane driver is to obey the dogman/ riggers
directions during the lift
• Before lifting any load, ensure all loads are secured to prevent any items falling
• Avoid any sudden starts and stops to prevent shock loading of the crane and lifting equipment
• Tag lines must be attached directly to the load – not the rigging gear
• Tag lines are to be clean and dry and checked safe before use
• Tag lines are to be at least 16mm in diameter and made of non-conductive material.
• Lifting gear is not to be used as a tag line.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
• Before giving direction to hoist up, ensure the boom is positioned directly over the load
• Loads are to be lifted slowly to prevent swing
• Loads are to be lifted just high enough to clear obstacles
• Operators must not leave the load suspended in the air when leaving the cab
• No person is allowed to climb on or off a moving crane or load
• Do not allow anyone to stand under a suspended load or near lines under stress
• No person is to enter the fall zone until the load is as close as practicable to the landing point
6.8.3 Management of change during a lift
• If the operation cannot continue in accordance with the agreed procedure, the operation shall stop
and the procedure reassessed to take into consideration the reason for the stoppage.
• If the reassessment is considered a relatively minor deviation from the agreed procedure the
documentation (SWMS) shall be clearly marked with the actions considered appropriate and
agreed prior to operations recommencing.
• If the reassessment is considered a major deviation from the agreed procedure then the appropriate
actions shall be taken, as a minimum will require the documentation to be marked and amended in
accordance with the revised proposals agreed. If the deviation is significant it may require
production of a drawing revision, calculations or other information as applicable.
6.9 INSPECTION, REPAIR AND MODIFICATION
6.9.1 Inspection
All chains and slings purchased new are to be accompanied by manufacturers testing certificates and
tagged appropriately as per the equipment’s required standard.
Used equipment coming to site, must have records that it has satisfactorily passed inspections by a
competent person in the previous twelve (12) months.
The person performing annual inspections is to be a person employed by an accredited third party specialist
testing and inspection organization (such as Bullivants, Nobles or a local equivalent) that has completed
appropriate training and has the skills and knowledge to carry out such inspections.
Quarterly inspections (3 monthly) are to be carried out on lifting equipment by a competent person. Records
of outcomes from these inspections are to be kept and maintained with the equipment’s records.
A person deemed competent to carry out these inspections is someone who has the practical and
theoretical knowledge and relevant experience, sufficient to enable the person to detect and evaluate any
defects or weakness that may affect the intended performance of the equipment. The visual inspection
checklist is located in Error! Reference source not found.. If any of the items fail to meet any of the
required checks, the equipment should be tagged out of service and not to be used and upon assessment
either discarded or repaired.
Rigging and Lifting Equipment - Testing/ Inspection Frequency Requirements
Equipment Type Test/ Inspection Frequency Who
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
Certificates of
Manufacturer/Supplier
equipment certification
and test results to be Before initial introduction
Certified lifting
provided with new or to service
testing/inspecting
used within last twelve
authority
(12) months
All Rigging and Lifting
Re-inspect equipment
Equipment
annually or as per Manufacturer/Supplier
manufacturer’s If not specified – twelve
recommendations or (12) monthly as minimum Certified lifting
relevant Australian interval. testing/inspecting
Standard or local authority
equivalent.
Inspect condition of
Prior to each use Competent Person
equipment
Chain Slings –Grade T
Inspect equipment and
Quarterly Intervals Competent Person
record results
equipment
Steel Wire Rope
record results
Round Slings – equipment
Synthetic Fibre Inspect equipment and
record results
Flat Synthetic – equipment
Webbing Slings Inspect equipment and
record results
equipment
Lifting Devices
record results
6.9.2 Repair and Modification
• All repair and modification to lifting equipment is to be designed and fabricated in accordance with
applicable standards and the modified design registered by the design authority.
• After repair or modification, lifting equipment must be tested by application of a proof load, specified
by a competent person, and then thoroughly examined. A test certificate stating the Working Load
Limit and the proof load is to be obtained and retained on site.
• The design and specifications of purpose made lifting equipment must be approved by the design
authority.
• A report of the examination is to be produced.
• Modification and repair of lifting equipment is to be in accordance to the applicable standards.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
7 OTHER EQUIPMENT USED FOR

LIFTING
7.1 EARTHMOVING EQUIPMENT USED FOR LIFTING
The requirements from AS 1418.8 or its local equivalent are to apply when earthmoving equipment including
backhoes, front-end loaders, excavators, tool carriers and similar units are used for lifting freely suspended
loads as a secondary function associated with the normal application of the equipment.
Where it is intended to use the earthmoving equipment for cranage operations other than those indicated
above, or where variable rated capacities are specified, all requirements of AS 1418.5 or its local equivalent
are to apply.
Lift point - A lifting lug located on the boom, arm, linkage, front end loader bucket or quick-hitch as specified
by the manufacturer, to which a load may be attached for lifting freely suspended loads.
Lift point radius/reach - The lift point radius/reach is the horizontal distance from either the centre-line of
the front wheel or equivalent position on track, or the axis of rotation or the centre-line of the load supporting
axle as appropriate, to the vertical load line. Where a non-slewing machine is fitted with stabilizers, the
reach shall be measured from the centre-line of the stabilizers nearest to the load.
Rated lift bucket position - The bucket attitude with the bucket fully rolled forward and the load suspended
from the bucket as recommended by the manufacturer.
7.1.1 General requirements for lifting with earth moving equipment
• The earthmoving equipment shall be travelled only with arm and boom retracted to minimum
practicable radius.
• No person is permitted under the boom or suspended load.
• All persons operating the earth moving equipment are to have the appropriate certificate of
competency and/or training
• The person slinging the load or directing the operator is to have a certificate of competency for
dogging or rigging.
• No persons are to be lifted by earth moving equipment.
• Lift points are to be arranged such that accidental unhooking of the load cannot occur.
• Operational speed is to be reduced from high-speed mode.
• Where the sling or tackle is wrapped over the back of the bucket, it is not to come into contact with
any sharp projection or sharp edge.
• Loads are not to be suspended from bucket teeth or adaptors.
• Reference is to be made to the manufacturer’s manual for correct operation.
• A service record (logbook) is to be used to record servicing, maintenance and repair work, and
details of any malfunction that may occur with the machine.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
7.1.2 Requirements for rated capacity at maximum reach/radius
The rated capacity is the maximum mass (expressed in kilograms) that may be handled at the maximum
lift point radius, or reach, expressed in metres in the most adverse configuration for each lift point without
the strength, hydraulic, and stability requirements being exceeded.
The rated capacity comprises of the mass of the lifted load and the lifting attachments. Where a bucket is
fitted, the rated capacity is to be established at the rated lift bucket position that results in the maximum
radius.
A rated capacity chart, identifying the lift point location(s) and the corresponding rated capacity at that
position, is to be mounted inside the operator’s cab and is to show the following:
• Manufacturer’s name and model.
• Boom identification (length in metres), where applicable.
• Arm identification (length in metres), where applicable.
• Shoe width (in millimetres) and track gauge and length (in metres), where applicable.
• Deductions for attachments such as a bucket, lifting devices or quick hitch device to allow
determination of the net load that can be lifted.
• Tyre track and size (in millimetres) and inflation pressure (in kilopascal), where applicable.
• Bucket mass (in kilograms) and width (in millimetres), or quick hitch mass (in kilograms), as
applicable.
• NOTE: Buckets and quick hitches should have their mass marked on them.
• Ground speed limit for pick-and-carry rated load for rubber-tyred equipment (in kilometres per
hour).
• The maximum permitted slope for lifting and pick and carry operations.
• Where controlled lowering devices are fitted, a notice of the effect to be displayed.
• Any other equipment conditions that may impact on rated capacity.
7.1.3 Controlled lowering devices
Earthmoving equipment that is used to lift freely suspended loads that have a rated lift capacity at maximum
radius/reach greater than 1 t is to be fitted with a controlled lowering device on the raising boom cylinder(s).
The control-lowering device is to meet the requirement of ISO 8643, to protect against hydraulic hose
failure. Where control lowering devices are not provided, the following is to apply:
• A load greater than 1 t shall not be lifted.
• Controls shall be in place to ensure that uncontrolled lowering shall not result in injury or death to
persons in the area.
• Suspended loads shall not be lifted over personnel, in any circumstances.
7.1.4 Stability
Stability of earthmoving equipment is to be such that the rated capacity is not greater than
the appropriate percentage of the tipping load that has to be applied to tip the earthmoving
equipment within AS 1418.8 Section 5 or it is local equivalent.
Where the earthmoving equipment requires the use of stabilizers in order to achieve stability, the equipment
is to be supported by such stabilizers.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
7.1.5 Rated hydraulic capacity
The rated hydraulic lift capacity of earthmoving equipment is to be such that the rated
capacity is not greater than 87% of the hydraulic capacity at maximum reach/radius.
The rated capacity at each lifting point is to be prominently marked at the lifting point. This is not to be
exceeded under any circumstance, that is, the lifted load plus any attachments (bucket, etc.) shall not
exceed the rated capacity.
Deductions from the rated capacity for larger than standard buckets or quick hitch devices are to be
considered to determine the maximum allowable mass of the item that may be lifted. Reference is to be
made to the manufacturer’s manual for correct operation.
7.1.6 Quick-hitches
Quick-hitches that are fitted to earthmoving equipment used to lift freely suspended loads are to comply
with the requirements in AS 4772 or its local equivalent. (Safe use of earth moving machinery fitted with a
quick-hitch)
Where equipment is used and is fitted with a quick hitch, the following requirements apply:
• Loads only to be suspended from the manufacturer’s designated lift point on the quick-hitch unless
a designated lifting attachment is fitted.
• All non-lifting attachments to be removed before any lifting operation is undertaken.
• Quick-hitches to be used only to support attachments specifically designed to fit and specifically
designed for the duty to be undertaken.
• Host machine load rating charts to allow for the additional mass of the quick-hitch.
• Quick-hitches to be maintained in proper working order at all times.
7.1.7 Marking and Labelling
The earthmoving equipment configured to lift freely suspended loads is to display at a readily accessible
and prominent location and on permanent and legible notices the following information, where appropriate:
• Name or mark of the supplier.
• Model designation.
• Serial number.
• Where earthmoving plant is to be used for lifting a freely suspended load, all controls shall be
labelled in accordance with ISO 7000.
8 RECORDS
Daily inspection records
Lift Plans
Maintenance records
Plant incoming inspections – internal and external inspections
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
9 REFERENCES
Competency Register 030-F044-100
Competency Register – By person 030-F045-100
Compliance with Legal & Other Requirements 000-D004-000
Crane Lift Plan 600-F003-100
Height 020-T005-100
HSE Risk Management 020-D012-100
Mobile Equipment Daily Inspection Report 045-F030-100
Overhead Power Lines 020-T009-100
Project Training Plan 030-J008-100
Plant & Equipment Register 045-F136-100
Plant Operator Assessment 030-F047-100
Project Compliance with Legal & Other Requirements 300-E012-100
Storage Maintenance & Refuelling of Machinery 025-L007-100
Workbox Use 020-T003-100
Cranes and Lifting Equipment ESH-047

Elevated Work Platforms ESH-111
ES&H Aspects of Plant and Machinery ESH-057
ES&H Training and Competency ESH-003
Forklift Trucks ESH-048
Procurement ESH-021
Singapore - Code of Practise for Safe Lifting Operations at Workplaces

Singapore - WSH Operation of Cranes Regulations 2011
Management Systems Australia. Environment, Safety and Health Management System ES&H Compliance
Guidelines. See Section 8 ‘External References’ in the guidelines listed below for relevant legislation,
standards and guidance material.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
10 APPENDICES
APPENDIX A – LICENCES TO PERFORM HIGH RISK WORK
The following is a list of the licenses for high risk work, as given in the National Standard
for Licensing Persons Performing High Risk Work (April 2006), that are relevant to the crane industry in
Australia:
(DG) Dogging
(RB) Basic rigging
(RI) Intermediate rigging
(RA) Advanced rigging
(CT) Tower crane operation
(CS) Self-erecting tower crane operation
(CP) Portal boom crane operation
(CB) Bridge and gantry crane operation
(CV) Vehicle loading crane operation
(CN) Non-slewing mobile crane operation
(C2) Slewing mobile crane operation (up to 20 t)
(CO) Slewing mobile crane operation (open/over 100 t)
(WP) Boom-type elevating work platform operation
(HM) Materials hoist (cantilever platform) operation
(HP) Hoist (personnel and materials) operation
(BP) Concrete placing boom operation
NOTES:
1. The above list was correct at time of publishing.
2. The National (Australian) Standard for Licensing Persons Performing High Risk Work can be downloaded
from the Safe Work Australia website at: www.safeworkaustralia.gov.au
3. For crane operations conducted outside of Australia, local regulations should be consulted to determine
any specific local requirements.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
and turnbuckles
Pre-Use Inspection/Check for rigging
Wire Rope
Synthetic Slings
Chains
Hooks
Sheave blocks
Shackles
Sockets
Rigging screws
Eye Bolts
Hoists
Clamps
Winches
and Lifting equipment
SWL or WLL is clearly legible ✓ ✓ ✓ ✓ ✓ ✓  ✓ ✓ ✓ ✓ ✓

Clean before use and inspection ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
The is no excessive gouging or wear - no more than 8% ✓  ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Broken wires are no more than one broken at an end connection, two at
✓
areas beyond end connection
There is no deformation of deformation such as bending twisting, knotting,
✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
stretching, kinking, nick and cracking
No Corrosion or chemical attack ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
End fittings, terminal attachments or links are not deformed/damaged ✓ ✓ ✓ ✓ ✓
No wear to external or internal cover  ✓
No Heat Damage (Discolouration) ✓ ✓
No holes in cover ✓
No Local Abrasion ✓
No Sunlight degradation ✓
No Deterioration to stitching ✓
Safety catch fully functioning  ✓ ✓
Increase in throat opening is less than 15% ✓ ✓
Moving parts have free movement ✓ ✓ ✓ ✓ ✓ ✓ ✓ ✓
Any threads to be in good working order ✓  ✓ ✓ ✓ ✓ ✓
All pins and attachments are the correct type and size and free of damage ✓ ✓ ✓ ✓ ✓ ✓
There is an end stop fitted ✓
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
APPENDIX C – COMMUNICATION SIGNALS AND ALARMS
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
APPENDIX D – WORKING NEAR OVERHEAD POWER LINES - NO GO ZONE
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
APPENDIX E – FREE FALL FEATURES ON CRANES
Definition
A feature fitted on some mobile cranes that allow the hook and load to fall under gravity in an uncontrolled
manner.
Background
There have been a number of serious accidents caused by loads dropping in a free fall manner.
The free fall feature has been traditionally fitted on cranes for activities such as clam shell dredging and
dynamic pile compaction. However, the risk associated with an inadvertent activation of the free fall
feature can be high and the provision is rarely needed. Most mobile crane manufacturers dot not provide
this feature on new cranes. The risk to workers from falling loads and potential damage to the crane and
crane operator is considerable.
McConnell Dowell Policy
McConnell Dowell policy is that no crane is to operate with an active free fall feature. This policy can only
be relaxed with written approval of the relevant Executive/General Manager. The policy applies to both
McConnell Dowell and hired in cranes.
Requirements for McConnell Dowell Cranes
The free fall capabilities on McConnell Dowell cranes are to be permanently deactivated. This
deactivation of the free fall should include removal of free fall switches on the crane and a certificate from
the crane manufacturer or a competent person (preferably a professional engineer) to state that the free
fall function has been permanently removed.
Requirements for Hired-in Cranes
Owners of cranes with free fall features that do not have a physical lockout arrangement to prevent
inadvertent activation are to engage a competent person to install a lockout and test the arrangement.
Owners are also to engage a competent person to inspect and test to ensure that the lockout has been
correctly installed and free fall cannot be inadvertently activated.
Guidelines for Relaxation of Policy
The use of the free fall function on a mobile crane should be extremely rare and only be permitted where
a documented safe work method statement has shown there is no other reasonable alternative. A
documented risk assessment is to be prepared for this situation and submitted to the relevant Executive
/General Manager with a request for a waiver of the policy.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
APPENDIX F – TYPICAL ADVERSE WEATHER GUIDELINES
Beaufort Scale Ave. Ave. Ave. Effects of wind speed Effects of wind speed over Operating
Wind Wind Wind over land water Information
Speed Speed Speed
(knots) (km/h) (m/s)
0 Calm Less Less 0 - 0.2 Calm, smoke rises Sea like mirror Normal Lifting
than 1 than 1 vertically. Zone for most
cranes:
1 Light Air 1-3 1-5 0.3 – Direction of wind shown Ripples with the appearance of
Confirmation of
1.5 by smoke drift, but not scales are formed, but without
operating
by wind vanes. foam crests
parameters
should be
2 Light 4-6 6-11 1.6 – Wind felt on face; Small wavelets, still short, but sought from the
Breeze 3.3 leaves rustle; ordinary more pronounced; crests have crane operations
wind vane moved by a glassy appearance and do not manual and
wind. break reviewed by the
crane operator.
3 Gentle 7-10 12-19 3.4 - Leaves and small twigs Large wavelets; crests begin to
Breeze 5.4 in constant motion; wind break; foam of glassy
extends light flag. appearance; perhaps scattered
white horses
4 Moderate 11-16 20-28 5.5 – Raises dust and loose Small waves, becoming longer;
Breeze 7.9 paper; small branches fairly frequent white horses
moved.
5 Fresh 17-21 29-38 8.0 – Small trees in leaf begin Moderate waves, taking a more
Breeze 10.7 to sway; crested pronounced long form; many
wavelets form on inland white horses are formed
waters. (chance of some spray)
6 Strong 22-27 39-49 10.8 – Large branches in Large waves begin to form; the Review and
Breeze 13.8 motion; whistling heard white foam crests are more Assess Zone:
in telegraph wires; extensive everywhere (probably
Review crane
umbrellas used with some spray)
operation limits
difficulty.
and effects on
loads lifted.
7 Near Gale 28-33 50-61 13.9 – Whole trees in motion; Sea heaps up and white foam
17.1 inconvenience felt when from breaking waves begins to Agreement to
walking against the be blown in streaks along the continue with
wind. direction of the wind entire crane
crew and person
in charge of
lifting
operations.
8 Gale 34-40 62-74 17.2 – Breaks twigs off trees; Moderately high waves of No Lifting
20.7 generally impedes greater length; edges of crests Zone:
progress. begin to break into the spindrift;
the foam is blown in well-
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
Beaufort Scale Ave. Ave. Ave. Effects of wind speed Effects of wind speed over Operating
Wind Wind Wind over land water Information
Speed Speed Speed
(knots) (km/h) (m/s)
marked streaks along the

direction of the wind
9 Strong 41-47 75-88 20.8 – Slight structural damage High waves; dense streaks of
Gale 24.4 occurs (chimney pots foam along the direction of the
and slates removed). wind; crests of waves begin to
topple, tumble and roll over;
spray may affect visibility
10 Storm 48-55 89-102 24.5 – Seldom experienced Very high waves with long
28.4 inland; trees uprooted; overhanging crests; the
considerable structural resulting foam, in great patches,
damage occurs. is blown in dense white streaks
along the direction of the wind;
on the whole, the surface of the
sea takes a white appearance;
the tumbling of the sea
becomes heavy and shock-like;
visibility affected
11 Violent 56-63 103- 28.5 – Very rarely Exceptionally high waves (small
Storm 117 32.6 experienced; and medium sized ships might
accompanied by be for a time lost to view behind
widespread damage. the waves); the sea is
completely covered with long
white patches of foam lying
along the direction of the wind;
everywhere the edges of the
wave crests are blown into
froth; visibility affected
12 Hurricane 64 and 118 32.7 – Severe and extensive The air is filled with foam and
over and 36.9 damage. spray; sea completely white
over with driving spray; visibility very
seriously affected
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
APPENDIX G - COMMONLY USED TERMS AND ALTERNATIVE NAMES
Cranes
TERM COMMONLY USED TERMS
Crawler Crane with tracks.
Spragg / spragging To turn left or right on tracks
Jib Boom / Mast The main section of the crane used for lifting. It has 3 or 4 chords and
lattice sections.
Headache Ball Used above the hook to weight down and steady the hoist line.
(Auxiliary Hook)
Main Block A sheave block above the main hook used to take multiple parts of the
hoist rope.
Rooster Usually the part at the top or tip of the boom that holds the auxiliary line
or whip hoist rope.
Whip / Auxiliary Line The secondary line for doing smaller or lighter lifts.
Tip The working end of the boom holds the rooster and the main hoist rope
sheaves.
Bridle Holds the pendant ropes and is connected to the luffing ropes allowing
the boom to move up and down.
Pendant/ Pendant The main supports holding the boom or jib in place.
Ropes
Rams Horn Usually on the main block. This is a double hook used partly to balance
the load but it is made to put multiple slings on it for big or awkward
lifts and spread weight out more evenly.
Traming / Tracking / The forward or backward motion of a crawler crane.

Travelling
Butt The bottom section of the boom. This is the part that is connected to the
crane that has pins to pivot up or down the crane.
Carbody This is the part that holds the engine winches and boom of the crane as
well as the cab and counterweights
Base / Chassis This frame supports the car body through the slew ring and the tracks
are also fixed to the base
Counter Weights These provide the balance that the crane requires to lift objects.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
Belly Weights This provides extra weight to the crane to perform larger lifting capacity.
Mobile-hydraulic / As the name implies it can be setup quickly to move around a site(s).
Oilcan Not for pick and carry these cares usually have some of the attributes of
a crawler crane however the boom is telescopic and retracts; it has
outriggers for stability and usually has rubber tyres.
Rough Terrain / These usually are similar to mobile cranes however they usually have a
Roughie pick and carry capability. They are sometimes very quick to set up.
Franna This is proprietary name however they usually have a pick and carry
capability.
Tom Thumb A small hydraulic crane used to set up in very tight or small areas
however they cannot pick up large amounts of weight or sizes.
Tower Cranes These are fixed on top of a frame or tower and are self climbing using
extra pieces on the tower. There are usually two types.
Luffing Boom
Meaning the luffing boom can either move up or down on a pivot point
on the main boom
Saddle Jib or Hammer Head
Meaning the jib is in a horizontal position and a trolley or saddle moves
in and out along the boom carrying the hoisting rope with hook below.
Fibre Rope Slings
Rope Polypropylene, polyethylene, hemp, sizal, cotton, dyneema. These are

some of the types mentioned above. There are numerous others, too
may to mention. They should be used as per specifications,
recommendations or regulations. They can be used for all of the below.
Taglines To tie to a load to control load (16mm minimum)
Shark Hook A hook sometimes connected to the tagline. They alleviate the need to
tie the rope to the item being lifted.
Sheep Shank A rope hitch used to shorten the rope and can be also used to give you
purchase when tying a load down.
Clove Hitch A rope hitch to secure a load.
Bowline A rope hitch in conjunction with a tagline.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
Figure of 8 A rope hitch to join two ropes together.
And many more knots and stitches.
Wire ropes
Snotter Is a sling with an eye either hand or machine spliced at each end.
Sheave This is a grooved wheel used to run a wire over. Usually used on cranes,
however can be used for rigging applications.
Stinger 1. Beam between crane and super lift tray or trailer

2. A sling or oblong ring used on the hook for ease of attaching rigging
Grommet Is formed into a circle and is either hand spliced or machine spliced.
These types of wire rope slings can be used for stingers. However they
are generally used to increase capacity without increasing the size of the
wire rope.
FSWR Flexible steel wire rope.
IWRC Independent wire rope core.
FC Fibre core.
Bulldog Grip For temporarily joining two ropes together or making an eye.
Thimble A piece of formed or cast metal formed into an eye to help support the
way rope sits and stops deformation of the rope.
Ferrule Is a piece of metal to clamp two pieces of rope (called a swage) together
to form an eye grommet.
Superflex Is a woven wire rope generally used where a tight bend cannot be
overcome or on painted items reducing paint damage.
Flemish Eye Is a type of splice to form an eye. It is used when steel ferrules are used
in making FSWR slings. These should never be used for lifting without
being swaged and tested first.
Swage Is the term used for a ferrule compressed to form an eye in a wire rope.
Hambone / Wedge Is a fitting generally used on the hook of a crane by wrapping the rope
Socket around a wedge and welding the rope into a socket.
MCCONNELL DOWELL
MMS # 020-T001-100
REVISION 5
OCTOBER 2015
Spelter Socket Is a socket that a rope terminates in. It is usually used in conjunction
with either hot metal or two pack epoxy type compound these have an
efficiency rating of 100%, based on the catalogue strength of wire ropes.
Chains
Latch Lock Hook Is a hook attached usually to chains. It is a hook with a positive latch
closing mechanism.
Sling Hook Has a spring latch.
Shortening Hook Small hook to shorten chain assembly.
Grab Hook Same as above (safer).
Oblong Ring Usually a fitting incorporated into chain sets.
Hammer Lock / An important link to make up a chain set or join to equipment.

Connecting Link
Multi Large oblong with two smaller ones permanently fitted to it.
Shackles
Safety Bow Bow type, has a pin and nut.
Bow Same as above however has a screw type pin.
Dee As the name implies is good for thickened pad eyes.
Other lifting gear
Cumalong / Lever Hoist Hoist for short lift jobs.
Chain Block / Chain Hoist for short to long lift jobs.

Hoist
Tirfor / Creeper Winch Used in communication with wire rope for guy wires or temporary stays.
MCCONNELL DOWELL

020-T001-100 Crane Lifting Operations Rev5 PDF

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McConnell Dowell Corporation

MCD Management System

CRANE AND LIFTING OPERATIONS

Rev Date Details Author Reviewer Approver

1 14Jun2012 Added Section 6.11.18 Crane Free fall R Brown J Phillips

2 22Jul2013 Full Review D Woods J. Phillips

6.1 Crane Selection and Planning ..................................................................................................14

6.7 Rigging and lifting ....................................................................................................................27

Appendix D – Working near overhead power lines - No go zone .........................................................43

“Never be under a suspended load.”

• Ensure that this procedure is communicated to relevant Project personnel.

4.2 SENIOR PROJECT OHS REPRESENTATIVE (SPOHSR)

• Assist the Project Manager, Superintendents, Supervisors and Contractor Representatives to

4.3 SUPERINTENDENTS AND SUPERVISORS (S)

4.4 MCCONNELL DOWELL AND SUBCONTRACTOR PERSONNEL

• Comply with all relevant aspects of this procedure

4.5 CONTRACTS AND PROCUREMENT PERSONNEL

4.6 CRANE LIFT SUPERVISOR

• Review all technical details and plans for lifts

WHAT HAS TO BE DONE WHEN WHO INFORMATION

Identify any Standards, Codes of Practice etc Start of project SPOHSR

SOP MMS# 020-T003-100

5.1.2 Select lifting equipment that is fit for purpose

WHAT HAS TO BE DONE WHEN WHO INFORMATION

Select crane Commencement Project See section 6.1 cranes

WHAT HAS TO BE DONE WHEN WHO INFORMATION

Record any additional

5.1.4 Select Plant operators

WHAT HAS TO BE DONE WHEN WHO INFORMATION

5.1.5 Initial inspection and approval to bring plant on site

WHAT HAS TO BE DONE WHEN WHO INFORMATION

Initial inspection and approval to bring plant on site

5.1.6 Report defects

WHAT HAS TO BE DONE WHEN WHO INFORMATION

5.1.7 Statutory plant inspections

WHAT HAS TO BE DONE WHEN WHO INFORMATION

5.1.8 Develop a plant maintenance schedule

WHAT HAS TO BE DONE WHEN WHO INFORMATION

5.1.9 Arrange maintenance and refuelling

WHAT HAS TO BE DONE WHEN WHO INFORMATION

Arrange maintenance and refuelling

5.2 DO THE JOB

5.2.1 Plan the lift

WHAT HAS TO BE DONE WHEN WHO INFORMATION

5.2.2 Daily plant inspections

WHAT HAS TO BE DONE WHEN WHO INFORMATION

5.2.3 Report defects

WHAT HAS TO BE DONE WHEN WHO INFORMATION

5.2.4 Prepare work area and evaluate weather

WHAT HAS TO BE DONE WHEN WHO INFORMATION

5.2.5 Conduct the lift

WHAT HAS TO BE DONE WHEN WHO INFORMATION

5.3 SUPERVISE AND MONITOR LIFTING OPERATIONS

5.3.1 Supervise the lifting operation

WHAT HAS TO BE DONE WHEN WHO INFORMATION

5.4 TAKE ACTION WHEN SAFETY RISKS ARE IDENTIFIED

5.4.1 Report and Take Action

WHAT HAS TO BE DONE WHEN WHO INFORMATION

Report any defective equipment to the supervisor. Immediately All employees

Stop the job if unsafe Immediately on Supervisor

The following planning activities are to be carried out by a competent person(s):

6.1.2 Crane location planning – vicinity, visibility