Chapter 27

Cranes, Hoists, and Rigging Safety

Contents

Approved by Michael Wisherop

Revised 07/15

NOTE:
..... Denotes a new section.
. . . . . . . . Denotes the beginning of changed text within a section.
. . . . . . . . Denotes the end of changed text within a section.

____________________

27.1 Policy

27.2 Scope

27.3 Applicability

27.4 Roles and Responsibilities

27.5 Definitions

27.6 Required Work Processes

Work Process A. General Requirements for Crane Operation

Work Process B. Procurement and Maintenance of Cranes and Hoisting and Rigging Equipment

Work Process C. Authorization and Qualification to Use Cranes

Work Process D. Restricted Operations

Work Process E. Mobile Cranes

Work Process F. Crane Inspections

Work Process G. Rigging and Other Below-the-Hook Devices and Fixtures

27.7 Standards

27.8 Related PUB-3000 Chapters

27.9 References

Appendix A. Typical Pre-use Inspection Tags

____________________

27.1 Policy

Persons involved in crane or hoist operations at Lawrence Berkeley National Laboratory (Berkeley Lab) must:

Be aware of the hazards related to the equipment and the load

Know the methods for controlling those hazards
Follow the proper operating procedures applicable to the type of lift and equipment

The designated operator must be qualified and authorized to use specific equipment.
Crane, hoist, and rigging equipment must be procured through the Facilities Division or from a Berkeley Lab approved vendor,
as well as properly inspected, tested, and maintained.

27.2 Scope

Berkeley Labs Crane Safety Program is implemented through planning, authorization, qualification, and the appropriate use of
properly inspected and rated hoisting equipment and rigging. Lifting and moving loads with forklifts is covered in PUB-3000,
Chapter 28, Forklifts and Other Powered Industrial Trucks. Construction operations involving cranes are covered in Chapter 10,
Construction Safety.

27.3 Applicability

This policy establishes requirements for Berkeley Labs Crane, Hoisting, and Rigging Safety Program and applies to work with any
crane or hoist operated at Laboratory-owned or -leased property, as well as Laboratory-managed field research. This program
applies to the following Berkeley Lab personnel:

1. Employees
2. Affiliates
3. Construction contractors
4. Nonconstruction contractors and vendors

27.4 Roles and Responsibilities

Role Responsibility

Supervisors and Work Leads Ensure that personnel know how to safely operate cranes and hoists,
and how to move objects safely
Ensure that only formally trained and certified employees may operate
a crane or hoist
Enforce the use of safe lifting techniques
Maintain lifting equipment in good mechanical and operating condition

Crane Manager Identifies oneself, in writing, as the Crane Manager to the

A Berkeley Lab employee must be identified as
the Crane Manager for each Berkeley Lab-owned
crane or hoist, unless it is locked out.
Environment, Health & Safety (EH&S) Division Crane Safety Subject
Matter Expert (SME) at cranesafety@lbl.gov or Mail Stop 75B0101
Possesses a valid certificate for the operation of the crane in question
Controls the use of the crane, and limits use of the crane to qualified
operators

Maintains control of any keys or other mechanisms for limiting crane

use
Maintains any logbooks used in lieu of inspection tags
Limits crane use to previously authorized operators
A qualified backup Crane Manager who has been identified to
the Crane Safety SME may issue new crane authorizations in the
absence of the Crane Manager.
Notifies the EH&S Crane Safety SME (cranesafety@lbl.gov, Mail Stop
75B0101) of any change

Employees (Operators, Riggers, and Maintain training and medical qualification

Helpers) Safely operate cranes
Possess a valid Berkeley Lab Crane Operators License
Are certified by an independent certification agency as competent and
qualified operators of mobile cranes with a greater-than-two-ton
capacity

Mechanical Engineering Designee
Responsible Designer
Customer Management
Facilities Division Structural Engineering
Group Designee
Facilities Division Rigging Supervisor
Facilities Division Crane Maintenance
Vendor
Facilities Division Maintenance Manager
Follows all established safety regulations related to safe lifting and
handling techniques
Reviews and approves Engineering Safety Notes for lifting fixtures and
high-consequence/high-value lifts/moves using overhead cranes
on behalf of the Engineering Division Director and for the Mechanical
Engineering Subcommittee of the Safety Advisory Committee
Approves reasonable engineering alternatives not in conflict with
Berkeley Labs Environment, Safety & Health Standards Set
Furnishes guidance to Berkeley Lab staff
Incorporates the requirements of the Cranes, Hoists, and Rigging
Safety program into the design of lifting fixtures and procedures
Initiates the required proof testing
Obtains design approval by means of an Engineering Safety Note
Defines and requests any lift/move
Determines which lifts are high-consequence/high-value lifts/moves
Writes lifting procedures where required
Provides technical information on relevant characteristics of the
apparatus, including special lifting fixtures when required
Assigns someone to represent the customer during planning and
coordination of all aspects of the job being performed
Provides suggestions on rigging and moving
Ensures that lifting devices and lifting fixtures are properly
documented and inspected, and that they are used and maintained
safely
Requests the Facilities Division to prepare the Engineering Safety
Note, and to manage the move on the Work Request as needed
Evaluates building floor loading, lifting fixtures, and lifting devices for
structural adequacy
Reviews and approves Engineering Safety Notes for high-
consequence/high-value lifts/ moves using mobile cranes, forklifts,
and jack and roll devices on behalf of the Facilities Division and the
Mechanical Engineering Subcommittee of the Safety Advisory
Committee
Establishes design parameters for all cranes and hoists
Provides guidance on wind loading for outdoor lifts/moves
Provides Berkeley Lab staff with guidance on lift-related matters
Provides guidance and supervision for routine lifts when requested
Participates in the development and review of high-consequence/high-
value lifts/moves
Participates in pre-lift meetings
Arranges for all inspection, testing, and certification of cranes, hoists,
and rigging
Arranges for the testing and certification of lifting devices and lifting
fixtures
Establishes the scope of work for the Facilities Division Crane
Maintenance Vendor
Follows technical advice from the Facilities Division Crane Maintenance
Vendor to ensure that Laboratory purchases of crane, hoist, and
rigging equipment, components, and devices are traceable (through
documentation) to a reputable U.S. manufacturer
EH&S Division Crane Safety SME Manages the Cranes, Hoists, and Rigging Safety program
Reviews Engineering Safety Notes for high-consequence/high-value
lifts/moves
Conforms to Cranes, Hoists, and Rigging Safety program requirements
Participates in pre-lift meetings for high-consequence/high-value
lifts/moves
Notifies the Facilities Division Crane Maintenance Vendor to lock all
cranes and hoists that do not have an official Crane Manager

Person In Charge Handles high-consequence/high-value lifts/moves in a safe manner

The customer may be a manager, engineer, or

other responsible person (other than the
operator).

Procurement
Ensures that approved vendors who sell hoisting equipment ordered
by divisions have provided manufacturer certification that equipment
is authentic and has been load tested at 200% of rated capacity

27.5 Definitions

Term Definition

Crane A machine used for lifting and lowering a load vertically

and moving it horizontally, and that has a hoisting
mechanism

Engineering Note A detailed description of a (fixture) design, or a detailed

description of a high-consequence/high-value lift/move,
including protection of the load, rigging, and method(s) of
transport

High-Consequence/High-Value Lift/Move The customers designation for parts, components,

assemblies, or lifting operations that could have the
following consequences in the event of falling from a
crane or colliding with other objects:

Damages in excess of $500,000 (This does not

apply to routine movements of shielding blocks
performed by members of the professional
rigging crew.)
Significant work delays or programmatic
impacts
Undetectable damages resulting in future
operational or safety problems
A significant release of radioactivity or another
undesirable condition
A potentially unacceptable risk of personnel
injury or property damage

Any lift/move that requires the simultaneous use of

both the main and auxiliary hoists of a given crane
or the simultaneous use of two cranes
Hoist A device that applies a force for lifting and lowering

Lifting Device A device, other than a sling, used below the hoisting hook
for attaching loads to a hoist. There are four types of
lifting devices:

Structural and mechanical lifting devices (e.g.,

spreader bars, plate clamps, gripping devices, etc.)
Vacuum lifting devices
Close proximity lifting magnets
Remotely operated lifting magnets

Lifting Fixture A fixture used below the hoisting hook designed and
engineered for lifting a specific item

Mobile Crane A crane system fixed to a vehicle, typically a truck

Overhead Crane A crane system fixed to a structure, including but not

limited to bridge cranes, monorail cranes, gantry cranes,
and jib cranes

Rigging The hardware or equipment used to safely attach a

load to a hook or lifting device
The art or process of safely attaching a load to a
hook by means of an adequately rated and properly
applied sling and related hardware

27.6 Required Work Processes

Work Process A. General Requirements for Crane Operation

The work flowchart below provides a step-by-step overview of crane and hoist operations requirements (go here to download a
PDF of the flowchart):
The following rules apply to all use of crane and hoist operations at Berkeley Lab.

Whoever needs to move a load must:

First determine the value of the load and consequences of a failed move
Determine if the load needs to be moved by a crane
Determine who can operate the crane
Loads meeting the definition of High-Consequence/High-Value Lifts/Moves or other restricted operations (see Work Process
D) require more detailed planning and may require the lift to be performed by the Facilities Division Riggers.
Operators must be authorized by Line Management to use cranes.
Operators must be authorized by the Crane Manager to use a specific crane.
Operators must be qualified to use the type of crane they intend to use.
Operators must plan each lift, taking into account the path of travel to avoid contact with personnel and objects.
Loads meeting the definition of High-Consequence/High-Value Lifts/Moves or other restricted operations (see Work Process
B) require more detailed planning and may require the lift to be performed by the Facilities Division Riggers.
Operators must inspect the crane and associated rigging prior to using the crane.
Cranes and rigging found to be deficient must be taken out of service, and cannot be used unless repaired and recertified
by the Facilities Division Crane Maintenance Vendor.
Cranes and rigging must be rated to lift the intended load; no load (including rigging, devices, and lifting fixtures) may
exceed the limits of the crane and rigging. If an employee is unsure of the weight of a load, or if the load weight exceeds
75% of the cranes capacity, contact the Facilities Division Rigging Supervisor for assistance. Crane testing by the Facilities
Division Crane Service contractor is the only exception to this rule.
Operators are responsible for ensuring that the load is properly rigged to avoid shifting during the lift. Test lifts of less than
one foot from the ground to check for load shifting are permitted.
All personnel who are operating a crane or hoist, are participating in the lift, or are located within 15 feet of the vertical
plane of the load where the undercarriage of the bridge is more than 12 feet from the ground must wear hard hats.
Post or barricade the area as needed.
Sturdy work gloves must be worn when handling wire rope or loads with rough or sharp edges or splinters.
Suspended Loads

These rules apply to operators of suspended loads:

Test brakes under load when load is 80% of the crane's rated load. Raise the load a few inches and apply the brakes.
Ensure loads are never lowered below the point where less than two full wraps of rope remain on the hoisting drum.
Do not allow hoisting chains or ropes to kink or twist, or to wrap around the load.
Attach the load to the load block hook ONLY by means of slings or other approved devices; NEVER wrap the hoist rope
around the load.
Ensure loads are well secured and properly balanced in the sling or lifting device before it is lifted more than a few inches.
Avoid suddenly accelerating or decelerating the moving load.
Do not allow the load to contact obstructions.
Do not allow loads moved with any material-handling equipment to pass over any personnel.
Select the load path to eliminate the possibility of injury to employees should the material-handling equipment fail.
Do not permit work on suspended loads. Rest the load on adequate cribbing if it needs to be worked on.
Never leave a suspended load unattended nor leave the controls while the load is suspended. Lower the load to the floor or
the working surface or onto cribbing, and secure the material-handling equipment before leaving the load unattended.

Component Failure or Unintended Movement

If any component fails during a lift, or if there is any uncontrolled or unintended motion of the load during the lift, the lift must
be terminated immediately in the safest manner possible. Immediately notify the Crane Manager of the component failure.
Contact EH&S and the Facilities Division Rigging Supervisor.

Lifting may only resume after the failure or unintended motion has been investigated, and appropriate corrective steps have
been implemented.

Securing Cranes

Any electric-powered crane, when not attended by a qualified operator during an entire shift and off-hours, must be secured by
locked controls or equivalent means to prevent access to the crane, such as locking the doors or locking up radio controls. Only
the Crane Manager or another qualified and authorized user of the secured crane may have control of the locking mechanism.

Work Process B. Procurement and Maintenance of Cranes and Hoisting and Rigging Equipment

Approval from the Facilities Division Structural Engineer must be obtained before purchasing hoists or cranes that will be
attached to any LBNL building or structure. Free-standing lifting equipment or cranes as well as rigging such as shackles,
clevises, wire rope or fabric slings, or spreader bars (strongbacks) must be purchased from an LBNL-approved hoisting and
rigging vendor. Use of the pre-approved vendors ensures that the required standards and certification requirements are met. The
Facilities Rigging Superintendent or the EHS Crane Safety SME can provide assistance in selecting cranes and rigging equipment
to meet specific needs or circumstance.

If used equipment is procured, it must be inspected and certified to meet all applicable standards in force at the time of the
acquisition prior to use at LBNL.

For Berkeley Labdesigned and/or fabricated lifting devices, see Work Process G.

When equipment is received, the recipient must contact the Facilities Division Crane Maintenance Vendor (ext. 7667 or
cranesafety@lbl.gov) to have the equipment inventoried for routine inspection and maintenance. Do not discard any certification
papers received with the equipment. All hoisting and rigging equipment (except when impractical, e.g., shackles, swivel lifting
rings, etc.) used at the Laboratory must have a Laboratory proof-load tag attached with a current inspection sticker. The user,
supervisor, and operator are directly responsible for verifying the presence of current, proper tagging of hoisting and rigging
equipment prior to use.

Work Process C. Authorization and Qualification to Use Cranes

All crane use must be authorized by an employees Job Hazards Analysis (JHA), and by the Crane Manager for the particular
crane(s) to be operated. The Crane Manager is a qualified crane operator who has been designated as the individual responsible
for the safe operation of a specific crane. Before operating a crane in an area for the first time or in a new application, employees
must discuss the proposed crane use with the Crane Manager and obtain approval. The Crane Manager will determine whether
the operator is familiar with the controls for that particular crane and knows how to properly rig loads, and will verify that crane
use will not conflict with other operations in the area.
Cranes may also be operated by qualified Crane Service personnel who have been authorized by either a JHA (for the on-site
Facilities Division Crane Maintenance Vendor) or a SWJHA, and have been subcontracted to install, maintain, or repair cranes.

Qualifications, Training, Certification, and Approval Requirements for Overhead Crane and Hoist Operators

The operation of overhead cranes and hoists is restricted to trained personnel who have completed Berkeley Labrequired
training, and who have been certified in accordance with the requirements of this chapter. This includes the operation of cranes
without a load for any reason. Requirements for operating mobile cranes can be found in Work Process F.

To become certified for operating cranes up to a two-ton capacity, the following requirements must be met:

All prospective operators of cranes and hoists up to a two-ton capacity must meet the health requirements that would
entitle them to operate a motor vehicle in the state of California. Individuals who do not hold a valid drivers license must
be examined and approved by Health Services at Berkeley Lab.
The prospective operator must complete EHS0210, Crane/Hoist Operator 2 Tons or Less. This course includes hands-on
instruction, and a certificate will be issued after the successful completion of the course.

Note that crane and hoist operators with this certification may NOT operate cranes or hoists with a capacity of
greater than two tons to lift loads of less than two tons or without any load.

To become certified for operating overhead cranes or hoists with a capacity of greater than two tons, the following is required:

All prospective crane operators must complete an application and must pass a medical examination and/or review of
medical information on file at Health Services prior to training. The application must identify a qualified crane operator who
will provide hands-on instruction and close supervision during an initial training period. The supervisor and the operator
who will provide the instruction must sign the application and agree to the initial training. If the prospective operator has
prior experience operating cranes, he or she may be examined and certified without an initial training period.
The prospective operator must complete EHS0206 (Crane/Hoist Operator Greater than 2 Tons). Upon completion of this
classroom training, a learners permit is issued when needed, and the individual may operate cranes and hoists under the
direct supervision of the operator identified on the application. The learners permit will expire no later than 60 days from
the date of issuance.
When the prospective operator is ready, he or she may contact an overhead-crane practical-examination instructor to be
examined on the operation of the specific crane to be operated most frequently. A list of qualified overhead-crane practical-
examination instructors is maintained by the EH&S Division Training Group.

Crane operators must renew their training every three years, and must be medically recertified every three years.

Work Process D. Restricted Operations

High-Consequence/High-Value Lifts and Moves

The customer (i.e., the manager who requires the items to be moved) or a program organization designates parts, components,
assemblies, or lifting operations as high-consequence/high-value lifts/moves, because the effect of those items falling from the
crane, or colliding with other objects, could:

Cause damage in excess of $500,000

This requirement does not apply to routine movements of shielding blocks performed by members of the professional
rigging crew.
Cause significant work delay or programmatic impact
Cause undetectable damage resulting in future operational or safety problems
Result in significant release of radioactivity or other undesirable conditions
Present a potentially unacceptable risk of personnel injury or property damage

In addition, any lift/move that requires the simultaneous use of both the main and auxiliary hoists of a given crane or the
simultaneous use of two cranes must be considered a high-consequence/high-value lift/move.

High-Consequence/High-Value Lift/Move Requirements

A detailed, step-by-step procedure in the form of an Engineering Note must be prepared for each high-consequence/high-value
lift/move. This requirement covers lifts and moves performed with forklifts or cranes. An Engineering Note template may be
obtained from the Engineering Division at https://dcc.lbl.gov/dcc/EngNotes.php. While high-consequence/high-value lift
procedures are customarily prepared for one-time use, general high-consequence/high-value lift procedures may be employed to
accomplish routine, recurrent high-consequence/high-value lift operations. For example, a general high-consequence/high-value
lift procedure may be applied to lift shielding blocks or a frequently lifted item. Examples can be found through the search page
of the Berkeley Lab Engineering Note Repository at https://dcc.lbl.gov/dcc/EngNotes.php (enter the keywords high value in the
Title 3 field).

The customer, i.e., the Laboratory manager who requires the item to be moved, is responsible for preparing the high-
consequence/high-value lift/move Safety Engineering Note. The customer can discharge this responsibility by indicating on the
Facilities or Engineering Division Work Request that the scope of work should include preparation of the Engineering Safety
Note and management of the move. It is the responsibility of the customer to notify all personnel whose review is required
early in the process. See High-Consequence/High-Value Move Lift/Move Approval below.

Reviewers have special expertise and are available to provide guidance during the design of the lifting procedure. Please
allow sufficient time for the review-and-approval process. There is no charge for the review-and-approval process.

The procedure must contain the following:

Identification of the item to be moved

Identification of the Laboratory manager or engineer who is responsible for planning the lift
Identification of the rigging supervisor or designated qualified rigger (other than the equipment operator) who will be the
Person In Charge (PIC) of all aspects of the lift while the load is suspended
Special precautions
Weight of the item
Total hook load (all component parts of the item plus tackle and load-measuring devices)
Determination of the center of gravity
A list of each piece of equipment and each accessory (e.g., slings, spreader bars, yokes) to be used in the lift
Each accessory must be identified by type and rated capacity
If a portable item to be used has no manufacturers serial number, a Berkeley Lab identification number must be assigned
and affixed to the item
Surveillance procedures, checkpoints, and estimated instrument readings (if used) must be listed to enable confirmation
that the lift is proceeding as planned
Calculation of stresses to be generated in the item during lifting and determination of the adequacy and proper labeling of
the attachment points of the item to be lifted.
A rigging sketch or sketches that include the following:
Lifting points
Load vectors at all stages of the lift/move
Sling angles at all stages of the lift/move
Accessories used
Method(s) of attachment
Method of rotating about either horizontal axis, if applicable
Other factors affecting the capacity of the equipment or accessories
Identification of the capacity (or limit) of equipment and load
Identification of the expected load in each item of equipment and each accessory
A load-path sketch of the load path with the expected height of the load at each point in the lift
Where appropriate, floor loading diagrams are to be included to provide for setting the load down at any point in the path if
that should be necessary.
A travel sketch, either as a part of the load-path sketch or a separate sketch, indicating the planned travel path, and lifting
and travel speeds
Where clearances are an issue, a detailed drawing with verified dimensions that demonstrates the lift can be accomplished
as planned
An assessment of wind loading and weather concerns for all outdoor work
Obtain assistance from the Facilities Division Structural Engineering Group for wind loading concerns.
A checklist detailing each step of the procedure, with each step initialed by the Laboratory manager or engineer responsible
for the planning of the lift
A sign-off sheet where all personnel involved in the lift verify that they are familiar with the contents of the procedure
Load tests and practice lifts, if required
Verification that all primary and secondary hoisting equipment is within the current inspection and test time requirements
as specified in this chapter (for example, yearly periodic inspections and certification)

High-Consequence/High-Value Lift/Move Approval

The procedure must be reviewed by:

 Customer management
The Engineering Division Mechanical Engineering Department Designee
The assigned Facilities Division Structural Engineer
The Facilities Division Rigging Supervisor
The EH&S Division Designee

The procedure must be approved by the appropriate engineer:

For lifts/moves using overhead building cranes, the Engineering Division Mechanical Engineering Department Designee is
the approver.
For lifts/moves using mobile cranes, forklifts, or jack and roll devices, the assigned Facilities Division Structural Engineer is
the approver.

All reviewers and approvers should be consulted early in the process to ensure their concerns are addressed, avoiding the
need for later revisions to the procedure.

Unanticipated conditions may require on-the-spot changes of the lift procedure. Approvers of the lift procedure should be present
during the lift or at least immediately available to approve changes. Changes must be recorded on the procedure and initialed by
all available approvers before they are implemented.

Personnel Participating in High-Consequence/High-Value Lifts/Moves

Each person involved in a high-consequence/high-value lift/move must be familiar with the procedure before beginning work. A
pre-lift meeting with all participating personnel must be held before the lift. All participating personnel must initial the procedure
sign-off sheet to verify that they are familiar with the procedure.

Cab-Operated Cranes

Operation of cranes from a cab is restricted to professional riggers. The following rules apply to cab-operated cranes:

Do not store personal belongings (including necessary clothing) in a manner that interferes with operations.
Store other necessary equipment (tools, oil cans, waste, extra fuses, etc.) in the toolbox. Do not store equipment loosely
in or about the cab.

Heavy Lifts

Heavy lifts should be made by the professional rigging crew that performs such work routinely. Where there is a need for other
personnel to lift loads over 10,000 lb., and lifts exceeding 75% of the cranes maximum capacity, the proposed lift must be
reviewed with and approved informally by the supervisor of the professional rigging crew or his or her designee.

Tilting Loads

Using a crane to tilt a load (standing up a load that is lying down or vice versa) carries a significant risk of shock-loading the
crane or losing control of the load. When such operations involve loads that exceed 50% of the rated capacity of the crane, they
must be reviewed by and may be performed only with the informal approval of the supervisor of the professional rigging crew or
his or her designee. If two hooks are required to tilt the load, follow the high-consequence/high-value lift procedures listed
above.

Work Process E. Mobile Cranes

The operation of mobile cranes is restricted to those who have been certified as competent and qualified mobile crane operators
by an independent certification agency. The Facilities Division Riggers have authorized and qualified mobile crane operators.

Mobile crane operations for construction have additional requirements, which are found in PUB-3000, Chapter 10. For the
purpose of the Berkeley Lab Cranes, Hoisting, and Rigging Program, small truck-mounted jib cranes with capacities of less than 2
tons are not considered mobile cranes. Mobile crane operations are conducted in accordance with all applicable Occupational
Safety and Health Administration (OSHA) (and Cal/OSHA for construction) requirements.

Any mobile crane, when not attended by a qualified operator during an entire shift or during off-hours, must be secured by
locked controls or equivalent means to prevent access to the crane, such as locking the doors or locking up radio controls. Only
the Crane Manager or another qualified and authorized user of the secured crane may have control of the locking mechanism.

Work Process F. Crane Inspections

Each crane or hoist must be inspected by a qualified crane operator before use, during any given work shift. The inspection can
be documented either on a tag attached to the crane controls or in a log that is kept with the key to the crane controls. If the
crane is not used during any shift, it does not need to be inspected. Cranes used infrequently (idle for one to six months) may
be inspected by a qualified operator as a before-use inspection. However, if a crane has been idle for more than six months, the
Facilities Division Crane and Hoist Services Contractor must perform a periodic inspection before it may be used. Where
applicable, crane inspection logs will be reviewed by the Crane and Hoist Services Contractor. Typical crane inspection checklists
are shown in Appendix A of this PUB-3000 chapter.

All other required equipment inspections (including periodic crane and hoist inspections) and tests are performed by the
Facilities Division Crane and Hoist Services Contractor. Equipment and the frequency of equipment inspections and tests are
listed in a Facilities Division database as required by applicable regulations and/or standards. Facilities Division Crane and Hoist
Services Contractor work orders are automatically generated monthly and are based on information in the database.

Work Process G. Rigging and Other Below-the-Hook Devices and Fixtures

The crane operator is responsible for verifying that the load is properly rigged. The crane operator must also take the following
precautions when performing work:

Thoroughly inspect rigging before use (document the inspection on the Daily Crane Inspection Tag).
Remove defective rigging from service. DO NOT USE and DO NOT REPAIR defective rigging.
All other required rigging inspections and tests are performed by the Facilities Division Crane and Hoist Services
Contractor. The frequency of these various inspections and tests are detailed in Facilities Division work orders.
Only use slings in accordance with the manufacturers recommendations.
Use engineered attachment points and standard hardware (swivel lift rings, shackles, and nylon slings) wherever possible.
Verify that all slings and hardware are rated for more than the expected load and are appropriate for the intended type of
load and configuration.
Verify that all slings and special lifting hardware have current Berkeley Lab inspection tags.
Never shorten slings with knots, bolts, or other makeshift devices.
Never load rigging in excess of its rated capacities.
Use padding to protect natural fiber or synthetic slings from damage (e.g., contact with sharp edges).
Verify loads are balanced to prevent slippage (e.g., when using a basket hitch).
Remove slings from a load when the load is not resting on the sling.
Contact the EH&S Crane and Hoist Subject Matter Expert (cranesafety@lbl.gov) or the Facilities Division Crane Maintenance
Vendor (ext. 7667) before rigging is used in any manner or environment (e.g., used in close proximity with corrosives or
degrading chemicals, operated in temperature extremes of 20F or +180F, etc.) that may compromise its construction
or strength.

Inspection and Testing of Lifting Devices

Each division is responsible for the safety and pre-use inspection of its lifting devices (such as screw pin shackles, hoist rings,
commercial equipment, etc.) and for its lifting fixtures (such as spreader bars, special slings, equipment designed at Berkeley
Lab, etc.). Berkeley Lab proof-load tags and inspection stickers must be current, where applicable. Special-purpose
lifting fixtures must be marked with a Laboratory equipment number and labeled to identify applicable Engineering Safety Notes
for fixture design and/or high-consequence/high-value lifts/moves.

All lifting fixtures designed at the Laboratory must be proof-tested to twice their maximum rated loads before being placed in
service. A Non-Destructive Examination (NDE) is required after the proof test. The exact type of NDE must be specified in the
Engineering Safety Note for the lifting fixture. The rated capacity must be marked on the lifting fixture so that it is clearly visible
to the equipment operator.

Order commercially available lifting fixtures through the pre-approved hoist and rigging vendor or the Facilities Division
Maintenance Manager or Designee to assure they are ordered with a certificate of proof load testing. For commercial lifting
fixtures without certified load ratings, an Engineering Safety Note must be written to determine the safe load capacity and
furnish guidance for load testing.

Where the lifting fixture cannot be proof-tested because it is an integral part or component of the experimental device,
equivalent alternative safety precautions acceptable to the Mechanical Engineering designee must be described in the
Engineering Safety Note, which delineates the lift procedure.

All lifting device pins of 5 cm (2 in.) in diameter or larger must have a magnetic-particle inspection before they are placed in
service. These pins are always part of a lifting device or fixture. Make arrangements with the Facilities Division Crane
Maintenance Vendor, ext. 7667, or the Work Request Center, ext. 6274, to have lifting fixtures inspected.

Active lifting devices and fixtures must be examined by an NDE at least once every four years (or upon request), using
magnetic-particle detection or other appropriate methods. Make arrangements to have lifting fixtures inspected with the Facilities
Division Crane Maintenance Vendor, ext. 7667, or contact the Work Request Center, ext. 6274. Records must be maintained by
the Facilities Division and NDE organizations. Inactive lifting devices and fixtures must be clearly marked STOP: DO NOT USE,
and must be load tested and certified prior to renewed use.

The Responsible User must ensure that:

Proof-testing is performed by the Facilities Division on all lifting fixtures designed at the Laboratory, before they are placed
in service
Adequate test records are kept
Lifting devices and fixtures are used and maintained correctly

The Responsible Designer must obtain design approval by means of an Engineering Safety Note, as described below. For
equipment designed at the Laboratory, the Responsible Designer must provide the user with the information required to operate
the lifting device or fixture safely. The Facilities Division will provide a test report to the user upon request.

Design of Lifting Fixtures

A qualified engineer must be designated to be responsible for the design, fabrication, and testing of lifting fixtures not purchased
commercially. The actual physical testing usually will be performed by the Facilities Division in accordance with the written test
procedure specified by the Project Engineer.

All lifting fixtures not procured through the Facilities Division, a Berkeley Lab approved vendor, or provided by the equipment
(to be hoisted) manufacturer with proper engineering documentation must be covered by an Engineering Safety Note. The
Engineering Safety Note must include the calculation of lifting fixture stresses and deflections, and must be reviewed by:

The Responsible Designer

Customer Management
The Engineering Division Mechanical Engineering Department designee

The Facilities Division Plant Operations Department Rigging Supervisor

The EH&S Division designee

The Engineering Safety Note must be approved by:

The Engineering Division Mechanical Engineering Department designee.

The design stress for lifting fixtures or lifting attachment points must not exceed one-fifth the ultimate strength of the material at
its operating temperature. If welded fabrication is used, the design stress must take into consideration any weakening effects of
welding, such as those that occur in aluminum alloys.

If practical, avoid welding in the fabrication of lifting fixtures. If welding must be used, design and fabrication in conformance
with the latest standards of the American Welding Society (AWS) are required. Careful, thoughtful design and follow-up are
required.

Follow these rules for all lifting fixtures:

All welds in lifting fixtures must be certified welds, performed by certified welders, and inspected and certified by certified
weld inspectors.
If at all possible, do not allow welds to be subjected to tearing loads. Stresses in welds must be substantially uniform.
Where possible, design lifting fixtures so that the main loads are carried only by structural members, plates, or shear pins
rather than by welds. Examine this possibility carefully.
Proof-test lifting fixtures to twice the maximum rated load. Follow by a nondestructive examination. X-ray
primary load-carrying welds and welds in tension, or perform other suitable subsurface crack-detection
examinations.
The screw-thread engagement required for conservative development of the full strength of a screw fastener depends upon
the screw-fastener material and the material of the threaded member.
If the fastener is made of the same material as the female threaded member e.g., a low-carbon steel bolt and a
hole threaded into low-carbon steel an engagement of at least 1 diameters is required.
A hardened steel screw (Allen screw) in mild steel requires at least 2 diameters of engagement.
 A low-carbon screw fastener, threaded into a tapped hole in aluminum alloy, copper, or cast iron must have a
threaded engagement of 1 diameters.
Other material combinations must be approved by the Mechanical Engineering Department designee.
Safety hoist rings may be used to make lifts up to their rated load when screwed 2 hoist-ring bolt diameters
into materials such as aluminum alloy, copper, or cast iron.
When special high-strength bolts are required, test any bolt used as part of Laboratory-designed lifting fixtures or pickup
devices to two times its rated load. A crack-detection inspection must be performed after the load test to ensure integrity.
Try to maintain a supply of tested bolts in the event that one is lost, or better yet, to have the bolt on a permanent
lanyard. Once a lifting device or fixture has been delivered to the user, the user is responsible for ensuring that the proper
bolt is inserted to the proper depth and correctly torqued.
When the lifting fixture also serves as a shipping container or frame holding the experimental device during transport,
specify tie-down requirements and other special shipping requirements to ensure the integrity of the experimental device,
e.g., anticipate flexing of the truck bed, acceleration due to bumps and potholes, and/or vibration.
Label lifting attachment points adequately to ensure proper and safe use of the fixture.

Any deviation from these rules requires equivalent alternative safety measures that have been explicitly approved by the
Mechanical Engineering Department designee.

Single-Bolt Pickup Devices

When equipment is designed to be crane-lifted at a single point with a single-bolt pickup device, the vertical lifting load through
the screw thread of the bolt must be in line with the axis of the bolt so the load will remain level when it is lifted. With this bolt
alignment, the lift will be through the center of gravity and will be safer, since the load will not tilt or kick out when it is lifted. A
single-bolt pickup device must be used, such as a safety hoist ring or an equivalent in-house device that is carefully designed
and maintained. The threaded engagement must comply with the requirements in the Design of Lifting Fixtures section, above.

When a load is to be crane-lifted by slings from a crane hook through two, three, or four pickup points located at the corners of
the load, and without the use of a spreader bar, the forces at the lift points are nonvertical. Again, a single-bolt pickup device,
such as a safety hoist ring or an equivalent in-house device that is carefully designed and maintained must be used at each
pickup point.

Eyebolts without shoulders are not allowed for use in lifting any load. Eyebolts with shoulders are permitted for lifting loads when
the following conditions are met:

These devices shall be rated for the load and approved for the application, e.g., a carbon steel eyebolt rated at 1,500 lb.
Threaded into a carbon steel block.
The load is in line with the axis of the eyebolt, and side loads are minimal (a spreader bar may be required).
The thread engagement is at least 2 bolt diameters. The eyebolts are torqued to a manufacturers recommendations, if
given, or another reasonable torque substantially greater than finger tight. Angled sling usage is allowable if a
manufacturers recommendations for load reduction are given.

The use of unrated eyebolts or eyebolts in applications not specifically approved by the manufacturer must be specifically
approved by an Engineering Safety Note.

27.7 Standards

29 CFR 1910, Occupational Safety and Health Standards for General Industry, Subpart N Materials Handling and Storage,
Paragraphs:

1910.179, Overhead and Gantry Crane

1910.180, Crawler, Locomotive and Truck Cranes

1910.184, Slings

29 CFR 1926, Occupational Safety and Health Standards for Construction, 1926 Subpart CC, Paragraph 1926.251, Rigging
Equipment for Material Handling

California Code of Regulations, Title 8, Subchapter 4, Construction Safety Orders (as it pertains to cranes used in construction
work)

27.8 Related PUB-3000 Chapters

 Chapter 24, Environment, Health and Safety (EH&S) Training
Chapter 10, Appendix A, Code of Safe Practices

27.9 References

ASME HST-1M, PerformanceStandard for Electric Chain Hoists

ASME HST-2M, Performance Standard for Hand Chain Manually Operated Chain Hoists
ASME HST-3M, Performance Standard for Manual Lever Operated Chain Hoists
ASME HST-4M, Performance Standard for Electric Overhead Wire Rope Hoists
ASME HST-5M, Performance Standard for Air Chain Hoists
ASME HST-6M, Performance Standard for Air Wire Rope Hoists
Crane Manufacturers Association of America, Inc. (CMAA) Specification No. 61, Electric Overhead Traveling (EOT) Cranes
CMAA Specification No. 70, Specifications for Top Riding Bridge and Gantry Type Multiple Girder Electric Overhead
Traveling Cranes
CMAA Specification No. 74, Specification for Top Running and Under Running Single Girder Electric Traveling Cranes
Utilizing Under Running Trolley Hoists
DOE-STD-1090-2004, Hoisting & Rigging

Appendix A. Typical Pre-use Inspection Tag

Figure A-1. Front of Daily Crane Inspection Tag

 Figure A-2. Back of Daily Crane Inspection Tag

_____________________

<< Chapter 26 || Table of Contents|| Chapter 28 >>