Chapter 41 Table of Contents. View the entire chapter in a PDF format. Please use the pdf for printing.

Requirements:
General (5.1)

This chapter will frequently use such terms as qualified inspector, qualified person, and qualified engineer. The first-line supervisor directing H&R activities is responsible for ensuring that personnel who they supervise and who perform hoisting and rigging activities such as designing, inspecting, maintaining, and using hoisting and rigging equipment, preparation and approval of lift plans, and review of equipment compliance are qualified to do so. A person may be qualified to perform one of these tasks but not qualified to perform another.

Supervisors must be knowledgeable of the specific types of H&R operations under their supervision and the associated hazards. Further, supervisors must be familiar with applicable rules and procedures implemented at the site to ensure that H&R work under their control is done efficiently and safely, with safety as top priority. Supervisors must ensure that employees fully understand the importance of safety and that they recognize their own authority and responsibility to stop activity when safety is questionable.

Equipment

SLAC owns thousands of pieces of H&R equipment and routinely purchases and fabricates new equipment. To ensure that equipment meets extensive and frequently complex standards, all equipment (including rigging hooks but excluding other rigging hardware and accessories) must undergo a review of conformance. The review of conformance process ensures that the equipment is properly evaluated, tested, and inspected by qualified personnel. The process also ensures that all equipment is registered in the H&R equipment database, which tracks the equipments inspection, maintenance and repair status.

Equipment Custodian

All H&R equipment, including rigging hardware and accessories, must have a formally designated equipment custodian. The custodian is responsible for ensuring that

• All H&R equipment completes a review of conformance prior to being placed into service
• Equipment undergoes all required inspections
• Non-compliant equipment is removed from service

Review of Conformance

The review of conformance process ensures that, prior to being placed into service, equipment is evaluated by qualified personnel for compliance with the requirements of DOE-STD-1090-2004 and this chapter. This process verifies that equipment is

• Assigned to a designated equipment custodian
• Uniquely identified and registered in the H&R equipment database
• Designed, engineered, manufactured, inspected, and tested to meet applicable requirements
• Approved by the Hoisting and Rigging Citizen Committee
• Given an initial inspection
• Authorized and released for use

For rigging hardware and accessories and synthetic slings (excluding rigging hooks), the review of conformance requirement is satisfied by performing an initial inspection of the equipment prior to being placed into service.

For all other H&R equipment, the review of conformance must be documented using the Hoisting and Rigging: Review of Conformance Form [word] [pdf].

Equipment Procurement and Fabrication

All purchased and SLAC-fabricated H&R equipment must meet all applicable standards and regulations, including ASME/ANSI standards, OSHA regulations, and DOE-STD-1090-2004.

It is the responsibility of the requestor to ensure that purchase specifications require that the vendor supply the documentation required for the review of conformance, which includes

• Certificate of compliance with applicable standards
• Load test certification

Procurement and installation of fixed-location hoists and cranes must receive prior approval from the Hoisting and Rigging Citizen Committee.

Note: The Hoisting and Rigging Citizen Committee is available to advise on H&R purchase requirements.

Identification

All H&R equipment, including rigging hooks (but excluding other rigging hardware and accessories and synthetic slings), must be marked with a unique identification number.

• For cranes, hoists, and miscellaneous lifting devices, the identification number is the number assigned by the Conventional and Experimental Facility Department (CEF), also known as the CEF CRN.#
• For other H&R equipment, the identification number is the equipment serial number provided by the manufacturer, or designated by the design engineer, or assigned by the equipment custodian.
  
  Note: Permanent assemblies (such as wire rope bridle with rigging hooks) require only a single identification number.
   

• The identification label, tag, or marking must be durable and legible

Registration

Equipment custodians must register all H&R equipment (including rigging hooks but excluding other rigging accessories and hardware) with the H&R inspector for inclusion in the H&R equipment database.

• Cranes, hoists, and miscellaneous lifting devices that have a CEF CRN# are already registered in the H&R equipment database
• All other equipment must be registered through the review of conformance process

Tracking

CEF maintains the H&R equipment database, which tracks the inspection, testing, maintenance, and repair of H&R equipment (including rigging hooks but excluding other rigging hardware and accessories and synthetic slings).

Inspections

Initial, pre-use, and periodic inspections are required for all equipment. Certain types of equipment must also pass third-party inspections, such as the Plate V. Requirements and procedures for various inspections vary with the type of equipment and are specified in DOE-STD-1090-2004. Each type of inspection must be conducted and documented in accordance with specified requirements noted below and in Hoisting and Rigging: Inspection and Maintenance Requirements [pdf].

• Only equipment bearing a current SLAC H&R inspection tag may be used; equipment without a current tag must be removed from service until it is re-inspected and tagged. (This applies to all H&R equipment, including rigging hooks but excluding other rigging hardware and accessories and synthetic slings.)
• Inspection tags are only issued to equipment that has undergone a documented review of conformance.
• Inspection tags are dated to expire per the inspection requirements for the equipment.
• Synthetic slings: equipment custodians must establish custodian records for all required inspections.
• Third-party inspectors must submit copies of inspection reports, load tests, compliance certificates, and other supporting data to the H&R inspector for inclusion in the H&R equipment database.

Note: All initial, periodic, and Plate V inspections must be documented, including the inspection of rigging hooks but excluding the inspection of other rigging hardware and accessories and synthetic slings.

Initial Inspection

Prior to initial use, a qualified inspector or person must perform an initial inspection on all H&R equipment, as appropriate for the equipment type. (see Inspection and Maintenance Requirements [pdf].) Additionally, modified lifting devices, or reinstalled, modified, or repaired cranes or hoists, must pass an initial inspection by a qualified inspector. Inspections of repaired and modified cranes may be limited to the provisions affected by the alteration, repair or modification as determined by a qualified person. Initial inspections

• Must be documented and recorded as described in Hoisting and Rigging: Inspection and Maintenance Requirements [pdf]
• Are required as part of the review of conformance

Pre-use Inspection

A pre-use inspection for all types of equipment is performed by the operator before each use. Inspection checklists for many types of equipment are included in Section 6, “Exhibits” (Forms & Tools).

• The pre-use inspection of a crane, hoist, or miscellaneous lifting device must be documented and the documentation must be readily available and retained for five years
• The pre-use inspection of other H&R equipment must be performed but no documentation is required

Periodic Inspection

A qualified inspector or person must perform and document an annual periodic inspection on all H&R equipment as appropriate for the equipment type, as described in Hoisting and Rigging: Inspection and Maintenance Requirements [pdf].

Inspection tags are affixed to equipment, including rigging hooks but excluding other rigging hardware and accessories and synthetic slings, upon successful completion of the periodic inspection. Prior to affixing a current H&R inspection tag on the equipment, the qualified inspector must consult the H&R equipment database to ensure that a review of conformance was completed.

Plate V Certification

Cal/OSHA Plate V certification must be performed by a qualified third-party Plate V inspector.

• Plate V certifications must be documented and recorded in the H&R equipment database
• Cranes, hoists, and miscellaneous lifting devices with a rated capacity greater than three tons: certifications must be performed initially and once every four years thereafter. In addition, a Plate V certification must be performed after relocation of a fixed crane.

Testing

Requirements and procedures for testing H&R equipment vary with the type of equipment and are specified in DOE-STD-1090-2004. Specifically:

• All testing must be performed in accordance with the recommendations of the manufacturer
• Operational tests are required following maintenance or servicing of cranes and hoists
• Documented load tests are required:

• As part of the initial inspection for all H&R equipment, including rigging hooks but excluding other rigging hardware, accessories, and synthetic slings
• For any H&R equipment, including rigging hardware and accessories used in critical lifts
• All cranes and hoists where load bearing parts have been altered or repaired
• All below-the-hook lifting devices where load bearing parts have been altered or repaired

Rented Equipment

All rented equipment must conform to all Cal/OSHA requirements.

Maintenance, Modification, Repair

Note: Specific maintenance and repair requirements for various H&R equipment are specified in DOE-STD-1090-2004.

All cranes must be maintained according to the schedule in Hoisting and Rigging: Inspection and Maintenance Requirements for preventative maintenance; operational testing; and load testing after an alteration or repair.

• Maintenance and repair of cranes, hoists and miscellaneous lifting devices is the responsibility of CEF and may only be performed by qualified personnel. Third-party maintenance must be coordinated through CEF. All maintenance records and documentation will be maintained and entered into the H&R equipment database by CEF.
• Maintenance and repair of all other H&R equipment is the responsibility of the line organization, and must be performed by qualified personnel only.
• Altered, repaired or modified equipment must pass an initial inspection prior to use

Approval to Use a Forklift as a Hoist

A forklift may only be used as a hoist with an approved attachment in place. To be approved

• A written procedure for the lift must be developed and approved
• A safety analysis must be performed by a qualified engineer
• A data plate must be affixed to the fork lift specifying load analysis

Note: Free rigging, or the direct attachment to or placement of rigging equipment (such as slings, shackles, or rings) onto the tines of a powered industrial truck for a below-the-tines (forks) lift, is prohibited at SLAC. Commercially available attachments can only be used if they have passed the review of conformance and are within the rated capacity as specified on the forklift data plate.

Storage

Lifting devices must be stored appropriately to protect the device from damage, preferably in a dry, indoor location.

Loads

The lift planning process (see below) requires that the load be fully characterized. The weight and center of gravity (determined from drawings, calculations, markings or estimates) must be known for all lifts. Describing the load is the responsibility of the load owner, who may enlist the assistance of others to help make determinations.

The load owner will ensure that the stresses and deflections induced on the load and attachment points during normal hoisting and rigging operations are within acceptable limits. Upon request, the load owner must provide written documentation.

Manufacturer-provided Lift Points

All lift points designed for and installed on engineered or manufactured equipment are considered part of the equipment and are acceptable for their intended use. Manufacturer-supplied lift points must

• Meet manufacturer's pre-operational inspection, testing, and maintenance criteria
• Be inspected by a qualified person prior to initial use
• Used in accordance with manufacturer's instructions. In the absence of such information, further qualified technical support may be needed.

Note: The load owner will be responsible for ensuring that manufacturer-provided lift points on their loads comply with this section.

Lifts

All lifts must be planned and conducted in compliance with DOE-STD-1090-2004, which includes guidance on classifying, planning, and performing lifts.

Initiating

Many SLAC organizations have trained and qualified employees who are able to meet the hoisting and rigging needs of their organization. Lifts within the organization are generally initiated as part of the supervisor/employee work assignment process.

If an organization's trained and qualified H&R personnel are unavailable to perform the lift, or if the lift is beyond their expertise, another organization may perform the lift. A request for professional riggers is initiated through a CEF service request.

Classifying

At the initial stage of the planning process, an appointed qualified person within the lifting organization, with the approval of line management, must classify each lift into one of the DOE-STD-1090-2004 specified lift categories (ordinary, critical, or pre-engineered production). Load owners will be consulted as necessary to make this determination.

Planning

Once the lift has been classified, requirements appropriate for the designated class according to DOE-STD-1090-2004 are applied in planning, documenting, and performing the lift. Consistent with ISEMS, the level of planning rigor, work controls, and documentation for lifts should be commensurate with the level of risks, work complexity, and coordination requirements.

Ordinary Lifts

The majority of the lifts performed at SLAC are classified as ordinary. Ordinary lifts can range from simple to very complex. Ordinary lifts must be planned and can be conveyed verbally or documented in a lift plan.

• Requirements for lift planning are determined by the line first-line supervisor responsible for the lift, in coordination with specific organizational policy; some organizations may require documentation for all lifts.
• The first-line supervisor in charge of the lift must ensure that all elements of work planning and authorization are met.
• For lifts requiring more than one person, the first-line supervisor must assign a designated leader. If only one person is required for the lift, that person assumes the role of the designated leader.

Critical Lifts

A written lift plan is required for all critical lifts, and the lift plan must be approved by the Hoisting and Rigging Citizen Committee chairperson or designee before any lifting activity begins.

DOE-STD-1090-2004 provides guidance with regard to

• Lift planning and documentation
• Pre-lift meeting requirements
• Requirements specific to the equipment to be used
• More stringent proof-testing requirements

Pre-engineered Production Lifts

The first-line supervisor in charge of the lift must ensure that

• All elements of work planning and authorization are met and that the lift is planned and performed in compliance with DOE-STD-1090-2004 and this chapter
• An operation evaluation is made that includes load identification, hazards evaluation, and equipment and personnel selection
• The mandatory detailed step-by-step procedure is written and adhered to. The procedure must incorporate specified content, approval, and periodic review.

Performing

All Lifts

• Must be performed as planned. Any deviation must be made in accordance with the departmental work authorization protocol.
• Only trained, qualified, and authorized personnel will be allowed to rig loads or operate cranes or hoists. Training for the type of equipment used must be completed to the required level.
• All pre-use inspections for hoists, cranes, and H&R hardware and accessories must be performed prior to the lift
• Rigging practices and operator conduct provided in DOE-STD-1090-2004 will be followed

Ordinary Lifts

• Must have a designated leader
• Deviations from the established lift planning must be reviewed by the designated leader, and the first-line supervisor may be consulted as necessary

Critical Lifts

• A critical lift requires assignment of a person-in-charge (PIC), other than the operator, to oversee the lift
• Crane operators for critical lifts must be trained to professional rigger level

Pre-engineered Lifts

• Must be performed according to an approved step-by-step procedure
• Must be periodically reviewed
• Any deviation or modification from the original approved plan must receive the same review as the original plan

Lifting of Personnel

All hoisting and rigging activities that involve lifting of personnel must receive prior written approval from the Hoisting and Rigging Citizen Committee chairperson or designee. Requests for approval must include detailed documentation showing how the lift will meet the requirement specified in DOE-STD-1090-2004.

Subcontractors

All subcontractors and subcontractor-owned equipment and the services they perform must conform to all Cal/OSHA requirements.

In addition, subcontractor activities at SLAC are regulated as specified in Chapter 42, "Subcontractor Construction Safety", and Chapter 49, "Service Subcontractor Safety", in addition to the H&R-specific requirements in this section.

Note: The relevant section in DOE-STD-1090-2004 can be used by the university technical representative (UTR) for guidance when overseeing H&R activities conducted by subcontractors.

Subcontractor Personnel

All subcontractor operators must have in their possession a valid certificate of competency by an accredited certifying entity for the type of equipment to be used.

Lift Classification and Planning

Lifts performed by subcontractors must be classified as high, medium, or low hazard by the project manager. For associated requirements, see Chapter 49, "Service Subcontractor Safety".

• Lifts classified as high hazard require that the subcontractor submit a detailed work plan (including a lift plan) as part of the site-specific safety plan.
• Lifts classified as medium, low, and very low hazard require a detailed work plan (including a lift plan) that must be submitted as part of the pre-work hazard analysis.

Work Plan Approval

• The ES&H Building and Construction Safety Group must review and approve subcontractor work planning documents (including lift plans) and review and approve changes in scope of work.
• The H&R inspector must be included in the ES&H Building and Construction Safety Group review process.

Performing the Lift

• The UTR must ensure that all preoperational inspections are performed by the subcontractor.
• For mobile cranes, the UTR must ensure that the subcontractor's inspection and maintenance records are current.
• The UTR must be present during the setting up and performance of each unique lift or as specified in the scope of work.
• The H&R inspector is available to the UTR to provide expertise on hoisting and rigging equipment and activities.

Personnel

Qualifications

Only qualified persons will perform H&R activities. (See Section 4, "Definitions", for H&R roles and qualifications , and see Section 5.3 "Training", for training requirements.)

Personal Protective Equipment

Hoisting and rigging hazards include

• Being struck by or against the load
• Falling objects from crane, hoist, or load
• Lacerations from rigging or load

To mitigate these hazards, hard hats and safety-toed shoes are required for all lifts and when handling the load. Hard hats are also required for all personnel who may be working under a crane or hoist. Other personal protective equipment (PPE) such as gloves and safety-glasses may be required to mitigate hazards. Any deviation from the mandatory PPE must be authorized by the first-line supervisor.

Medical Surveillance

Operators of cab-operated, pulpit-operated, or mobile cranes must successfully complete a medical surveillance program in compliance with an accredited certifying entity. This requirement is documented through ES&H Course 280ME, Crane Operator Medical Exam (see Medical Surveillance Programs [pdf]).

continue to Requirements, Roles & Responsibilities (5.1.6)