Aa Afrg 000008

AA_AFRG_000008
ISSUE 0
ANGLO FATAL RISK GUIDELINE
LIFTING OPERATIONS
LIFTING OPERATIONS GUIDELINE
AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 1 of 99
This document is intended for Company use only. Reproduction for external use is allowed only under specific authorisation.
Anglo American assumes no responsibility for the content and/or the implications of its use by third parties.
AA_AFRG_000008
ISSUE 0
CONTENTS PAGE
1 AIM 3
2 APPLICATION 3
3 DEFINITIONS 6
4 REASON FOR INCLUSION 11

5 REQUIREMENTS 11
6 PLANT AND EQUIPMENT REQUIREMENTS 12
7 SYSTEM AND PROCEDURAL REQUIREMENTS 37

8 PEOPLE REQUIREMENTS 69
APPENDIX A: REFERENCE DOCUMENTS 80
APPENDIX B: RECORD OF AMENDMENTS 83

APPENDIX 1: A GUIDE TO LIFTING HAZARDS AND CONTROLS 84
APPENDIX 2: LIFTING EQUIPMENT MAINTENANCE AND INSPECTION 95
APPENDIX 3: LIFT PLANNING GUIDE 99
AA_AFRG_000008
ISSUE 0
1 AIM
To eliminate or minimise the risk of fatalities, injuries and incidents arising from the
performance of lifting operations.
This guideline refers to the Group-wide implementation of the Anglo Fatal Risk Standard
“Lifting Operations” and should be read in conjunction with the respective Standard.
The guidelines contained in this document are considered as "highly recommended" and
deviations are to be documented and justified. Full adherence to these guidelines will not
be a factor in determining compliance with the Standards, since alternative methods can
be available if justified on a risk basis.
In case of conflict with requirements of any other Anglo document or guideline, the
following hierarchy will apply:
1. Anglo Safety Way - ASW
2. Anglo Fatal Risk Standards - AFRS
3. Anglo Fatal Risk Guidelines - AFRG
It is important that when implementing Standards the organisation takes cognizance of,
and comply with the relevant legal requirements in the country of application.
2 APPLICATION
This Standard applies wherever lifting operations are undertaken. It includes lifts
involving Anglo American owned, hired or contracted cranes and lifting machines such as
mobile, crawler, tower, derrick, portal and pedestal-type equipment (e.g. cherry pickers),
vehicle loading cranes, electric overhead travelling cranes, hoisting blocks/tackle and
monorail cranes. The Standard also applies to lifting equipment including slings, chains,
wire ropes, shackles, pad-eyes, containers, baskets, tuggers, winches, man-riding
winches, jacks, work-belts, harnesses and transfer baskets for equipment and personnel.
In addition to the manufacturer’s standard safety features, local statutory requirements

or, in the absence of these, ISO Standards, the minimum safety features indicated in this
Standard shall or should be included.
This Standard applies to all Anglo American Group managed businesses and operations,
including contractors and visitors when involved in controlled activities.
The purpose of this Guideline is to provide guidance and clarification on the

requirements of the Anglo Fatal Risk Standard: Lifting Operations which is
intended to eliminate or minimise the risk of fatalities and injuries arising from the
performance of lifting operations.
This guideline has been developed to provide more detail and clarification for the
implementation of the requirements of the Standard. This should enable sites to be more
aligned with each other on what the boundaries are with regards to meeting the
requirements.
AA_AFRG_000008
ISSUE 0
This guideline is by no means exhaustive and will be updated periodically and supported
by good practice sharing. It is not intended as a template for achieving compliance.
The Lifting Operations Standard details the requirements for Anglo owned, hired or
contracted cranes and other mechanical lifting equipment to operate on Anglo owned or
managed sites. It includes the planning, resourcing (equipment), training, competency,
operation, monitoring and auditing requirements and responsibilities. Reference is made
to Appendices providing additional information as needed. The standard requires that a
system of work for the use of cranes and lifting equipment is established and maintained.
This is achieved through:
Ensuring all lifting operations have been adequately assessed with regards to their risk
Ensuring all cranes and lifting equipment utilised on a lift are fit for their intended purposes
Ensuring all personnel involved in the lift have the necessary skills, experience and
competence to safely perform such lifts
Included are cranes such as mobile, crawler, tower, derrick, portal and pedestal-type,
vehicle loading cranes, electric overhead travelling cranes, and monorail cranes or crawl
beams. The Standard also applies to lifting equipment including slings, chains, wire ropes,
shackles, pad-eyes, containers, baskets, tuggers, winches, man-riding winches, chain
blocks, and workbaskets. Shaft slinging of long or heavy material or equipment below
conveyances in vertical mine shafts, and installation or removal of conveyances, are also
included as a lifting operations, requiring the use of winches and performed by a Rigger.
1. Mine shaft lifting operations
Shaft slinging is the term used for transporting long or heavy equipment down or
up mine shafts. Shaft slinging must be treated as a lifting operation and the
requirements of AA_AFRS_8: Lifting Operations shall apply.
Installation and removal of conveyances in mine shafts is required from time to

time. This shall be treated as a lifting operation. The requirements of AA_AFRS_8
shall apply.
AA_AFRG_000008
ISSUE 0
Installation or removal of cages from mine
Pipes prepared for shaft slinging down mine shaft
These operations occur adjacent to open mine shafts, so the requirements of

AA_AFRS_7, Working at Heights shall also be applied.
2. Application Exclusions
This guideline does not cover manual lifting operations. Injuries do occur when lifting
using the wrong posture, or lifting heavy items, but this is excluded from the scope of
AA_AFRS_8 so the guideline makes no reference to manual lifting.
AA_AFRG_000008
ISSUE 0
3 DEFINITIONS
Competent person : a person who has the right training and experience to be
regarded as competent under relevant legislation and/or
internal regulations.
External rated : refers to clearly-visible green, amber and red lights mounted
capacity lighting externally to the crane: green to indicate safe operating range,
amber when approaching maximum rated capacity and red
when maximum rated capacity has been exceeded.
Lifting crew : persons working directly with a crane operation.
Lifting equipment : any device which is used or designed to be used directly or

indirectly to connect a load to a crane and which does not form
part of a load (e.g. wire rope slings, chain slings, man-made
fibre slings, hooks and fittings, swivels, shackles, eye bolts,
rigging screws, wedge sockets, plate clamps and lifting
beams).
Lifting operations : any operation using a crane and lifting equipment that involves
the raising and lowering of a load, including the suspension of
a load.
Workbasket : a personnel-carrying device designed to be suspended from a

crane or other lifting machine.
Controlled Activities/ : Those sites where the Group Company has the authority to
sites determine how to manage the operation.
It does not include monitored or uncontrolled activities.
Monitored Activities : Those sites where Anglo American can exercise some influence
but cannot set Policies and/or comprehensive Control Standards
and/or directly supervise and enforce their application (i.e.
contractor and supplier transporting their goods and/or
personnel to or from “controlled sites”).
Uncontrolled Activities : Those sites where Anglo American does not set or influence
Policies or Control Standards and does not supervise safety
performance. These include services provided by public
Companies, activities performed at supplier or manufacturer
shops, etc.
Where there is uncertainty over whether the activity is controlled, monitored or uncontrolled,
the matter should be referred to the Safety function for determination.
Other definitions and abbreviations used in this Standard
Note: There are various different terms used for equipment, competencies, and activities in different countries
in which Anglo operates. The definitions below give the term used in these guidelines, and where
relevant, alternative terms that may be used.
AA_AFRG_000008
ISSUE 0
Anti two-block cut out : a cut out to prevent damage or injuries due to two solid blocks –
or components – being pulled or pushed together. The most
commonly applied anti two-block cut out stops the hoist drum on
a crane if the hook block is pulled up too close to the sheave
block. Additional anti two-block cut outs may be applied to cut
hydraulic power on a mobile crane if the boom is retracted too
close to stops, or if the boom is elevated or lowered too close to
its stops.
Note: in South Africa this would generally be described as an interlocked limit
switch or an interlocked trip switch.
Anti two-block
devices
Competence (Lifting : refers to a person’s ability to execute specific task/s in

Operations) accordance to a prescribed method or specification for which
he/she was trained by a certified/reputable institution.
Competent person : a person who has the right training and experience to be
regarded as competent under relevant legislation and/or internal
regulations.
Crane : any powered device intended for raising and lowering a load and
moving it horizontally. Mobile cranes, EOT cranes, fork lifts
Crane chart rated : means the lifting capacity of the crane at a given boom length,
capacity boom angle, radius, outrigger configuration and boom
configuration and orientation (over rear / over front / over side)
as defined in accordance with AS 1418 Pt5 and AS2550 and in
accordance with the crane manufacturers recommendations.
The crane chart rated capacity is specified in load charts
provided with all cranes.
Drop zone : the area below a lift into which the lifted item may fall if
something breaks or goes wrong with the lift. The minimum size
of the drop zone should be taken as the footprint of the object
being lifted plus an additional 1 m outwards on each side for
every 2 m of lift height. The risk assessment may identify that
this should be increased for difficult loads or lifts in constricted
areas.
AA_AFRG_000008
ISSUE 0
Dunnage : soft material (usually timber) placed on the ground or on the

structure to temporarily support a load. Dunnage may be used to
ensure the load is kept above the ground to prevent corrosion or
moisture damage, or it may be used to cushion impact during
lifting or placing of the load.
EOT crane : means an electric overhead travelling crane.
Note: Portal cranes have a similar action to EOT cranes, but rather than
running on elevated rails they have legs at each side and run on rails
at ground level. Portal cranes may also be referred to as goliath
cranes or gantry cranes. Semi-portal cranes (or semi-gantry cranes or
semi-goliath cranes) may also be encountered, and are also included
within the intent of this requirement. A semi-portal crane has one side
supported on an elevated rail, as for an ordinary EOT crane, and the
other side supported on a leg with the rail at ground level
External rated : refers to clearly visible green, amber and red lights mounted
capacity lighting externally to the crane: green to indicate safe operating range,
amber when approaching maximum rated capacity and red
when maximum rated capacity has been exceeded.
Lifting crew : are persons working directly with a crane, or other lifting,
operation.
Lifting equipment : any device which is used or designed to be used directly or
indirectly to lift a load or connect a load to a crane or shaft
conveyance, and which does not form part of a load (e.g. wire
rope slings, chain slings, man-made fibre slings, hooks and
fittings, swivels, shackles, eye bolts, rigging screws, wedge
sockets, plate clamps and lifting beams).
Lifting operations : any operation using a crane and lifting equipment that involves
the raising and lowering of a load, including the suspension of a
load.
Lifting plan : a study which reviews a proposed lift with the specific intent of
providing assurance that the lift can be executed in a safe
manner. This will always include at least: a risk assessment;
identification of loads and lifting equipment capacities; ground
condition; and identification of the personnel to be involved
Note: This may also be referred to as a rigging study or a significant lifting
study.
Lift complexity types : Three complexities of lift are defined:

 A Routine lift is a straightforward lift, having no complications
and being well within the capacity of lifting equipment.
 A Serious lift is a lift that has additional risks and aspects
requiring specific consideration.
 A Critical lift is any lift in which there are significant
complexities that require specific consideration by a
competent person to ensure safety of the lift.
AA_AFRG_000008
ISSUE 0
Load chart : means a chart, or set of charts, specifying the crane chart rated
capacity under all possible operating conditions. These charts
should be provided by the crane Manufacturer crane mounted
on a mobile chassis specifically designed for that crane.
Mobile Crane : a crane mounted on a mobile chassis specifically designed for
that crane.
Note: this is sometimes more fully referred to as a mobile truck mounted
crane.
Pad-eye : means a steel plate or bracket with a hole intended for

attachment of lifting tackle to an item to be lifted. It may be
bolted or welded to the item to be lifted.
Note: this is also referred to as a lifting lug.
Register : a record of all important documentation related to each item of

lifting equipment used on the site.
Note: this is also referred to as a logbook.
Rigger : the competent person in charge of lifting operations. The Rigger

is a person empowered to apply slinging techniques to a range
of lifting tasks, including the selection and inspection of lifting
accessories and directing the Crane Operator in the movement
of the load, including when the load is out of view of the Crane
Operator.
Note: references to a rigger should also be read as references to a
banksman or a dogger.
In different jurisdictions the terms rigger, banksman and dogger have
specific different connotations. In Australia, a Dogger may select and
attach slings and direct the Crane Operator in straightforward lifting
tasks, whereas Basic Riggers, Intermediate Riggers and Advanced
Riggers may do the work of a Dogger, and direct progressively more
complex lifting operations. In South Africa the term banksman is used
specifically of the person who directs lifting operations in a mine shaft.
However, in this document, which aims specifically to cover safety
aspects of lifting operations, it is assumed that the same safety
considerations apply.
Risk analysis : a formal, rational process of giving consideration to all the risks
potentially associated with a particular job or project, and
determining what actions are necessary in order to reduce any
risks assessed as being too high.
Note: a similar process, frequently done in Australia is a job safety analysis
(JSA).
Shaft slinging : the process of lowering or raising long material or heavy

equipment in a vertical mineshaft either below a mine shaft
conveyance or attached directly to the front end of the hoist
rope.
Slinging : means the process of selecting and using lifting gear to support
and attach loads to lifting equipment.
Spotter : a person appointed to ensure that cranes working in the vicinity
of overhead electric power lines are not in danger of electrical
AA_AFRG_000008
ISSUE 0
contact, or that cranes working where surrounding structures,

services or vehicles may intrude into their operating area are not
in danger of striking these obstructions.
Note: may also be referred to as a signaller.
SWL : means the Safe Working Load for a crane or other lifting
equipment
Note: three equivalent terms used in some countries are WLL – working
load limit or MRC – maximum rated capacity or MML – maximum
mass load.
Tag line : means a line attached to a load during lifting for the purpose of
steadying the load against swinging or rotating
Note: this may also be referred to as a guide line.
Tugger : means a mechanical lever device, usually attached to a steel

wire rope, which can be used to exert a high pulling load on the
rope
Note: this may also be referred to as a tirfor
VLC : (a Vehicle Loading Crane) means a crane that is mounted on a

vehicle and is used to load and unload and do other tasks within
the operating parameters of that crane. A Vehicle Loading Crane
must not be confused with a Mobile Truck Mounted Crane which
refers to Mobile Cranes.
Note: this may also be referred to as a vehicle mounted crane.
Wind Vane Mode : means the method of parking a crane to ensure it will have
minimum resistance to weather conditions prevalent during the
period the crane is parked and unattended. This refers
predominantly to tower cranes and port cranes that are able to
slew. When parked, these cranes should not be locked in a fixed
parking position, so that under high wind conditions they can
swing into the position that minimizes the total wind load on the
crane.
Work basket : refers to a personnel carrying device designed to be suspended
from the hook of a crane or other lifting machine.
Note: this may also be referred to as a work box, a man cage, a boatswain’s
chair or a personal transfer basket.
AA_AFRG_000008
ISSUE 0
4 REASON FOR INCLUSION

A significant proportion of our fatal and significant incidents have occurred in the course
of lifting and crane operations. Identified causes and contributing factors include:
(a) lack of job planning and hazard assessment. It is frequently found that lifting
studies contain inadequate risk assessments. Risk assessments presented tend to
only cover the actual lifting equipment, but not the ground conditions, weather
conditions, or other factors.
(b) incorrect selection of cranes and lifting equipment for the task. A common error is
use of incorrect lifting points when tuggers, chain blocks or winches are used for
lifting operations.
(c) inadequate knowledge of lifting operations by personnel involved
(d) inadequate inspection, maintenance, tagging and storage of cranes and lifting
equipment
(e) lack of training in correct use of lifting equipment
(f) lack of competence in lifting operations
(g) incorrect use of cranes and lifting equipment, including poor practices such as out-
of-vertical loading and over-loading
(h) poor recognition of unsafe conditions, including environmental conditions
(i) operation of cranes and lifting equipment with safety and warning devices
overridden, inoperable or illegible
(j) incorrect design of cranes and lifting equipment
It is commonly found that mine workers have made up a tripod, “A” frame, or other
makeshift structure for the purpose of lifting some equipment. Often this makeshift lifting
equipment has inadequate strength for the lifting operation being performed.
5 REQUIREMENTS
This section is structured using exactly the same numbering sequence as the Fatal Risk
Standard document. Each requirement is repeated in a box, followed by a statement of
intent. This is followed by discussion and clarification of that particular requirement with
reference to other related requirements, Appendices and other relevant documents.
Appendices are used to reduce the size of this document, and allow more efficient
continuous improvement.
Detail has been added to some, but not all requirements, as some sections were deemed
self explanatory. Links to associated reference material has been given throughout this
document. The main source of reference material and examples of leading practice can
be found on the Anglo Fatal Risk Standard Quickplace.
AA_AFRG_000008
ISSUE 0
6 PLANT AND EQUIPMENT REQUIREMENTS

1. Electrical isolation
All electrical cranes shall have power supply isolation points capable of being
positively locked out and isolated.
Intent
All energy sources for all cranes and other powered lifting equipment (e.g. air hoists)
must have positive isolation capability to prevent inadvertent operation of the crane
or lifting systems or components (inclusive of mobile cranes and vehicle mounted
cranes). The intent is also to comply with Standard 2: Surface Mobile Equipment
and Standard 6: Isolation (where applicable). Other energy sources such as braking
of hoist drums and wheels, air winches, etc. must be considered.
Note: Although this requirement is aimed primarily at electrical cranes, some mobile cranes have
multiple isolation points to enable the isolation of any potential energy such as the power unit,
hydraulics, freefall mechanism levers and compressed air.
Common Hazard
Although there are many examples of lockable isolation points for electrical cranes,
the intent is that power is removed and access is controlled.
Where the removal of power does not guarantee the total immobilisation of the
crane, alternative measures must be implemented to ensure the safety of the
person/s that intend to work on the unit. Movement of the whole crane or
components of the crane may result from gravity, wind, or other causes.
Typical electrical switch boxes for cranes
Leading Practice
Ensure that all access to monorail cranes, electric overhead travelling cranes or any
other type of cranes accessible by a ladder system, is locked out and controlled.
Ensure that all access to walkways along overhead crane rail gantries is locked out
and controlled; unless the walkway is separated from the path of the cranes by
adequate guardrails (see Anglo Fatal Risk Standard No 7: Working at Heights for
information on adequate guardrails).
AA_AFRG_000008
ISSUE 0
Warning and lock out on access to overhead cranes

 Fit air drain valve to cranes and air powered lifting equipment to allow potential
compressed air to be isolated.
 Lower hooks to the ground prior to working on the winch brake system to
eliminate the potential energy risk.
2. Operability and fall protection
Cranes shall have their operability assessed against site conditions and workforce
(e.g. language for the controls) and have fall protection systems provided for
people in charge of their operation, maintenance and inspection.
Intent
The operators and/or maintainers of the crane must have:
Unrestricted and safe access to the seating position

 Comfortable seating for prolonged periods of operation
 Clear and unrestricted visibility for the vision field of normal and expected
operation
 Comfortable reach to controls
 Safe and practical access to perform pre-start checks, lubrication checks
maintenance checks and any other routine and non-routine work that may be
required in the normal operation of the machine.
 Safe access and egress in terms of working at heights, slips trips and falls.
Note: Refer to Standard 2: Surface Mobile Equipment and Standard 7: Working at Heights for
additional requirements and guidelines for access to machine and inspection points and where
working above 2 meters from a safe working level or ground level is required.
 Working decks that are below 2 meters should be assessed to identify the risk
to persons working at that level.
Common Hazard
When safe access is not fixed and persons are required to make use of other means
of temporary access, the risk is that at night or away from the workshop, persons will
take a shortcut due to unavailability of these temporary means resulting in injury or
fatality exposure.
AA_AFRG_000008
ISSUE 0
Access ladder extended Access ladder retracted

Note: this ladder should be steeper to enable users to make use of the permanent handrail for support
Leading Practice
 Provide safe means of access to Operator’s cabin or platform.
 Provide fall protection to all other raised work areas where practical.
Guardrails on mobile crane

3. Physical locking system
Cranes shall not be used without a physical locking system that disables and
isolates their free-fall capability.
Intent
Cranes equipped with freefall devices require the ability for these devices to be
positively isolated to stop inadvertent free fall of the hook blocks. This isolation shall
be in place unless a particular task may require the use of free fall, in which case a
risk assessment is required and appropriate site authorisation obtained prior to
removal of the locking mechanism to enable the device to operate as intended.
Common Hazard
On some cranes these levers are in an exposed position where accidental activation
is possible.
AA_AFRG_000008
ISSUE 0
Isolation of free fall levers

4. Overload protection
Electric overhead travelling and portal cranes should have overload protection.
Intent
Overload protection is intended to prevent a crane from lifting a load more than the
SWL thus placing a mechanical, electrical or other risk to equipment, load and
personnel. The overload protection should stop the lifting of the load yet allow the
safe removal of the load. Whilst this requirement refers specifically to electrical
overhead cranes and portal cranes, any other types of cranes and lifting devices
where practical, should not be excluded. In the case of manual winches such as
chain blocks, a portable load cell may be required to confirm the load being applied.
5. Temperature control
Crane cabins should be air-conditioned or heated in accordance with

environmental conditions.
Intent
The intent is to enable cabins to be closed at all times.
The reason for this inclusion is to stem the effects of fatigue in both hot and cold
climates. Be aware of placement of air conditioning units to allow for safe access.
This requirement is also to ensure a positive cabin pressure with filtered air to
prevent ingress of atmospheric contaminants. Air conditioning and heating allows
the cabin to remain closed which will also have positive effect on reducing operator
exposure to unacceptable noise levels.
Note: be aware of potential fogging issues, particular in underground situations, which may affect
operator visibility.
Common Hazard
The exposure time of the operator to heat or cold is an important factor in the risk
assessment to determine the need for air conditioners or heaters. Even non extreme
environmental factors could have a huge effect on the judgment of the operator
when executing lifting operations. Positioning of the air conditioning units must be
AA_AFRG_000008
ISSUE 0
carefully planned to ensure that a working at heights risk is not present when
servicing this unit.
Air-conditioning
Safe access to air-
unit on cab conditioning unit
Crane cabin with air conditioning unit

6. No interruption of operator
All crane cabins shall have signs to warn against interruption or distraction of the
operator.
Intent
The intent is to prevent distractions and loss of concentration of the crane or lifting
equipment Operator.
This requirement shall be applied to all lifting operations, including shaft slinging
operations in mine shafts. The Crane Operator or the Winder Driver shall not be
interrupted nor distracted in any way.
Note: Ensure that the signage is sized and placed correctly as to enable persons from all possible
approach angles to see.
Leading Practice
 Where cranes are controlled via a pennant or radio transmitter, it is Leading
Practice to have positive identification of the operator by wearing a high
visibility jacket containing the words “Do not interfere with me or distract me
while I am busy with a lift” This method will also aid easy identification of the
person operating the crane in particularly busy areas.
AA_AFRG_000008
ISSUE 0
 When complex lifts, or shaft slinging operations in mine shafts, are being
performed, a Person In Charge (PIC) should be appointed who should be
clearly identifiable via a special jacket or insignia. The PIC should be a
competent Rigger.
7. Sufficient controls to prevent crushing
Vehicle loading cranes shall have sufficient engineering controls to prevent the
operator from being crushed during lifting operations.
Intent
The intent is to prevent the operator from being crushed between the jib and the
operator station. Where these units are equipped with multiple controls, interlocks
should be considered to ensure that the unit is operated from the safe side at all
times if operated manually. Positioning of personnel involved in a lifting operation is
a key issue for all crane operations.
Common Hazard
Do not rely on operators and their experience or on procedures to work safely with
these types of cranes. Fatalities world wide involved highly experienced operators
with access to good procedures.
Leading Practice
 It is possible to use remote controls as an alternative to ensure the Operator is
separated from the danger zone. There is a risk however of the Operator
placing himself in other danger situations if not careful due to the possibility of
being in any position when operating with this remote control unit.
 A procedure should be in place to train personnel to avoid these hazards as a
remote control is not a guarantee that lifting will be executed safely. Controlling
the crane from a remote position does of itself not guarantee the elimination of
all hazards or ensure that the operation will be executed safely.
AA_AFRG_000008
ISSUE 0
8. Positive locking safety catch
All crane hooks shall be fitted with a positive locking safety catch.
Intent
The safety catch or safety clip is designed and positioned in such a way as to
prevent the unintentional dislodgement of the suspended load from the hook. These
units are exposed to severe punishment in the normal line of duty due to the hooks
being bumped and dragged in normal operations thus sustaining heavy wear and
tear. Maintenance of these units should be scheduled to ensure that they are always
in good working order.
Note: Should the sling attached to the hook be exposed to a rolling or twisting action, it is possible for
detachment (roll out) to occur and particular attention should be given to this danger when lifting using
this type of attachment.
Leading Practice
A large shackle should be used to connect the sling to the hook. This shackle should
be of adequate diameter to physically stop the safety catch from opening and
causing roll out.
AA_AFRG_000008
ISSUE 0
Typical hooks with safety catches

9. SWL to be clearly marked
The safe working load (SWL) shall be clearly identified and marked on all cranes
and relevant lifting equipment and shall not be exceeded.
Intent
To ensure all personnel involved in lifting operations are aware of the Safe Working
Load of a particular lifting device. This is to prevent equipment being overloaded and
for use in planning of lifting tasks. The mass of all components suspended from a
hook, when added together, must not exceed the SWL. This includes shackles,
slings, lifting beams, and the item being lifted. The mass of all components must be
known prior to commencing any lift.
Note: The only time when the SWL is exceeded on purpose, is when statutory load testing is
undertaken by an appropriately qualified person/s undertaking such testing.
Note: It is important to note that SWL is known by different terms in different countries, and may be
noted differently on equipment supplied from different countries. The terms WLL (working load limit) and
MRC (maximum rated capacity) are equivalent terms to SWL. The most common term used in various
countries is listed in Table 9.1.
TABLE 9.1: TERMS USED AS EQUIVALENTS TO SWL
Country Short term Long term Standard
Australia (since 2002) MRC Maximum Rated Capacity AS 1418
Australia (before 2002) WLL Working load Limit
South Africa SWL Safe Working Load
UK SWL Safe Working Load
USA WLL Working Load Limit
AA_AFRG_000008
ISSUE 0
Common Hazard
SWL not known. This is particularly often the case on monorail hoist beams which
have been repainted, and on tripods and “A” frames made up by mine personnel.
Safe working load of equipment and tackle being used must be known and used in
the calculation for a safe lift. These limits may never be exceeded
The SWL of all hoisting equipment and rigging hardware are based on almost ideal
conditions seldom achieved in the field. It is therefore important to recognise the
factors such as wear, improper sling angle, point loading and centre of gravity that
can affect the rated safe working loads of equipment and hardware.
EOT cranes with SWL and Equipment Numbers
Mobile crane with SWL clearly marked EOT crane with MRC and serial no
4000 kg SWL rope block Crawl beam with SWL 5000 kg clearly marked
AA_AFRG_000008
ISSUE 0
10. Load monitoring and indication
For cranes, the following should be made available:

a. load cells
b. load moment indicators
c. external rated capacity lighting
d. stability monitoring devices (to prevent overturning)
Intent
To enable all persons involved in or affected by a lifting operation to ascertain that a

crane does not operate outside of its safe working capacity.
Table 10.1 below gives the load monitoring and cut-out requirements as shall (i.e.
compulsory), should (i.e. to be applied wherever practicable – see section
“Requirements” above) or not applicable.
TABLE 10.1: REQUIREMENTS FOR LOAD MONITORING AND CUT-OUT

Load Moment External Rated Anti two-block cut
Crane Type Load Cell
Indicator Capacity Lighting out
All Mobile Slew Cranes Shall Shall Shall Shall

Pedestal and Tower Shall Shall Should Shall
Electric Overhead Traveling Not Applicable Should Should Shall
Mobile Pick & Carry Should Should Should Should

Vehicle Loading Crane Should Should Should Shall
Portal Not Applicable Should Should Shall
Note: the anti two-block cut out referred here is to prevent the hook block being pulled up against the
sheave block, possibly resulting in rope break. Anti two-block cut outs on retraction and luffing of the
boom should be used where relevant and practicable.
Total load lifted
EOT Crane equipped with load cells for all hoisting mechanisms
AA_AFRG_000008
ISSUE 0
Cable
drum
Typical load cell arrangement on an overhead crane
Note: External Rated Capacity Lighting should be installed as follows:

 A set of green, amber and red lights is installed in a visible place on the crane so as to be highly
visible to persons involved or affected by lifting operations.
 The lights indicate green (<90% of crane chart rated capacity), amber
(90% – 100% of crane chart rated capacity) and red (>100% crane chart rated capacity) and are
suggested to be of a robust digital LED type.
 A red light shall also be activated when the crane’s moment indicator over-ride switch is
activated or disabled or the crane is put in “rigging mode” to pack the crane up and place the
boom in its cradle.
 The green and amber units should be of the continuous type lighting, not flashing or rotating.
The red light shall be of a flashing type and is activated when the crane’s moment indicator over-
ride switch is activated or disabled or the crane is put in “rigging mode” to pack the crane up and
place the boom in its cradle.
Leading Practice
To also have an audible alarm that activates to alert the crane Operator and Crew
when the crane chart rated capacity is exceeded. The audible alarm is activated
when the crane’s moment indicator over-ride switch is activated or disabled but will
not be activated when the crane is put in rigging mode to pack the crane up and
place the boom in its cradle. This should be interlocked, so that the alarm can only
be cancelled by only one responsible person who holds the key.
Note: There is evidence that continuous exposure at close range to flashing or rotating lights can create
unsafe working conditions.
LED digital type lights are favoured for this type of application because they have
proven to be more robust than bulb type lights. This could reduce potential crane
downtime.
AA_AFRG_000008
ISSUE 0
Green – 00% to 90% Amber –90% to 100%

(Safe) (Caution)
Red – crane chart rated

capacity exceeded
Examples of external rated capacity lighting

11. Compliance with standards
All cranes and lifting equipment shall comply with the requirements of the relevant
approved design standard. The minimum acceptable design standard shall be the
relevant ISO Standard. In countries where the requirements of the relevant national
standard exceed the requirements of the ISO Standard, the national standard shall
apply.
Intent
To ensure that all equipment used in lifting operations is fit for purpose. Due to the
many standards of design and differences in interpretation, it is very important that a
recognised relevant and approved design standard is followed. Where these
standards are not present, the relevant ISO standard shall apply. The most stringent
of AAplc Standards, ISO Standards and local national standards shall apply.
Leading Practice
1. Ensure that procurement and reconditioning of lifting tackle is very clearly
specified and preferred Suppliers and products established via a technical
specification.
2. Ensure that manufacturing and reconditioning of lifting tackle is done under
proper quality control. The more stringent of AA STD 100 or the
manufacturer’s Quality Assurance procedure shall apply.
AA_AFRG_000008
ISSUE 0
Poor Quality Hook

12. Identification of crane and lifting equipment
All cranes and lifting equipment shall be identifiable with a unique identity code and
its rated capacity should be visibly displayed.
Intent
For all equipment involved in lifting operations to be issued with an identify number
and documented on a register to facilitate the inspection and maintenance program
and monitoring of compliance. To ensure that users know the safe strength of all
equipment, and that it is structurally sound and fit for purpose.
Note: In the past, colour coding has been used on some sites in South Africa and various other
countries to designate the SWL of slings and other lifting tackle. This practice must no longer be used,
and all personnel must be trained accordingly. The actual SWL shall be clearly marked, either by being
painted on or hard-stamped on a tag.
Cranes
Cranes should be clearly marked with their identity number and their SWL.
Clear and reasonable size
Typical marking of a crane
AA_AFRG_000008
ISSUE 0
Mine Shaft conveyances
Mine shaft conveyances shall be clearly and permanently marked with their serial
number and the maximum shaft slinging load permitted.
Typical marking of Mine Shaft Conveyance
Slings
All slings (whether wire rope slings, fibre slings or chain slings) shall be marked with
an identification number and their SWL. This marking should be on a flat ferrule or
permanent attached ring.
Typical marking of Sling
In some cases the SWL for use of the sling at an angle of 45 degrees is also
marked, but this is not specifically required. However, ensure that everyone using
slings is aware that their capacity is reduced when used at an angle, and knows how
to evaluate this reduced capacity.
AA_AFRG_000008
ISSUE 0
The reduced capacity of slings can be evaluated using the formula:
SWL at angle θ  SWL vertical SIN( )
Remote Control Units
Cranes may be operated from a cabin, using a pendant, or using a remote control
unit. The use of remote control units has unique hazards associated with it, because
the remote control units are not physically linked to the crane. Crane remote control
units generally utilize unlicensed frequencies (in the industrial, scientific and medical
(ISM) bands), with frequency hopping and encryption to ensure that there is no
interference from other radio signals. Specific guidance is provided by the British
Colombia Heath and Safety Act, Part 14 Crane and Hoist. This is a requirement in
British Colombia, and elsewhere it should be applied as leading practice. Section
14.28 requirements 6 to 10 read:
1. A remote control panel for a crane or hoist must be designed to safeguard
effectively against the unintended activation of the crane or hoist.
2. A wireless remote control system for a crane or hoist must incorporate
a. error checking to prevent the controlled equipment from responding to
corrupt data, and
b. identification coding methods to prevent a transmitter other than the
designated transmitter for that crane or hoist from operating the
equipment.
3. A remote control system for a crane or hoist must be designed to ensure the
following:
a. if the power to the remote control system is removed for any reason, all
crane or hoist functions stop;
b. if the control signal for any crane or hoist motion becomes ineffective,
the crane or hoist motion stops;
c. the remote control panel has an operator controlled emergency stop
feature that
i. permits the operator to stop all crane or hoist movement
regardless of a malfunction within the remote control system, and
ii. requires resetting of the emergency stop feature before equipment
operation can resume.
4. A remote control panel for a crane or hoist must be marked to identify the
corresponding base control unit to be used with it.
AA_AFRG_000008
ISSUE 0
5. The maximum distance between a remote control panel and the crane or hoist
being operated by the remote control system must
a. not exceed the limit specified by the control system manufacturer, and
b. be communicated to the operator before the operator uses the crane or
hoist.
Each site shall ensure that a procedure is in place covering storage and use of the
remote control units.
Leading practice
Remote control units must be clearly marked with the identification number of the
crane they control, and they must be kept in a locked cabinet, for which only the
designated Operator has a key.
13. Maximum environmental conditions identified by competent person
A competent person shall determine the maximum environmental conditions under

which cranes and lifting equipment can be used safely. Except in the event of an
emergency, cranes and lifting equipment shall not be put into service if the
maximum environmental conditions are exceeded. Risks shall be assessed in
emergency situations.
Intent
To ensure that personnel involved or affected by lifting operations are not placed at
risk from operating cranes in adverse weather conditions such as high winds, rough
seas, lightening, heavy rains, poor ground conditions etc.
Note: The environmental hazards described here are indicative. They should not be regarded as a
comprehensive list. There may be additional environmental conditions specific to a particular site that
must be considered.
Common Environmental Hazards include:

1. Wind
Never carry out any hoisting or rigging operations when winds create hazards
for workers, the general public, or property. A swinging load cause additional
hazards, increases the size of the drop zone, and makes accurate placement
very difficult.
Assess load size and shape to determine whether high winds may cause
problems. In particular, avoid handling loads that present large wind resistance
surfaces. Even though the weight of the load is within the normal capacity of
the equipment, height or gusting winds may prevent proper control during the
lift.
Wind loading can be critical to how the load is rigged, lifted and landed with
consequences for the safety of everyone involved.
Wind noise must be considered when using radio communication. All

movement must stop when communication is lost or not clear.
AA_AFRG_000008
ISSUE 0
Centered
crane boom
Load swinging
well downwind of
centered boom
Large drop zone
Load pushed off centre in a wind that is beyond the recommended speed. There is a
danger that accurate placing cannot be done, and the drop zone is significantly larger
Note: All cranes, with the exception of those working underground or in enclosed buildings and
thus protected from wind, should be fitted with an anemometer for wind speed detection.
(Australian Standard for maximum wind speed during lifting operations is 10m/s or 36 km/hr).
Typical wind speed measurement unit on mobile crane

2. Visibility
When the visibility of crane Operators, Riggers and Crew is impaired by snow,
fog, rain, poor light, dust or any other factor, strict supervision must be
enforced and the operations must be stopped if the risk is increased.
3. Temperature
At sub-freezing temperatures steel components may become brittle.

Supervision must ensure that no part of the hoisting device or tackle is shock
loaded or impacted upon, since catastrophic brittle fracture of the steel may
result.
Electronic equipment may malfunction at very low temperature, or very high

temperature. Load indicators, anti two-block cut out devices and
communications equipment shall all be rated for the temperature ranges
typically encountered on the particular site.
AA_AFRG_000008
ISSUE 0
At high ambient temperature hydraulic oil pressure, motor performance and

braking efficiency may be adversely affected. These all need to be considered
in the lifting plan calculations.
4. Lightning
Cranes, with their tall steel booms or towers are prone to lightning strikes
during electrical storms, which could cause injury or fatalities to personnel
and/or damage to the crane.
It is considered best practice to earth cranes as an additional control against

electrical hazards.
5. Waterlogged, Muddy or Sandy Ground
Following prolonged rain, or on poorly drained sites, ground may become

waterlogged, or muddy. Ground may also be dry and sandy. Where any doubt
exists in regard to the ability of the ground to resist the bearing pressure below
crane outriggers, a registered Professional Engineer or other competent
person must approve the use of the ground for the lift.
14. Colour coding for maintenance
Items of lifting equipment that are subject to wear and frequent replacement (e.g.
slings, shackles, pad-eyes, shipping and handling baskets) or are used to transport
equipment to and from sites shall be colour-coded to confirm compliance with
inspection requirements.
Intent
Colour coding allows quick visual identification to confirm that lifting equipment
covered under this requirement has undergone specific periodic inspections as per
the colour code for the present period.
Leading Practice
Include the year of inspection on the colour coding tag to ensure that the potential is
eliminated where equipment might have not been inspected for twelve months.
Pad-eye colour coded as per current Typical colour coding information board and
lifting equipment standard per site tags
AA_AFRG_000008
ISSUE 0
Colour coding on fibre slings shall not be used due to detrimental chemical effect of paint on
fibre strength
Notes:
i. South African Sites
Many sites in South Africa (and some other countries) have in the past used colour coding to
identify the SWL of slings and other lifting tackle. With the introduction of this Standard, this
practice must be discontinued. It is very important that as a matter of urgency, sites in South
Africa (and elsewhere) where colour coding has in the past been used for identifying the SWL of
slings and other lifting tackle, must plan and implement a programme to ensure:
a. Re-training of personnel in accordance with this new practice.
b. Removing the old colour coding, and replacing it with the new maintenance schedule
colour coding. To avoid confusion, and ensure a safe transition, it may be worthwhile to
consider complete removal of all colour coding for a period of a few years, and rely solely
on serial numbers and the logbook for compliance with the necessary maintenance
schedule.
This programme requires careful risk assessment and implementation to ensure a safe, simple,
trouble-free transition to the new system.
ii. The colour coding system does not authorize unlicensed users to use the equipment, nor does it
negate the requirement for an inspection prior to use. It merely confirms that the device is
registered and was fit for purpose at the last periodic inspection.
15. Lifting only from designated lifting point
Lifting by the use of a block and tackle, for example, shall only be done from
designated lifting points or be authorized by a competent person.
Intent
When lifting heavy loads it is imperative that lifting equipment is properly anchored,
to sufficiently strong structural supports. The intent of this requirement is to ensure
that no injuries or fatalities occur as a result of the failure or collapse of structural
supports to which lifting tackle is attached.
Leading Practice
i. All designated lifting points should be marked with the SWL. Alternatively, the
SWL of designated lifting points should be clearly shown on drawings.
ii. Designated lifting points should be provided directly above equipment that may
need to be removed for maintenance, or directly above the lifting position.
iii. Designated lifting points should be maintained in good condition.
Common Errors
i. Lifting tackle is attached to inadequate structural members. Light roof trusses,
bracing members, light posts, walkway grating and guardrails are not
adequate attachment points for lifting tackle.
AA_AFRG_000008
ISSUE 0
ii. Lifting tackle is attached to lifting points that are not above the lifting point. This
leads to the load swinging sideways as soon as it is lifted off its supports. This
can result in injury to personnel, or damage to equipment.
Grating
damaged by
slings
 Walkway grating may

present a convenient
place to attach slings,
but it is not strong
enough.
iii. “A” frames are made up on site, without proper design or approval by
registered Professional Engineers. The most common error is that “A” frames
do not have adequate bracing, allowing them to sway sideways resulting in
collapse.


“A” frame made up on site. “A” frame “A” frame properly designed. “A”
has leaned against the wall, but if it frame supports load safely.
had leaned the other way it would
have fallen over.
AA_AFRG_000008
ISSUE 0
No SWL noted because lifting

hangers added by site. Lifting
from angle bracing has damaged
bracing.
iv. SWL is not indicated at the lifting point. This may occur because the lifting
point has not been properly designed for a particular SWL. It may occur
because repainting of the steelwork has obliterated it. It may occur because
there is only one item that may need to be lifted, so that it does not seem
necessary to note it.
Pulley force aligned Pulley force not

with anchor aligned with anchor
 
Pulley force
Example of shaft slinging cage into mine shaft using winch and pulleys
v. Lifting lugs are welded to structural steelwork on site, without design or
approval by registered Professional Engineer. This is commonly done when no
provision has been made for lifting of equipment such as pipes, electrical
motors, pumps, liner plates, and when the constraints of the location prevent
the use of mobile cranes or forklifts.
vi. Lifting beams have no end stops, allowing hoists or trolleys to fall off the end
during lifting operations.
AA_AFRG_000008
ISSUE 0
This beam has no

end stop. A lifting
trolley will come off
the end
vii. Slings or winch cables are not aligned with the lifting point anchor, leading to
bending and potential failure of the anchor.
Lifting underground
Where there are no cranes or crawl beams available for lifting underground, loads
are commonly lifted using permanent or temporary eyebolt clusters set in the
hanging wall. Each underground site shall have its own procedure for installing
eyebolt clusters and using them as lifting points. The procedure shall include at least
the following:
 Hanging wall rock to be approved for installation of eyebolts by Rock Engineer
or appropriately qualified Mining Official
 Number and configuration of eyebolts to lift different loads
 Length and size of eyebolts to be used
 Inspection and approval that the eyebolt clusters may be used for the intended
lift
A typical list of lifting configurations is provided in Table 15.1.

Note: this information is given as a typical example only, and may not be generally applicable.
AA_AFRG_000008
ISSUE 0
TABLE 15.1: TYPICAL EYEBOLT CLUSTERS FOR LIFTING FROM HANGING

WALL
Mass to Typical Eyebolts to use Sketch of eyebolt cluster
be lifted equipment
Less than 1/Set of 3 – 16
1 tonne mm x 1200 mm
pigtail eyebolts.
Eyebolts to be Centre of lift 500
lashed together
using 16 mm wire
rope, lashed 3
times through
each pigtail and
secured with 3
crosby clamps.
1 tonne to 3/Sets of 3 – 16
less than 3 mm x 1200 mm 500
tonnes pigtail eyebolts.
Eyebolts to be
lashed together 1000
using 16 mm wire Centre of lift

rope, lashed 3
times through
500
each pigtail and
secured with 3
crosby clamps.
3 tonnes to 3/Sets of 5 – 16
less than 5 mm x 1200 mm
tonnes pigtail eyebolts.
Eyebolts to be 1000 500
lashed together
Centre of lift
using 16 mm wire
rope, lashed 5
times through
each pigtail and
secured with 5 500
500
crosby clamps.
500
5 tonnes to Raiseborers 4/Sets of 5 – 16 500
less than mm x 1200 mm

10 tonnes pigtail eyebolts.
Eyebolts to be 1000
lashed together Centre of lift

using 16 mm wire
rope, lashed 5
times through
each pigtail and
secured with 5
crosby clamps. 500
500
10 tonnes Load Haul To be defined by the Appointed Section Engineer

and more Dumpers
AA_AFRG_000008
ISSUE 0
DO:
i. Check that the load to be lifted is within the SWL of the designated lifting point
to be used. If no SWL is shown, find out what the SWL is before proceeding.
ii. Inspect the designated lifting point for signs of deterioration, such as corrosion,
cracks, wear, or damage.
iii. Ensure that the lifting tackle cannot slip off the designated lifting point.
DON’T:
i. Weld, or attach lifting equipment to any structural steelwork just because it
happens to be convenient.
ii. Use any designated lifting point if it has deteriorated or been damaged.
TO BE DONE:
i. All locations at which lifting is required, but cannot be done with cranes, must
be identified.
ii. Where no designated lifting points exist at identified locations, a competent
person must be appointed to specify the work required to install designated
lifting points. The designated lifting points must then be installed.
16. All lifting equipment to be maintained
All lifting equipment shall be maintained in good condition with inspection

maintenance log books. Proof-loading shall be undertaken as appropriate.
Intent
To ensure that all lifting equipment, including cranes and other lifting devices, as
well lifting tackle including shackles, slings, etc, remains in good condition, so that it
is at all times adequate to carry the loads it is certified to carry.
The following inspections shall be done:
Daily
 Inspections shall be carried out by the Crane Operator or the user of other
equipment.
 Inspections of cranes shall be recorded in an equipment logbook.
Periodically
 Inspections shall be carried out by a competent person.
 Inspections shall be carried out at intervals as specified by legislation, or by
the equipment Manufacturer. These inspections are usually required at
intervals of 3 months to 6 months, or after a specified number of hours of
machine operation.
 Inspections of cranes shall be recorded in an equipment logbook.
AA_AFRG_000008
ISSUE 0
Annually
 Inspections shall be carried out by a testing and inspection authority.
 Load testing of cranes is generally required annually.
 Load test certificates shall be kept with the crane records.
Special
 Inspections shall be carried out by a competent person.
 Structural components of cranes are generally required to be comprehensively
inspected at intervals of about 5 to 10 years, or after 5 000 to 10 000 hours of
operation.
 Following any accident, overloading event, or other suspected damage lifting
equipment shall be inspected, and tested if necessary.
More detailed information about the inspection requirements for the various items of
lifting equipment is provided in Appendix 2.
Leading Practice
All air powered equipment should have lubricators, air filters and water traps fitted
prior to the equipment air inlet to ensure integrity and safe operation.
Additional Surveillance
Cranes and Lifting equipment being used in a corrosive environment, such as

marine environments, most underground areas, or where high levels of moisture or
chemicals are present, require particular attention and awareness regarding
maintenance requirements and pre-use inspections.
DO:
i. Conduct a daily and pre-use inspection of all lifting equipment that is used
daily, and conduct a pre-use inspection of all lifting equipment that is used
irregularly.
ii. Check that all equipment used has been properly inspected and tested.
iii. Discard damaged equipment until it has been properly repaired and certified
by a competent person to be fit for use.
DON’T:
i. Use damaged equipment.
TO BE DONE:
i. Make an inventory of all lifting equipment, and ensure that the inspection and
testing requirements are clearly indicated in the inventory.
ii. Ensure that all relevant lifting equipment has a logbook, and that all inspection
and testing requirements, repairs and the results of such inspection, test
and/or repair are correctly recorded and entered in the logbook.
AA_AFRG_000008
ISSUE 0
7 SYSTEM AND PROCEDURAL REQUIREMENTS

17. Acceptance process for all lifting equipment
A formal selection and acceptance process based on risk assessment shall be in

place for all new (to site) and modified lifting equipment, taking into account the
crane’s various safety features and cabin ergonomics, prior to commencement of
work.
Intent
This is to ensure that all new or modified lifting equipment is fit for purpose, meets
the appropriate design standards and that any modifications are approved by the
original equipment manufacturer or equivalent, as well as all the requirements of the
lifting operations Standard.
Identifying the different crane types
Mobile Rough Terrain Cranes (Mobile Slew Cranes)
AA_AFRG_000008
ISSUE 0
Mobile Truck Mounted Cranes (Mobile Slew Cranes)
AA_AFRG_000008
ISSUE 0
Crawler Cranes (Mobile Slew Cranes)
Pedestal or Tower Cranes

Vehicle Mounted (or Vehicle Loading) Cranes
AA_AFRG_000008
ISSUE 0
18. Load charts available
Manufacturer’s crane and lifting equipment operating instructions and load charts
shall be available to the crane and lifting equipment operator. These should be in
the language of the country in which the lifting equipment is being used.
Intent
This is to ensure that crane and lifting equipment Operators have access to legible
operations manuals and load charts that the Operator can understand, to facilitate
safe operation and use of lifting equipment.
Note: Always only use the load charts provided for the specific crane or other lifting equipment being
used.
Typical Mobile Crane Radius Chart
AA_AFRG_000008
ISSUE 0
Typical Mobile Crane Load Chart
AA_AFRG_000008
ISSUE 0
19. Ensure operators can understand load charts
Where crane and lifting equipment operators are not conversant with the language
of the country, provisions shall be made to ensure that the operators can
understand the operating manuals and load charts.
Intent
This is to ensure that crane and lifting equipment Operators can understand load
charts and manuals to facilitate safe operation and use of lifting equipment.
Reason: Some Anglo American Group operations are located in countries where
the main language is other than English. In other countries where the Anglo
American Group has operations, although English may be considered to be the main
language of business, it is not the home language of all the people (see the chart
giving the language breakdown of South Africa). This is relevant for permanent
Operators as well as contractor Operators.
South African Languages 2001
Afrikaans
English
IsiNdebele
IsiXhosa
IsiZulu
Sepedi
Sesotho
Setswana
Siswati
Tshivenda
Xitsonga
Other
AA_AFRG_000008
ISSUE 0
20. Procedure to address use of cranes
A procedure shall be in place to address:

a. That the load and reach do not exceed the capacity of the lifting equipment
b. Lifting operations when the arcs of operation of two or more cranes can
overlap*
c. Stationary multiple crane lifting operations*
d. That “pickup and carry” operations using multiple mobile cranes is prevented
e. The danger to lifting operations when adverse weather conditions are
present or imminent (e.g. electrical storm, high winds and sea state)
f. The safety of personnel when cranes and lifting equipment are operating in
the proximity of live electrical conductors*
g. Lifting operations when lifting near or over unprotected plant, equipment or
services, including live process or hydrocarbon processes*
h. The effective hand-over, from one operator to another, of cranes with
complex boom, jib or tower configurations
i. Availability and use of check-lists for pre- and post-operational inspections
* Detailed lifting plans are required for these procedures and shall be approved by
a competent supervisor. Co-ordination meetings shall be held prior to such lifts to
ensure all personnel understand how they are to be executed.
Note: In the point marked “*” “co-ordination meetings” refers to meetings held with all affected parties
prior to the lift, to ensure that all affected personnel understand how the lift is to be executed and what is
required of them. These meetings are also commonly referred to as “safety meetings”.
Each of items (a) to (i) is dealt with individually below.

a. The procedure shall address that the load and reach do not exceed the
capacity of the lifting equipment
Intent
To ensure that lifting equipment is used within its capabilities.
The mass of items to be lifted shall be known and the maximum radius of the
lift shall be known. These can be established by calculation or measurement,
as appropriate.
b. The procedure shall address lifting operations when the arcs of operation of
two or more cranes can overlap*
Intent
The intent is to ensure that procedures are in place and followed where the
potential exist of conflicting arcs of different cranes. Measurements must be
done and controls put in place to ensure that the cranes can safely work within
overlapping work space.
Note: This is also applicable to areas where two or more cranes (typically EOT cranes) have
potential to conflicting with other types of cranes such as service cranes.
AA_AFRG_000008
ISSUE 0
Overlapping of arcs of various cranes must be well managed

c. The procedure shall address stationary multiple crane lifting operations*
Intent
To ensure that a lifting plan is developed that takes into account all the risks
when two or more cranes are involved in a common lift.
Multiple crane lifts must be well managed

d. The procedure shall address that “pickup and carry” operations using multiple
mobile cranes is prevented
Intent
To ensure that the lifting plan does not, at any time allow loads to be carried
by more than one crane. Where attempts are made to carry loads using two or
more cranes, the distribution of loads becomes uncertain and uncontrollable
due to unevenness of the ground, movement of the cranes without outriggers,
etc. This makes any carrying of loads with multiple cranes a dangerous
operation, which must thus not be contemplated.
If loads need to be moved, but cannot be safely moved by a single crane, they
shall be loaded onto a trailer or low-bed transporter to be moved.
Note: “Carry” here means that the cranes are moving in order to move the load to a new
location. This does not prevent “Lifting” and luffing or slewing to move the load while the cranes
are stationary.
AA_AFRG_000008
ISSUE 0
e. The procedure shall address the danger to lifting operations when adverse
weather conditions are present or imminent (e.g. Electrical storm, high winds
and sea state)
Intent
To ensure that the lifting plan includes all facets of weather interference and
the negative effect and risks on lifting operations at that time. The plan should
specifically define the course of action to be taken in the event of adverse or
extreme weather.
Typically the greatest risk will be to supply boat to oilrig transfers due to rough
seas causing uncontrolled movement of the supply boat. The course of action
may be to abort the delivery and return to shore, it may be to wait for improved
sea conditions, or there may be other options.
Supply boat movement on rough seas
There are also risks to all crane lifting operations associated with rain, dust or
wind. The course of action may be to lower the load to the ground; it may be to
return the load to its transporter, or some other action.
f. The procedure shall address the safety of personnel when cranes and lifting
equipment are operating in the proximity of live electrical conductors*
Intent
To ensure that personnel and equipment are not harmed by electrocution or

electrical current, when working in the vicinity of live electrical conductors or
overhead power lines.
One of the most frequent killers of Riggers is electrocution caused by the

contact of a crane, hoisting device, load line, or load with power lines. When
working with or around cranes that are within a boom’s length of any power
line, ensure that a competent spotter is stationed at all times within view of the
Operator to warn when any part of the machine or its load approaches the
minimum distances from power lines.
The AA plc minimum working distances from overhead power lines are:
a. The minimum distance to be observed from any part of a crane, VLC,
EWP, hoisting device, load line or load, is given in the Table 20.1 below.
AA_AFRG_000008
ISSUE 0
TABLE 20.1: MINIMUM DISTANCE FROM ANY PART OF CRANE TO

POWER LINE
Voltage Rating of Power Minimum Distance from Power Line to

Line Crane
100 000 volts 3,0 metres
b. A Spotter shall be used when any part of a crane, VLC, EWP, hoisting
device, load line or load encroaches within these minimum distances for
any angle of inclination and swivel.
c. Due to thermal expansion and contraction, the height of power lines from
the road surface to the overhead conductor can vary substantially from
summer to winter. The clearance for vehicles passing under overhead
power lines shall be determined for the maximum summer temperatures
at the site.
d. The lateral clearance shall be determined assuming a swing of the

power lines due to a wind pressure determined for the site. The wind
pressure shall be not less than 500Pa.
Must have a Spotter because load line will reach power line if crane slews
There are many different requirements specified in the occupational

health and safety legislation applicable in different countries and different
jurisdictions in which AA plc operates. The appropriate local
requirements shall be identified, and the more severe of the above
AA plc requirements and the local requirements shall be applied to all
lifting operations.
AA_AFRG_000008
ISSUE 0
Do not need Spotter

if X exceeds the
minimum distance
Must use a Spotter even

if Y exceeds the
minimum distance
AA_AFRG_000008
ISSUE 0
Working in the Contact Supply authority Determine Can the work process Safe working
vicinity of to establish voltage and the result in employees, plant procedures to
overhead insulation of overhead danger or materials entering the be
power lines power lines zone danger zone? No established
Yes
Contact Supply authority to Can overhead power Safe working

determine if overhead power lines be adequately procedures to
lines can be effectively insulated and effectively be
insulated and cordoned off cordoned off? Yes established
No
Contact Supply Comply with

authority for Supply
approval authority
requirements requirements
Recommended process for ensuring safety
Marking of power lines
All overhead electrical conductors or power lines on construction sites and

mine sites where cranes are used shall be clearly marked with warning signs
showing the voltage and the height above the roadway surface.
Marking of overhead power line height
What to look out for:

- The voltage of overhead power lines has been established. Written
confirmation of this should be kept on site.
- All personnel, equipment and loads must stay outside the danger area.
- Where necessary, a properly positioned spotter has been assigned, and is
in communication with the crane Operator.
- Where work within the danger zone cannot be avoided, permission has
been obtained, risk assessments have been completed, and all necessary
precautions have been taken.
- Laydown areas, site access routes, and other site layout arrangements
have minimized the need to work in proximity to overhead power lines.
- Special precautions may need to be taken when Operators or other
persons who are unfamiliar with the site are working in the proximity to
AA_AFRG_000008
ISSUE 0
overhead power lines. For example, when deliveries are made, Drivers may
not be aware of the positions of overhead power lines. When cranes are
moved from one location on a site, to another location, the Operators may
not be aware of overhead power lines to be passed under.
g. The procedure shall address lifting operations when lifting near or over
unprotected plant, equipment or services, including live process or
hydrocarbon processes*
Intent
To ensure that the lifting plan considers the content of the process and any
protective measures to deal with the type of hazard. For example, toxic gas
might need breathing apparatus at hand when the task is in progress. Plant
handling harmful substances may need an Operator on standby to shut off the
flow in case of an accident.
Load being swung over unprotected plant
h. The procedure shall address the effective hand-over, from one operator to
another, of cranes with complex boom, jib or tower configurations
Intent
To ensure that the lifting plan considers the implications of a new shift
Operator taking over a crane which is rigged or loaded in a complex or
unusual way. It is imperative that the new Operator is fully aware of the current
state of all components of the crane, and any specific information that might
have a bearing on the safety of the lift. This is particularly important when
visibility is impaired for some reason, such as in poor lighting conditions or
when adjacent buildings obstruct the Operator’s view.
AA_AFRG_000008
ISSUE 0
Crane with unusual and extremely long boom configuration
i. The procedure shall address availability and use of check-lists for pre- and
post-operational inspections
Intent
To ensure that inspection points and procedures are not left out and to ensure
that deficiencies are logged for maintenance and shift handover purposes. To
ensure that any risks associated with lifting operations are identified, assessed
and controls put in place to ensure that safe working conditions are
maintained.
21. Operators to have time for familiarization
Cranes shall not be used for lifting operations until crane operators have been
given sufficient time to familiarize themselves with relevant aspects of the crane.
Intent
Crane operators should not only have the required formal qualification, but they
must also be assessed to be competent by a site authorized assessor to operate the
particular crane being used.
Cranes may be extremely complex pieces of equipment
AA_AFRG_000008
ISSUE 0
22. Risk assessment
Risks associated with all lifting, crane maintenance, assembly activities and
environmental conditions shall be assessed as part of the planning process.
Barricading, warning signs or other means of ensuring personnel protection shall
be in place during lifting operations and for those cranes left unattended in wind
vane mode.
Intent
The intent of a risk assessment considering personnel protection, prior to lifting

taking place, is to ensure all elements and risks are taken into consideration to
ensure a safe zone is established and no inadvertent access into the danger zone
takes place.
Notes on parking of cranes

 Wind vane mode allows certain types of cranes to slew down wind thus
offering least resistance to the wind force when unattended. When cranes are
left in this mode, it is possible to get 360 degree rotation on some cranes and
therefore a risk assessment should be performed taking the different parking
standards into consideration to ensure that the area is free from obstructions.
Cranes in wind vane mode must be able to swing through the full circle of 360°
without striking any obstructions.
Leading practice
Where more than one tower crane operate on a site, their booms should be at
different elevations to minimize the likelihood of booms colliding in wind vane mode.
 Some EOT cranes move on outside gantries and are therefore exposed to the
elements. These cranes should have storm lock facilities to prevent
uncontrolled movement by wind pressure. Part of the risk assessment
procedure should consider how the storm lock is applied. There have been
cases where workers have been exposed to additional risks (such as lightning)
in order to apply the storm lock.
Crane blown off gantry during a wind storm
AA_AFRG_000008
ISSUE 0
Risk analysis and lifting plan
The following procedures shall be implemented for the different types of lifts. The
different lift complexity types are categorized in Table 22.1.
a. Routine Lift
Lifting Crews shall complete a “Routine Lift Checklist”, such as that shown
below. If any questions in this checklist are answered by “no”, the lift should be
treated as a Serious Lift.
Standard site procedures for safe lifts may be used. Where there are no
standard site procedures, a risk assessment shall be conducted, and a
procedure developed.
b. Serious Lift
Lifting Crews shall do a risk assessment and prepare a lift procedure. The
Supervisor shall approve the risk assessment and lift procedure before
proceeding with the lift.
The Supervisor may provide guidance or additional expertise to the Lifting

Crew and the task can then be reassessed using the “Routine Lift Checklist”. If
any answers are still “no”, the lift should be treated as a Critical lift.
The lift shall be authorized by the Supervisor.
c. Critical Lift
A lifting plan shall be prepared for the lift.

The lifting plan should include at least the following:
- A site plan, showing routing of services, pipes and conveyors, as well as all
surrounding structures or buildings
- The site plan shall indicate the location of all major lifting equipment with lift
radius and load path, transport routes, and lift and placement positions
- A site hazard and obstruction assessment
- An environmental risk assessment
- A risk assessment for the lift
- Drawings, approved by a professional engineer, showing the items to be
lifted, with total calculated mass, centre of gravity, lifting lugs, any
temporary bracing or support, and all dimensions. It must be clearly shown
on the drawings that the professional engineer has checked and approved
the item to be lifted for all load conditions that will be applied during the lift
- Drawings, approved by a professional engineer, showing the crane and
sling configuration, including boom and sling angles and calculated forces,
as well as ground pressure under outriggers
- Full list of all lifting equipment and accessories to be used, with serial
numbers, SWL and current inspection certificates
- A list of Crane Operators and Lifting Crew to be used, with competence
certificates
The lifting plan shall be reviewed and approved by an independent competent
person with experience in lifting prior to the lift taking place.
AA_AFRG_000008
ISSUE 0
Note: when performing “critical lifts” on a routine basis as part of a regular production process (i.e.
transporting molten metal ladles in a smelter), the lifting plan should be prepared at the commissioning
phase and then updated whenever substantive changes are made. Substantive changes include
changes such as introduction of modified ladles, extension of the smelter building, the addition of a new
crane, any modification of the smelter building that impacts the ladle crane bay, etc. The lifting plan
should be reviewed every three years, even if no substantive changes have been made to the lifting
procedure.
A guide to likely lifting hazards and possible controls can be found in Appendix 1: “A
Guide to Lifting Hazards and Controls”. This guide may be used for risk analyses
and the preparation of lifting plans.
All parties (i.e. site Supervisor or Rigger, Contractor, Rigging Specialist, Project
Manager and the Design Engineer where appropriate) involved in a lift shall be
represented in the risk assessment and in preparation of the lifting procedure or the
lifting plan as required. All parties shall approve and sign-off the risk assessment
and the lifting procedure or lifting plan.
The lift complexity types can be determined using the information in Table 22.1
below.
TABLE 22.1: LIFT COMPLEXITY TYPE DETERMINATION

Item Routine Lift Serious Lift Critical Lift
Cranes and crane interactions
Number of cranes used 1 1 2 or more
Interaction with other cranes No Yes, but not in the Yes
or mobile equipment same lift
Load lifted
Ratio of crane chart rated 0 to 70 % 70 to 90 % Over 90 %
capacity
Total mass of load if lifted by < 10 tons 10 to 50 tons Over 50 tons
EOT crane
Total mass of load if lifted by < 5 tons 5 to 20 tons Over 20 tons
mobile crane
Persons lifted No No Yes
Lift of hazardous material No No Yes
Proportion of liquids in lift None < 20 % > 20 %
mass
Centre of gravity position Well known Well known Difficult to
determine
Centre of gravity near centre Yes No No
of load
Centre of gravity below sling Yes Yes No
attachments
Very large or flexible load No No Yes
AA_AFRG_000008
ISSUE 0

Strategically important, fragile No Yes Yes
or expensive load
Proximity of obstructions
Proximity of overhead Well clear of any Lift does not go Lift does go over
powerlines powerlines over or between or between
powerlines powerlines
Proximity of fixed obstructions Well clear to Crane boom or Crane boom or
sides, above and load can reach load can reach
below obstructions obstructions
Limited headroom for EOT No Tight clearance, Yes, requiring
crane lifts but no tilting or rotation
manipulation of of load
load
Slewing over plant, pipelines, No Yes Yes
conveyors or tanks that do not
contain any dangerous
substances, hazardous
chemicals or gases
Slewing over plant, pipelines, No No Yes
conveyors or tanks that do
contain dangerous
substances, hazardous
chemicals or gases
Visibility to Crane Operator Entire lift Part or none of lift Part or none of lift
Number of Spotters required None 1 2 or more
Outriggers and ground conditions
Ground soft or muddy No No Yes
Outriggers fully extended Yes Yes No
Outriggers close to steep No No Yes
embankment, large drains or
other holes
General
Straightforward lift with no Yes No No
complexities
Ease of slinging load No difficulty Difficult Difficult
Effect of weather None Small Significant
Access for lifting at lifting or Straightforward Straightforward Awkward
placement positions
Use of lifting beams or frames No Single beam only Yes
Specific unusual risks No No Yes
identified
Any persons are required to No No Yes
be close to the drop zone
AA_AFRG_000008
ISSUE 0

Crane supported on structure No No Yes
on which it is not normally
supported
AA_AFRG_000008
ISSUE 0
Mine Area
Project
Routine Lift Checklist Yes No N/A
The Load
Do you know the weight? Have you included all the items to be lifted i.e. all items on or below the boom
head?
If you are using lifting lugs have they been properly designed (preferably by the Designer of the
equipment or structure to be lifted) and tested? Are the lugs aligned with the slings so they are not bent?
If you are not using lifting lugs is the load attachment simple and clear?
Is the load free of loose unsecured items and is it ready to lift, e.g. restraints removed?
Will the lifting hook be directly over the centre of gravity of the load at pick up and placement?
Is all temporary bracing and support required by the Mechanical or Structural Designer in place?
The Lifting Equipment
Have the SWL of the slings, shackles, etc been checked for the load to be applied?
Have the sling angles and rigging method been considered in checking the capacity?
Has all equipment been checked for correct capacity and up to date inspection and test certificates?
Has the lifting equipment been inspected for defects and damage?
Are the slings protected from any sharp edges?
Is the lift within the specific limits of the relevant crane load charts for the configuration and radius?
Have the pre and post start operational checks been completed?
Are all the crane safety devices functioning correctly?
If the crane exceeds 10 tonne capacity, is the external rated capacity lighting functioning correctly?
Have the ground conditions or structure been determined to be adequate?
Is the crane set up with outriggers fully deployed and supported on the correct crane mats?
Is there adequate ancillary equipment, e.g. boom lifts, scissor lifts, fork lifts?
The Lift
Have you determined the lift complexity type?
Is there a routine procedure, or have you done a risk assessment or prepared a lifting plan as
appropriate?
Does the lifting procedure include bringing equipment and loads to site, setting up equipment, lifting,
AA_AFRG_000008
ISSUE 0
Routine Lift Checklist Yes No N/A

moving and placing the load, and removal of equipment from site?
Are you using the procedure or lifting plan?
Is there adequate guidance in the defined behaviours and rules for your site for this lift?
Is the area of the lift free of operating plant, piping, live electrical lines and underground services? If not,
have the risks associated with these been properly considered?
Has the radius been checked with a tape measure or surveyed using Engineering plans, etc?
Has the area of the lifting operation been protected using barricades, tape and/ or spotters?
If people are working at height, has a risk assessment been done and correct PPE sourced?
Are environmental conditions safe for the lift e.g., not too windy, storms approaching?
If there any chance of the load impacting the boom, or the crane body or boom impacting obstacles has
a rigging study been done?
The crew
Does the Rigger have the appropriate statutory certification and certification by the site as being
competent for a lift of this nature?
If the load is heavier or more complex than the Rigger normally handles does the Rigger have the
Supervisor’s permission to lift?
Do the Operators of ancillary equipment have appropriate statutory certification? Have the Operators
been assessed by the site as being competent to operate the equipment as per the site standards?
Has the Controller of the lift been identified and is he/she wearing an appropriately coloured reflective
vest?
Has the Crane Operator the appropriate statutory certification and been assessed by the site as being
competent to operate this crane/ lifting equipment for this type of lift?
Have all members of the Lifting Crew been assessed as being medically fit for their tasks?
Date: Signed Crane Operator: Signed Rigger:
Note: The approval of a Supervisor is required before proceeding with the lift if any question is answered “No”.
AA_AFRG_000008
ISSUE 0
23. Side loading to be prevented
Side loading of crane booms should be prevented according to the manufacturer’s

specifications.
Intent
To ensure that cranes are not used outside of their specifications for safe operation
as designated by the OEM. This also includes horizontal pushing or pulling of loads
with the boom. On EOT cranes and hoists load should only be applied in the vertical
plane and no dragging of the load is permitted.
Note:
 This must be reinforced as part of the crane operators and dogger/rigger induction to all sites
 This also needs to be included as part of the pass out package for crane operators
 The consequences of side loading crane booms also need to be explained e.g.
- Tipping the crane over
- Bending of the crane boom
- Breaking or the damaging of head sheaves
- Damaging of hoist ropes
- Load swinging out of control
24. Outriggers to be used
With the exception of pick and carry operations, no lifting shall be carried out
without outriggers being deployed and locked.
Intent
To ensure that outriggers are fully deployed in such a way as to prevent the crane
from overbalancing. This requirement is applicable only to those cranes to which
outriggers are fitted.
Leading practice
Leading practice is to use packers under the outriggers, the dimensions of which
should be determined by the stability of the ground.
Typical Outrigger Packing Possible outcomes when ground is too soft or

outriggers are not used
Leading practice is also to have outriggers interlocked to the crane controls, to
prevent extending the boom or lifting unless the outriggers are fully extended.
AA_AFRG_000008
ISSUE 0
Common Hazards
a. Pick and carry operations should only be permitted where it is not practical to
transfer the load to a more suitable means of transport. In most cases pick and
carry operations are only required for a few meters to enable the crane to reach
an area where alternative transport can be safely made available. Pick and
carry operations using two or more cranes are not ever allowed.
All pick and carry operations should only be attempted by competent crane
operators and spotters must be used to ensure no risk is created during these
operations. All persons must be aware that the drop zone is enlarged during
pick and carry operations because the load is moving and swinging.
All pick and carry operations should be in line with the manufacturer’s
recommendations, particularly for tyre pressure and slope of the ground. This is
normally indicated on the machine’s load chart. These recommendations should
be considered as part of the risk assessment process.
b. Insufficient care is given to ground conditions. Soft or muddy ground, sub-

surface services such as storm water pipes, or close proximity to excavations
may lead to collapse of the ground supporting the outriggers.
Where cranes are to be used close to excavations or backfilled areas, special

care must be exercised to ensure that the excavation slope does not fail. As a
general rule of thumb, outriggers should not be closer to the edge of an
excavation than the following:
- twice the vertical depth of the excavation when the excavation is vertical
or near vertical
- a distance equal to the vertical depth of the excavation where the
excavation is sloped at an angle not steeper than 45°
If the ground is muddy, soft, or has bedding planes sloping into the excavation,
then this distance should be increased.
25. Controls to prevent falling objects
Controls shall be in place to prevent the falling of objects from lifting equipment and
suspended loads.
Intent
To prevent personnel from being injured or equipment being damaged, by objects

falling from the slung load or crane. Examples of objects that may fall are scaffold
tubes and tube clamps falling from carry frames, loose material falling from transfer
chutes, or components such as filters or even gearboxes falling from lifted motors.
The chart below shows the consequences resulting from a range of reported events
involving dropped objects. Although this chart should not be taken as definitive
because of the many variables involved, it does give some idea of the possible
consequences when objects of different weights drop from different heights. This
chart thus assists in understanding the risk of loose items dropping from heights
during a lift.
AA_AFRG_000008
ISSUE 0
Falling Object Consequence
100
Height of fall (m)
10
0.1
1 10 100 1000 10000 100000
Mass of object (kg)
Minor injury Serious injury Fatality
Examples of suggested controls to ensure minimum risk to others, include:

 Barricading or demarcating of work area to restrict and control access
Some demarcating styles and methods
Caution Tape Danger Tape
Some barricading styles and methods
Netting Tape Solid Units
 Use of lifting cages for small heavy items
AA_AFRG_000008
ISSUE 0
 Clear understanding of what has to be lifted and where it has to be positioned.
 Use of good slinging practices and securing loads.
26. Personnel to be lifted in work baskets only
The lifting of personnel with cranes shall be carried out only with the use of
approved workbaskets or cages. Cranes used for this purpose shall be approved
as suitable for man-lifting operations. A recovery plan should be in place before
personnel are lifted.
Intent
These controls should be in place and used to ensure that the risks associated with
the use of man cages are reduced to low as reasonably practicable. Any additional
controls as required after risk assessment per site should be included.
Requirements for using work baskets:

 Work baskets shall comply with local legislation. (If none exists, the Australian
Standard 1418.17 may be used as a good guideline.)
 As a minimum requirement, work baskets shall be designed by a competent
person, and an approved drawing of the wok basket should be kept in the
register.
 Have a relevant work basket permit approved.
Cranes used for lifting personnel require as a minimum the following:

 Be fitted with a safety hook.
 Be equipped with power lowering.
 Be equipped with controls that return to the neutral position when released
and cause the motion to stop.
 Be equipped with a lockout control to prevent free fall of the work basket and
its contents.
 Be fitted with an up limit switch on the hoist motion.
 Be fitted with a down limit switch, if the work basket is to be lowered below the
crane supporting surface.
 Secondary sling, large shackle to physically prevent the safety latch from
opening or secondary method for securing the safety latch to prevent roll out.
AA_AFRG_000008
ISSUE 0
 Total under hook load (which should be taken as not less than 750 kg)
multiplied by a factor of 2, should not exceed the crane chart rated capacity.
Note: the use of the work basket shall be limited to those situations where it is necessary to elevate
personnel to carry out work where it is not possible to use any other appropriate method and should
only be allowed where no other method is available for safely elevating personnel.
Common Hazard
In most incidents investigated, recovery plans were not present. Recovery plans
may need to be developed on a task by task basis. Personnel involved in the
formulation and/or carrying out of recovery plans must be competent in the skills
required to safely perform the rescue task.
27. No work in drop zone of suspended loads
The elimination of the need to work under or in the drop zone of suspended loads
shall be pursued. Where working under suspended loads is unavoidable, controls
shall be in place to eliminate or minimize the risks to personnel.
Intent
That working under suspended loads is the absolute last resort. In the unlikely
circumstance that working under a suspended load is required a comprehensive risk
assessment is required and shall be authorized by the senior site manager. It is vital
to ensure that all the controls that were identified in the risk assessment are
implemented.
Note: Counterweights are deemed to be suspended loads. Counterweight suspension chains are
deemed to be lifting chains. Leading practice is that counterweights should be suspended within
screened off or barricaded areas. Alternatively, counterweights should be adequately controlled by the
use of support beams placed beneath and above the counterweight.
Common Hazard
In the highly unlikely event where personnel are required to work under a
suspended load they should adopt the work basket rule as follows:
AA_AFRG_000008
ISSUE 0
 Double the required capacity i.e. if the load is 10 tonnes then the crane would
have to be capable of lifting 20 tonnes at the given radius and lifting equipment
must be rated at 20 tonnes.
 Where people may be in danger of being under a load that swings or rotates
the load should be kept under control by using one or more taglines.
Use of tag lines
28. Modifications subject to approval
Any modification to cranes and lifting equipment shall be subjected to the original
equipment manufacturer’s approval and to a rigorous change management
process.
Intent
To ensure that any modifications made to lifting equipment do not have a negative
impact on performance specifications. If situations exist where the OEM is no longer
in existence an approved equivalent will assess any modifications.
Note: The relevant site change management procedure must be used in conjunction with approval of
the OEM or approved equivalent.
This process should be followed irrespective of how small the proposed modification
is considered to be. For example, tack welding a small bracket or plate to the boom
of a crane may very quickly lead to fatigue cracking of the boom, and thus an unsafe
situation.
29. Preventative maintenance system
A preventative maintenance system should be in place to ensure that all cranes

and lifting equipment are maintained and in a serviceable condition, with
appropriate records being kept.
Intent
To ensure that all equipment utilized in any lifting operation is maintained in a safe
operating condition. Preventative maintenance activities need to be in compliance to
local legislation, the manufacturer’s specifications, and to any relevant regional
standards. Monitoring of preventative maintenance activities needs to be completed
to ensure that they are being completed as per the schedule.
AA_AFRG_000008
ISSUE 0
Note: The rated safe working loads apply only to equipment and hardware in a good serviceable
condition. Any equipment damaged in service should be taken out of service and repaired or destroyed.
See Appendix 2 for additional information relating to caring for, inspecting and
maintenance of cranes and lifting equipment.
Leading Practice
Personnel performing any maintenance on equipment involved in lifting operations

should have had adequate training by the manufacturer, or authorized agent, to
perform the required tasks. This ensures that maintenance is performed correctly
and minimizes the risk of future failure.
Common Hazards
Unsafe equipment – No one with reasonable cause to believe that equipment is

unsafe or unsuitable, shall use such equipment until the defect/s has been reported
to a responsible person, and appropriate action has been taken. The responsible
person shall have such equipment inspected and either declared safe or removed
from use.
Slings – After the hoist rope, the sling is the most commonly used piece of rigging
equipment. Observe the precautions in Table 29.1 when working with slings.
TABLE 29.1: PRECAUTIONS TO OBSERVE WHEN WORKING WITH SLINGS

Precaution Sketch
 Never use damaged slings. Inspect
slings prior to use to ensure their
safety. Check steel wire slings for
kinking, wear, abrasion, broken wires,
worn or cracked fittings, loose seizings
and splices, crushing, flattening, rust or
corrosion. Pay special attention to the
areas around thimbles and other
fittings
 Avoid sharp bends, pinching and
crushing. Use loops and thimbles at all
times. Corner pads that prevent the
sling from being sharply bent or cut can
be made from split sections of large
diameter pipe, corner saddles, padding
or blocking
 Never allow wire rope slings or any

wire rope to lie on the ground for
extended periods of time or on damp or
wet surfaces, rusty steel or near
corrosive substances
AA_AFRG_000008
ISSUE 0
Precaution Sketch
 Avoid dragging slings from underneath
loads and avoid crushing slings under
loads
 Keep wire rope slings away from flame
cutting and electric arc welding
 Never make slings up from discarded
hoist rope
 Avoid using single leg wire rope slings
with hand spliced eyes where possible.
The load can spin, causing the rope to
unlay and the splice to pull out. Use
slings with Flemish Spliced Eyes
 Never wrap a rope completely around a
hook. The sharp radius will damage the
sling

 Avoid bending the eye section of wire
rope slings around corners. The bend
will weaken the splice or swaging.

There must be no bending near any
attached fittings
AA_AFRG_000008
ISSUE 0
Precaution Sketch
 Ensure the sling angle is always
greater than 45 degrees. When the
horizontal distance between the
attachment points (S in figure below)
on the load is less than the length of
the shortest sling leg (L in the figure
below), then the angle is greater than
60 degrees and generally safe
Notes:
(a) When using slings in this configuration,
ensure that they cannot pull inwards,
allowing the load to tilt and fall out of the
slings.
(b) When using slings in this configuration,
always calculate the actual load on the
slings (see Section 12 “Identification of
Crane and Lifting Equipment” above)
 Do not assume that multi-leg slings will
safely lift a load equal to the SWL of
one leg multiplied by the number of
legs, although the rated SWL of the
multi-leg slings will be based on this
assumption. There is no way of
knowing that each leg is carrying its fair
share of the load. With slings having
more than two legs and connected to a
rigid load, it is possible for some of the
legs to take practically the full load
while the others merely play a
balancing role. It should always be
assumed that any two legs may carry
the entire weight of the lifted load.
30. Inspection and testing
All cranes and lifting equipment shall be inspected and tested to ensure all safety
devices are working (including non-destructive testing as required by the relevant
standard) prior to being operated or put into service. After any repair and/or
modification, cranes and lifting equipment shall be inspected (and non-destructively
tested as required by the relevant standard) prior to being returned to service.
Intent
To ensure that all lifting equipment and cranes are fit, and remain fit, for their
intended use.
Leading Practice
The following inspections are considered Leading Practice:

 Proof testing and certification of all new and modified equipment.
 Annual proof testing and certification of in use lifting equipment
AA_AFRG_000008
ISSUE 0
 3 monthly visual inspections by a competent person.

 Pre-start inspection by the person using the equipment.
 2 yearly random audit of lifting equipment conducted by a third party, who
must be a competent person.
The following items require proof testing:

 Chain slings
 Web/flat fibre slings
 Round fibre slings
 Pad eyes and lifting eyes.
 This list is not exhaustive
The following items do not require proof testing:

 Wire rope slings
 Shackles
Note: Proof testing should be completed by a nationally approved certifying body to ensure impartiality
of results.
31. Periodic inspections
A system of periodic inspection shall be in place for all cranes and lifting
equipment. Lifting equipment shall be inspected visually and confirmed fit for
purpose prior to being put into service. Visual inspection of lifting equipment by an
approved competent person shall be performed on a regular basis (e.g. six
monthly) unless regulations in the local area require examination more frequently.
Intent
To ensure that lifting equipment is in safe working condition and preventative

maintenance regimes are in compliance to statutory regulations
Examples of inspection times:

 Equipment : Prior to every lift
 Equipment used regularly: 3 monthly and tagged.
 Mobile cranes: Daily pre-start, 12 monthly, and every 10 years.
 Fixed Hoists and EOT cranes: 12 monthly, 10 year and 25 year.
Common Hazards
Defects are sometimes difficult to see if very close detailed inspections are not done.
Defective components – Examine all hardware, equipment, tackle and slings before
use. Destroy and de-register any defective components. Equipment merely
discarded may be picked up and used by someone unaware of its defects.
AA_AFRG_000008
ISSUE 0
Cracked EOT crane rail could lead to serious incident if not detected and repaired.
32. Register to be kept
A register of all lifting equipment (including slings) should be maintained. This

should include:
a. equipment’s unique identification number
b. documentary evidence of all inspections
c. certifications
d. maintenance
e. modifications and tests.
 Equipment’s unique identification number
 Documentary evidence of all inspections
 Certifications
 Maintenance
 Modifications and tests
Intent
To allow all lifting equipment to be monitored and tracked in terms of inspections,

repairs made, modifications or removal from service.
Each site should maintain a register of all lifting equipment owned by them.
When a Contractor’s equipment is used for lifting operations on a site, the

Contractor should maintain a register of the equipment on site. This register, or a
copy of this register, should be available on site at all times.
AA_AFRG_000008
ISSUE 0
8 PEOPLE REQUIREMENTS
33. Suitably qualified people
Suitably qualified, certified and competent person/s shall be involved in the

planning, supervision and implementation of the lifting operations.
Intent
To ensure that all personnel involved in lifting operations have the required
qualifications, certification, authorisation and competencies required to operate and
utilise lifting equipment in a safe manner. These qualifications will be to the relative
national standard.
Note: The single most important precaution in lifting operations is to determine load weight before
attempting any lift.
Competency assessment
This guideline provides minimum competencies for rigger and crane operators as
defined in the Anglo Fatal Risk Standard for Lifting operations. It is acknowledged
that different countries may use different terms to describe the jobs of the persons
defined below.
Note: All of the competencies specified here apply irrespective of whether the Riggers and Crane
Operators are employed by Anglo American through any of its Divisions, or by an external rigging
company.
Rigger
A person in charge of lifting operations; a person empowered to apply slinging

techniques, including the selection and inspection of lifting accessories and directing
the Crane Operator in the movement of the load, including when the load is out of
view of the operator, and must demonstrate:
 Compliance with behaviours in observations conducted against the site
behavioural observation sheets. At least 5 lifts are observed and compliance
with required behaviours on 5 consecutive observations is necessary for the
person to be judged to be competent.
 Competence in signalling all crane motions using hands, whistles and radio
protocols.
 Competence in selecting and inspecting the correct sling type including the
use of chain shortening devices.
 Competence in the correct use of the various sling types.
 Correct application of “rule of thumb” calculations for the capacity of slings.
 Correct interpretation of various forms of “SWL Rigging Cards” to determine
Lifting Accessory size selection.
 Correct interpretation of when to prepare a risk analysis or lifting plan.
 Compliance with site standards for the preparation of a risk analysis.
AA_AFRG_000008
ISSUE 0
 Knowledge of:
- Effects of angles on slings and lifting accessories.
- Effects of load moments on cranes.
- Estimation of approximate weights of loads composed of different
materials.
- Slinging loads including awkward loads and positioning loads in restricted
areas.
- Selection of crane and set up and crane rated capacity calculations.
- Attachment of hooks to lifting lugs and eye bolts.
- Procedures when working at heights.
- Procedures when thunder is heard or lightning is observed.
- Procedures in windy conditions.
- Procedures for working in the vicinity of, or when the potential exists for
coming into contact with live electrical conductors.
Note: Riggers need to demonstrate additional competencies to the above for activities such as:
 Lateral shifting of loads which may involve the use of chain blocks, tirfors, sheaves, winches etc.
sometimes in conjunction with cranes,
 Knowledge of crane selection and set up and crane chart rated capacity calculation for multi-
crane lifts,
 Competence in steel erection,
 Competence in directing lifts involving personnel in work baskets,
 Competence in demolition rigging,
 Specialist rigging applications.
Crane operator
In addition to the competencies for the Rigger, the Crane Operator must
demonstrate knowledge of:
 Interpretation of operator manuals.
 Interpretation of load charts.
 Interpretation of crane configuration requirements for the crane being
operated.
 Daily maintenance requirements as detailed in the Operating Manual for the
crane being operated.
 Emergency response strategies for loss of power during lifting operations.
In addition the Crane Operator must operate the crane and demonstrate the ability
to:
 Conduct a pre-start check of the crane and document the results.
 Set the crane up correctly for operation
 Correctly enter the crane configuration into the onboard computer, if
applicable.
 Check the operation of crane limit switches and safety devices.
 Boom up and down and hold a load 1 meter above the ground.
AA_AFRG_000008
ISSUE 0
 With an unloaded chain set on the hook, slew the crane to cause a pendulum
effect and then control (catch) the resulting swing bringing it to a standstill.
 With an unloaded chain set on the hook, raise and lower the boom to cause a
pendulum effect and then control (catch) the resulting swing bringing it to a
standstill.
 Float a load in a boom down and hoist up scenario and vice versa.
The competent Rigger as referred to above is required with his lifting crew to
undertake the planning and implementation of lifting operations and supervise the
lifting operations as required.
34. Roles and responsibilities to be defined
The roles and responsibilities of personnel engaged in lifting operations shall be

defined clearly.
Intent
To ensure that all persons involved in lifting operations clearly understand their roles
and responsibilities.
Common responsibilities of personnel involved in Lifting Operations:

 All personnel involved in a lifting operation are empowered to stop a lift when it
is unsafe due to miscalculations of the lifting plan or other reasons that result
in unsafe conditions. A competent person must review the lifting plan following
a stoppage and a meeting with the Lifting Crew must be held before lifting
resumes.
 The Crane Operator and the Rigger must be jointly responsible for determining
the load weight and placement of the crane so that it is set up within the radius
selected. The maximum radius of the lift shall be measured by tape if the load
is 70% or more of the crane chart rated capacity of the crane.
 The Crane Operator is responsible for setting up the crane and programming
its safety features where applicable and operating the crane within its safe
working limits.
 The Rigger is responsible for directing a lift and positioning the load.
 Only one person must be directing the crane operator at any one time. The
directing Rigger must be known to all in the Lifting Crew and must be the only
one to give signals.
 If a person in charge is utilised for a particular lifting operation, they need to be
able to be identified as such.
 In situations when more than one person is required to give signals (e.g. when
control passes from a person at ground level to a person on or in a structure)
an assessment of risk must be done detailing where directing of the Crane
Operator must be handed over.
AA_AFRG_000008
ISSUE 0
Individual Responsibilities
The Equipment Owner must ensure that:

 Safe, suitable equipment is provided to meet the requirements of the task at
hand
 Operators are capable and aware of their responsibilities
 Maintenance, repair, transport, assembly and other personnel are trained and
experienced to handle their specific jobs
 Training and skills upgrading is provided for all personnel
 Responsibilities and authorities are clearly designated for each member of the
lifting crew
 A thorough equipment maintenance and inspection program is in operation,
including keeping an up to date equipment register and other required
documentation
 Client and site supervision are capable and aware of their respective
responsibilities
 Equipment is maintained and inspected in accordance with the manufacturer’s
requirement and applicable regulations
The Equipment Operator is generally responsible for the safety of the crane
operation as soon as the load is lifted. Operators must know:
 The particular model of crane they operate, its characteristics, functions and
limitations
 The information in the crane’s operating manual
 The crane’s load chart, including all notes and warnings and how to calculate
or determine the crane’s actual net capacity in every possible configuration
 Proper inspection and maintenance procedures to be followed in accordance
with the guidelines of the owner and manufacturer
 Any site conditions that may effect crane operation, including the presence of
overhead power lines
 Basic load rigging procedures
In addition the Equipment Operator must:
Refuse to operate the equipment if there are any problems that may affect its safe
use. Inform the owner in writing of these problems with the equipment, preferably in
the machines logbook. Only recommence use of the equipment once repairs have
been completed, appropriate inspections and tests have been completed, and a
competent person has certified the equipment safe for use.
 Record in the register all inspections, maintenance and work done on the
crane in the field.
 Check that the site is properly prepared for crane operation.
AA_AFRG_000008
ISSUE 0
 Review plans and requirements with site supervision.

 Find out the load and rigging weight and where the load is to be placed.
Although operators are NOT responsible for determining load weights, they
become responsible if they do so or if they lift the load without checking the
weight with site supervision.
 Determine the number of falls and the length of hoist line required.
 Check the load chart to ensure that the crane has enough net capacity for
each planned lift.
 Select the best boom, jib and crane configuration to suit load, site and lift
conditions.
 Assume responsibility for assembling, setting up and rigging the crane
properly.
 Follow the manufacturers operating instructions in accordance with the load
chart.
 Consider all factors that may reduce crane capacity and adjust the load weight
accordingly.
 Maintain communication with Spotters.
 Operate in a smooth, controlled and safe manner.
 Shut down and secure the machine properly when leaving it unattended.
The Site Supervisor (Site Foreman, Rigger Foreman, Lead of the Trade
involved etc.) has overall responsibility as Person in Charge (PIC) of the lift and
must therefore plan all phases of the operation. Specifically the PIC must:
 Supervise all work involving the crane.
 Determine the correct load weight and radius and inform the Crane Operator.
 Ensure that the lifting crew is experienced and capable of establishing weight,
judging distances, heights and clearances, selecting correct tackle and lifting
equipment suitable for the load, rigging the load safely and securely.
 Supervise the lifting crew.
 Ensure that the load is properly rigged.
 Ensure the Spotters are capable of directing the crane and load, including use
of international hand signals where other forms of communication are not
possible.
 Designate Spotters and identify them to the Crane Operator.
 Ensure the safety of the rigging crew and other personnel that could be
affected by the crane operations.
 Keep the public and non essential personnel clear of the crane during
operations.
 Control the movement of all personnel in the area affected by the lift.
 Ensure all required precautions are in place when the lift is in the vicinity of
power lines.
AA_AFRG_000008
ISSUE 0
 Ensure that all personnel involved in the lift understand their respective roles
and responsibilities and their roles in the overall safety of each lift.
Important: The lifting plan must specify all responsibilities. These must not be
assumed. This is particularly important when there are several parties involved. For
example, a construction site may have a steel erection crew on site, which includes
a competent Rigger. For a particular heavy lift, a specialist rigging company may
have been appointed, with their own Rigger. If responsibilities are not clearly
defined, it may be unclear which Rigger is in charge of a particular lift.
35. Competency based training programme
A competency-based training programme for contractors, employees and

supervisors shall be in place. An approved examiner should assess the
competence of trainers performing such training.
Intent
To ensure that all personnel are appropriately qualified and competent to perform
required lifting operation tasks in a safe manner.
 Having personnel with the appropriate teaching/training qualifications to the
appropriate regional standard.
 Implementing a pass out system so that the operators have a clear
understanding of their role and are comfortable that they, within reason are
able to perform any task that is required.
 Documented experience of operators.
 Having a clear understanding of the experience and limitation of operators.
 Ongoing and refresher training.
 Knowledge of the relevant Mines Act and Regulations and other local statutory
requirements.
 Knowledge of the relevant regional Standards.
 Persons are required to be reassessed for competency on a frequency of 2
years
36. Inspections by competent inspector
A competent inspector shall perform inspections of cranes, lifting machines and

lifting equipment. An approved examiner shall assess the competence of the lifting
and handling equipment inspector.
Intent
To ensure that persons inspecting lifting equipment have the knowledge and skills to
be able to identify items that are not fit for purpose. The examiner should be
appropriately qualified to perform the assessments as per regional standards.
AA_AFRG_000008
ISSUE 0
37. Communication in common language and correct signals
Crane operators and crew shall be able to communicate in a common language

and to use the correct crane signals.
Intent
To ensure a common communication system is used among Crane Operators,

Riggers, and others on the Lifting Crew to avoid confusion.
Where radios are used for communication, these shall be on a unique frequency
channel provided by the local regulatory authority. Citizen Band (CB) or similar shall
not be used. Mobile phones shall not be used, and shall be switched off during lifting
operations.
Many countries have different signal standards. Local requirements should be

followed and where these do not exist, the chart below should be used.
Typical hand signals for Pendant Control
AA_AFRG_000008
ISSUE 0
Typical hand signals for Pendant Control
AA_AFRG_000008
ISSUE 0
Typical hand signals for mobile cranes
38. Solo crane operators trained in slinging
Solo crane operators shall be trained in slinging practices.
Intent
To ensure that crane drivers’ operating in a solo capacity, such as Vehicle Mounted
Cranes or pendant control cranes, are able to sling loads in a safe manner. Also to
ensure that Crane Operators are able to identify poor slinging practices applied by
others in the Lifting Crew before the load is lifted.
AA_AFRG_000008
ISSUE 0
Leading Practice
It is considered leading practice to use a Rigger for every lift. In some cases more
than one person may be required to safely supervise and control a load. This needs
to be considered when performing the risk assessment.
Not a good technique as the slings are not spread wide enough, no one is controlling the load,
the Operator is in the danger zone and he is not protected from falling from heights.
39. Fit for work policy
A fit-for-work policy shall be in place, incorporating the clearly defined maximum

levels of drugs (including prescribed medication) and alcohol allowed in the system
of drivers/operators, and a system shall be in place for fatigue management.
Intent
To reduce the risk of serious injury or fatality due to lifting accidents caused by
Crane Operators or other persons involved in lifting operations that are not fit for the
task. A selection process for personnel is required which will include medical
certification of fitness to work on lifting operations.
The intent is to avoid accidents and injuries such as:

 Falls from equipment during accessing and working on equipment due to a
lack of mobility, strength, agility, etc.
 Impacts or aggravation to existing health issues from the risks of equipment
vibration, dust, noise etc.
 Collisions or incorrect crane operation due to issues such as vision, depth
perception, reaction speed, coordination, hearing, sleep disorders, epilepsy
etc.
Paragraph 5.1 of the Anglo Occupational Health Way stipulates that “All operations
shall have systems in place to ensure that all personnel and contractors are
medically fit to perform their activities...” and, “...relevant personnel have been
certified medically fit to perform their activities based on fitness criteria that are
inherent to the requirements of the task or job”.
AA_AFRG_000008
ISSUE 0
The Anglo Occupational Health Guidelines have been incorporated into the
Occupational Health Way and the section on risk-based medical surveillance
describes the process for certification of fitness for work.
 All employees should be medically examined and certified fit for their own job
based on a man-job specification (which describes the inherent requirements
of the job).
 All medical examinations, pre-placement and periodical, will be conducted
against the fitness criteria for operating cranes and the certificate of fitness
issued will cover this.
Since medical examinations and certification of fitness are usually only undertaken
on an annual basis the employees health and fitness may have changed since the
certificate was issued and it is essential that employees are encouraged to come
forward should they feel unwell or know of a condition which may make them unfit to
operate cranes. In a project setting it is prudent to ask employees if there is any
condition that may make them unfit to do the task even if they have a current
certificate of fitness. A positive answer should result in referral to the company
occupational medicine practitioner.
Beyond the fitness to work assessments, the most important thing to remember is
for the supervisor to observe the team at work during the day. Knowing the team,
their ability and their how they perform during the day is critical. All supervisors
should be open to their team members who are working on lifting operations coming
forward to inform him/her if they do not feel comfortable. A decision may have to be
made about the team member continuing on the team but if the reason is a
temporary one then the person should be accommodated on other work for the day.
Illness should be referred as mentioned above.
40. Behaviour based observations
Behaviour-based observations shall be performed and any need for additional

specific training shall incorporate the results of these observations.
Intent
The intent is to avoid serious injury/fatality from lifting operations where unsafe
behaviour could result in selection of inappropriate equipment and methods. It is
vital that a ‘no blame no shame’ concept is incorporated during observations.
Common Hazards
The safe working loads of most rigging and hoisting equipment is determined from
the static loads and appropriate safety factors is applied to account for dynamic
motions of the load and equipment. To ensure that safety is not compromised due to
behaviour, allow for other dynamic forces created by the normal operational
movement of the machine and its load. Always avoid the sudden snatching,
swinging and stopping of suspended loads. Rapid acceleration and deceleration can
only increase the stresses on both machine and tackle and thus increase risk of
failure.
AA_AFRG_000008
ISSUE 0
APPENDIX A: REFERENCE DOCUMENTS

AA AFRG 8 Lifting Operations Guideline
AA_AFRS_000008 : Anglo Fatal Risk Standard 8
AA_SPEC_664004 : Hand Operated Lever Hoists
AA_STD_100 : Quality Requirements for Suppliers of Critical Equipment
AAC_SPEC_664003 : Hand Operated Chain Pulley Blocks
AAC_SPEC_664005 : Compressed Air Hoists
AAC_SPEC_664006 : Reconditioning of Hand Operated Chain Pulley Blocks
AAC_SPEC_664008 : Reconditioning of Compressed Air Hoists
AAC_SPEC_664009 : Reconditioning of Electrically Operated Wire Rope Hoist Units
AS 1418.8 : Cranes, Hoist and Winches – Special purpose Appliances
AS 2550-1 : Cranes, Hoists and Winches – Safe Use Part 1: General Requirements
ISO 10245 : Cranes - Limiting and indicating devices
ISO 10972-1 : Cranes - Requirements for mechanisms - Part 1: General
ISO 10972-3 : Cranes - Requirements for mechanisms - Part 3: Tower cranes
ISO 10972-4 : Cranes - Requirements for mechanisms - Part 4: Jib cranes
ISO 10972-5 : Cranes - Requirements for mechanisms - Part 5: Bridge and gantry
cranes
ISO 10973 : Cranes - Spare parts manual
ISO 11629 : Cranes – Measurement of the mass of a crane and its components
ISO 11630 : Cranes – Measurement of wheel alignment
ISO 11660 : Cranes – Access, guards, and restraints
ISO 11661 : Mobile cranes – Presentation of rated capacity charts
ISO 11662 : Mobile cranes – Experimental determination of crane performace
ISO 11994 : Cranes – Availability - Vocabulary
ISO 12478 : Cranes – Maintenance Manual
AA_AFRG_000008
ISSUE 0
ISO 12480 : Cranes – Safe Use
ISO 12482 : Cranes – Condition Monitoring
ISO 12485 : Tower cranes – Stability Requirements
ISO 12488 : Cranes – Tolerances for wheel and travel and traversing tracks
ISO 13202 : Cranes – Measurement of velocity and time parameters
ISO 14518 : Cranes – Requirements for test loads
ISO 15442 : Cranes – Safety requirements for load cranes
ISO 15513 : Cranes – Competency requirements for crane drivers(operators),

slingers, signallers and assessors
ISO 15696 : Cranes – List of equivalent terms
ISO 1834 : Unsintered polytetrafluoroethylene (PTFE) tapes for engineering

applications
ISO 1835 : Ductile iron pipes, fittings, accessories and their joints, for use in high
and low pressure systems for portable and foul water.
ISO 19961 : Cranes – Safety code on mobile cranes
ISO 2262 : General purpose thimbles for use with steel wire ropes - Specification
ISO 2374 : Lifting appliances -- Range of maximum capacities for basic models
ISO 23853 : Cranes – training of slingers and signallers
ISO 2415 : Forged shackles for general lifting purposes – DEE shackles and Bow
shackles
ISO 25599 : Cranes – Jib cranes – International standards for design, manufacturing,
use and maintenance requirements and recommendations
ISO 3056 : Non-calibrated round steel link lifting chain and chain slings – Use and
maintenance
ISO 4301 : Cranes and lifting appliances – Classification
ISO 4302 : Cranes – Wind Load assessment
ISO 4304 : Cranes other than mobile floating cranes – General requirements for
stability
ISO 4305 : Mobile cranes – Determination of stability
AA_AFRG_000008
ISSUE 0
ISO 4306 : Cranes – Vocabulary part 3: Tower cranes
ISO 4308 : Cranes and lifting appliances – selection of wire ropes
ISO 4309 : Cranes – Wire ropes – Care, maintenance, installation, examinational

discard
ISO 4310 : Cranes – Test code procedures
ISO 4344 : Steel wire ropes for lifts – minimum requirements
ISO 4347 : Leaf-chains, clevises and sheaves – Dimensions, measuring forces and
tensile strengths
ISO 5614 : Resistance to growth of Trichopyton Interdigitale
ISO 7296 : Cranes – Graphic Symbols
ISO 7363 : Cranes and lifting appliances – Technical Characteristics and acceptable
documents
ISO 7531 : Wire rope slings for general purposes – Characteristics and
specifications
ISO 7592 : Calibrated round steel link lifting chains – Guidelines to proper use and
maintenance.
ISO 7593 : Chain slings assembled by methods other than welding – Grade T(8)
ISO 7752 : Lifting appliances – Controls – Layout and characteristics
ISO 8087 : Mobile Cranes – Drum and sheave sizes
ISO 8539 : Forged steel lifting components for use with grade T(8) chain
ISO 8566 : Cranes - Cabins
ISO 8686 : Cranes – Design principles for load combinations
ISO 9373 : Cranes and related equipment – Accuracy requirements for measuring
parameters during testing
ISO 9374 : Cranes – Information to be provided
ISO 9926 : Cranes – Training of drivers
ISO 9928 : Cranes – Crane driving manual
ISO 9942 : Cranes – Information Labels
AA_AFRG_000008
ISSUE 0
CSAO (Construction Safety Association of Ontario) Hoisting and Rigging Safety
APPENDIX B: RECORD OF AMENDMENTS
Issue 0 : New document (Geoff Krige, June 2009)
AA_AFRG_000008
ISSUE 0
APPENDIX 1: A GUIDE TO LIFTING HAZARDS AND CONTROLS
The following provides a guide to likely lifting hazards and possible controls. Whilst this is detailed,
it does not cover all aspects and scenarios. Individual lifts need to be assessed within their own
particular context and specific hazards relating to the lift identified.
Note: If in doubt, do a lifting plan.
The following format of “Possible Hazard” and “Possible Controls” can facilitate the preparation of
risk assessments, or the Job Safety Analysis with or without pre- and post-risk scores.
STEP/ITEM POSSIBLE HAZARD POSSIBLE CONTROLS
Isolation Considerations
Electrical Lifting is carried out without properly electrically Necessary Electrical Isolations must be enacted
Isolations isolating the associated equipment as per site procedures e.g.:
 Restricted Operation
 Out of Service
 Danger Tagging
People operating ancillary equipment/ erecting No personnel operating ancillary equipment/
scaffold within the operating area of an EOT crane erecting scaffold etc must work within the
without the EOT crane being de-energised operating area of an EOT crane unless it is
isolated.
Please note that in incidents with EOT cranes
Isolation is a major factor, so give it particular
attention.
Mechanical, Lifting is carried out without properly mechanically Necessary Mechanical Isolations must be
Hydraulic and or hydraulically isolating the associated equipment enacted as per site procedures.
Pneumatic
Isolations
Lifting activities cause an item of mechanical In the case of conveyors, procedures must take
equipment to be moved by an energy source which into account that whilst the electrical energy
is not it’s own and others working on the source is isolated, the belt may still be capable of
equipment are unaware of the lifting activity movement as a result of lifting operations.
Unexpected mechanical movement occurs while A procedure must be in place to protect people
performing maintenance or the like on an working using isolation procedures from
electrically isolated EOT crane, e.g. due to wind, unexpected mechanical belt movements
being bumped resulting from lifting or mechanical operations
(e.g. “bag tag” procedures).
Check that brakes are functioning correctly to
guard against unexpected movement.
People
Inexperienced Person/ persons in Lifting Crew are not competent Ensure personnel have relevant local Statutory
Crew/ Unfamiliar to carry out the lift certification where applicable.
with Lifting Task
Ensure personnel have been assessed by the
site and have been judged to be competent
Use a competent person to guide and advise the
lifting personnel until people are competent.
AA_AFRG_000008
ISSUE 0

A new person is added to the crew part way Go through the job with the new member and
through the task ensure they are made aware of the details of the
JSA/ procedures relevant to task with full crew
participation. Have new person sign off JSA if
applicable.
Inexperienced Person/ persons operating support equipment Ensure personnel have relevant local Statutory
Operator of (e.g. boom lift) are not competent to operate the certification.
support equipment
equipment Ensure personnel have been assessed by the
site and have been judged to be competent.
Use a competent person to support the lifting
personnel until people are competent.
Crane Operator Crane operator is unfamiliar with crane to be used Allow time for Crane Operator to practice and
Unfamiliar with become familiar with the operation of the crane.
Crane
Support unfamiliar person with an experienced
operator.
Allow sufficient time for the operator to study the
crane operating manual and load chart (if
applicable) before requiring him to lift (can take a
minimum of half a day).
Use a competent operator for support until the
unfamiliar operator is competent.
Crane Operator Hazard depends on “fit for work” ailment. Ailment Ensure up to date medical certificate of fitness
or Crew impairs ability of Crane Operator or Crew to
medically unfit operate crane safely
Resourcing the Insufficient / inadequate resources as listed below Assess the risk, plan the job and select and list
Lift to carry out the task: resources required.
 people Check that resources are on site before
conducting the lift/ lifts.
 PPE, fall protection equipment etc
 support equipment (boom lifts etc)
 the correct Crane
 certified lifting accessories
 water, UV protection and the like
 chocks and dunnage
 approved outrigger packing
Communication Crane Operator receives signals from more than Nominate the person controlling the lift in the pre
one person lift planning process.
Have person/ persons controlling the lift wear
unique coloured high visibility vests.
Crane Operator is confused about who is Identify when control will be passes from one
controlling the lift when control passes from one person to another and detail in JSA.
Rigger to another
The person controlling the lift during placement is Ensure the person controlling lift can see
unable to see the personnel placing the load personnel placing the load during placement.
AA_AFRG_000008
ISSUE 0

Communication between Rigger and Crane Ensure an intrinsically safe radio channel is
Operator on radio channel is being interrupted by available when using radios for control signalling.
other traffic
Hand signal by Rigger is misinterpreted by Crane Rigger and Crane Operator are both competent
Operator with site hand signalling protocol.
Crane Operator is confused by terminology being Rigger and Crane Operator are familiar with
used by Rigger on the radio radio protocols.
Rigger and Crane Operator work together as a
regular crew.
Mobile phone ringing during lift distracts personnel Pre job briefing reminds personnel involved in
from their task the lift that all mobile and other phones will be
switched off until completion of the lifting
sequence.
Responsibility Weight of item being lifted is underestimated Require Rigger and Crane Operator to be jointly
responsible for determining the weight. Seek
Supervisor’s support if unsure.
Radius of lift is underestimated Require Rigger and Crane Operator to measure
the radius with a tape if the lift is over 70% of the
Rated Capacity of the Crane for the configuration
and radius.
Crane inappropriately set up for the lift Make Crane Operator responsible for setting up
the crane, programming the computer with the
correct configuration and operating within the
Rated Capacity of the crane.
People believe they are not empowered to stop the Make clear in job briefing that in case of
lift when they believe it is unsafe to proceed emergency, ANYONE may stop the lift.
Make clear to the signalling Rigger that he/she is
empowered to stop the lift whenever the lift
varies from the plan.
Make clear to the Crane Operator that he/she
can stop the lift whenever he believes it is unsafe
to continue.
Minimising Manual handling of heavy rigging accessories Planning allows for maximum use of Crane
Manual causes injury to Rigger or Assistants auxiliary hoist where applicable or other
Handling mechanical devices to minimise manual
handling.
Load
The Weight Weight of the item to be lifted underestimated Weight to be obtained from Engineering or
Vendor drawings or data sheets. Rigger and
Crane Operator may perform independent
calculation from first principles.
Weight of Container underestimated. Take a trial pick and confirm weight on crane
Load Cell (can’t do on demolition work).
Weight of all items on and below boom head not Take a trial pick and confirm weight on crane
allowed for Load Cell.
Know the weights of rope fall, block etc and keep
in crane cabin.
Require use of “Lift Calculation Sheet” to ensure
rigour
AA_AFRG_000008
ISSUE 0

Lifting Lugs Use of improperly designed lifting lugs Ensure a competent person designs or approves
the design, of the lugs
Use of poor quality lugs Visually check lug welds for proper weld quality.
Confirm with NDT if unsure.
Improperly slinging load in weak direction of the Check drawings and engineering records
lug
Align sling in strong direction of the lug.
Strength of Load collapses during lift (this may be expected on Strength of load to be checked by Designer of
load long or slender loads, such as roof trusses or equipment.
conveyor gantries)
Load only to be lifted at designated lifting points.
Pre-assembled structure inadequately braced or Structural Designer to prepare a general

supported during lift arrangement drawing showing all self weight
loads, and temporary bracing. Structural
Designer shall approve this drawing, and shall
sign lifting plan.
Damage or failure due to impact Use impact factor of 3,5 as specified by AA
114001.
Awkward Loads The load awkward to lift and place Use certified and competent riggers. Obtain
Engineering input if necessary.
It is difficult to attach slings to the load Use certified and competent riggers. Obtain
The load contains liquids Use certified and competent riggers. Obtain
Wind can apply significant loadings to the lifted Use certified and competent riggers. Check
load (e.g. shutters) weather forecasts before lifting if load is to be
suspended for an extended period of time.
The load has sharp edges which may damage the Protect slings from damage using packers/
slings protection. Rig correctly to avoid any chance of
slings slipping (use spreader beams?).
Load tilts and slides out of slings Ensure slings are attached above load centre of
gravity
Ensure slings are well spread towards the ends
or corners of the load
Have stability checked by a competent person if
spreader beam or lifting frame is used
Load has Pieces may be loose or loosen during lift Ensure all pieces are properly secured prior to lift
separate pieces commencing
Crane
Crane access to Crane cannot be set up in correct location Prior to lift, check site plan or drawing,
site considering headroom, road width and turning
circle requirements.
Crane is damaged or damages services along Prior to lift, check site plan or drawing,
access road considering headroom, road width and turning
circle requirements. Check bridges and culverts
for load carrying capacity.
AA_AFRG_000008
ISSUE 0

Lifting On Crane lifting load in stationary lift without deploying NOT PERMITTED
Rubber outriggers
Lifting with Lifting with outriggers not fully extended Only lifts without outriggers fully extended if the
outriggers not Crane Chart permits it and a risk assessment or
fully extended lifting plan has been done.
Require approval from the relevant Manager of
the lifting operation.
Preparing crane Crane lifts with safety devices not functioning Post start checks include checks that limit
to lift devices and brakes are functioning correctly and
are done in the morning and/ or prior to lifting
sequences commencing.
Lifts outside of Rated Lifting Capacity of the crane Install Rated Capacity Indicator Lighting and
alarms on cranes so that all are aware when this
situation occurs.
Lift within the specific limits of the crane load
charts for the configuration and radius
Crane configuration checked for consistency with
risk assessment or lifting plan. If a pin jib, ensure
that the boom and/or fly sections are configured
as per the operating manual.
Ensure that the correct counterweight is fitted for
the planned configuration of the crane.
Crane Operator cannot see out of and around Ensure that crane cabin windows and mirrors are
crane due to dirty glass clean in pre start routines.
Lifts in an area where static and other electric Ensure insulation of mobile crane from the floor
sources are present without proper insulation of level is correct before lifting.
crane
Crane Operator is drowsy and concentration Ensure crane cabin air conditioning is functioning
effected by a hot, stuffy or cold cabin. correctly and allows circulation of fresh air.
Lifting with Side loading to crane booms/ carriages. Plan lifts to avoid producing out of vertical lifting
hoist rope out ropes.
of vertical Load is likely to slide sideways as weight is Plan lifts to avoid producing out of vertical lifting
transferred from ground or floor onto crane ropes.
When this is necessary because of load transfer,

keep any pulling forces in line with the boom and
use certified and competent riggers.
Welding a Hoist ropes and crane electronics damaged by Planning allows for isolation of crane hook from
suspended earth leakage induced by welding suspended load, e.g. using soft slings or approved isolating
load loads device.
Longer period of time taken to weld suspended Check out weather forecasts before proceeding
load increases risk of lift being effected by wind or with the lift. Ensure item being welded is correctly
bad weather earthed.
AA_AFRG_000008
ISSUE 0

Lifting Accessories
Sling or chain Soft slings chosen when they may be damaged by Don’t use soft slings without considering the
selection bumping against objects potential for damage.
Chains used when they may damage the load. Protect the load or choose an alternative type of
Load has sharp edges and may cut or damage the sling. Protect the sling from the load and choose
sling appropriate sling type.
Use of heavy sets of slings or chains causes back Use auxiliary hoist to help lift slings or use other
injuries etc to Rigger ancillary equipment to assist.
Use of slings or chains with inadequate SWL. This Use lifting plan, or Rigger to calculate actual
is particularly likely when slings are angled with loads in slings before selection. Obtain
lifting beams engineering input if necessary.
Ensure that slings are not inadequately specified
because of uneven sharing of tension from load
between multiple slings.
Shackle Use of shackles with inadequate SWL. This is Use lifting plan, or Rigger to calculate actual
selection particularly likely when shackles are used with loads on shackles before selection. Obtain
slings that are angled with lifting beams engineering input if necessary
Sling, chain and Wrong slings, chains or shackles used because All slings, chains and shackles to be tagged with
shackle not properly identified serial number, SWL and next inspection date
identification
Sling, chain and Slings, chains or shackles break because of All slings, chains and shackles to be tagged with
shackle deterioration or damage serial number, SWL, current certification and
maintenance next inspection date
All slings, chains and shackles to be thoroughly
visually inspected by competent Rigger prior to
use
Lifting beams Use of beams with inadequate SWL Use lifting plan, or Rigger to calculate actual
loads on beams before selection. Obtain
engineering input if necessary
Damage or failure due to impact Use impact factor of 3,5 as specified by AA
114001.
Tuggers (tirfors) Tugger breaks because of inadequate SWL Only use properly identified tugger.
Ensure that maximum tension in tugger is known.
Specifically, consider the effect of over-tightening
the tugger so that load is not unevenly spread
between slings.
Tugger breaks because of damage Only use tugger with up to date inspection
certificate.
Perform pre-start inspection.
Work basket Injury to personnel due to collapse of work basket Only use work basket which has been properly
designed by a competent person, and which has
been constructed to proper specifications.
Only use work basket with up to date inspection
record, and with no visible damage.
Collapse of work basket due to overloading Ensure work baskets are properly tagged with
clear statement of people and equipment loads
that can be carried.
AA_AFRG_000008
ISSUE 0

Injury to person due to falling from work basket Use proper “Working at Heights” procedures and
equipment (see AA_AFRS_7)
Lifting brackets Load falls due to failure of lifting bracket Lifting brackets must be designed and approved
for use by competent person.
Damage or failure due to impact Use impact factor of 3.5 as specified by
AA Spec114001.
The Area Where The Lift Is To Be Performed

Ground Ground unable to bear weight of load Inspect ground before lifting. Look for filled or
Capacity to soft ground, evidence of old trenches. If in doubt,
Support Weight get engineering input
of Load.
Structure Structure unable to bear weight of load Get engineering input to confirm adequacy of
Strength to structure to support load
Support Weight
of Load.
Ground Ground unable to bear weight of load, crane and Inspect ground before lifting. Look for filled or
Capacity to accessories imparted through outriggers or tracks soft ground, evidence of old trenches. If in doubt,
Support Weight e.g. wharf get engineering input. Use packing and/ or mats
transferred under outriggers/ tracks
through Tracks/
Outriggers.
Structure Structure unable to bear weight of load, crane and Get engineering input to confirm adequacy of
Strength to accessories imparted through outriggers or tracks structure to support load
Support Weight e.g. wharf or suspended slab
transferred Use packing under outriggers/ tracks to transfer
through Tracks/ weight correctly to structure
Outriggers.
Uneven Ground Ground is uneven where crane is to be set up Assess whether able to be compensated for by
using safe amount of outrigger packing
Level the crane set up area by installing a crane
pad
Underground Loads imposed by lifting activity damages Check Plans and get Engineering advice
and Aerial underground plant / services
Services
Trenches for underground services, sumps, or Check Plans and get Engineering advice
large storm water pipes, weaken bearing area
Crane contacts overhead power lines Inspect for overhead power lines and other aerial
services. Apply site procedures if aerial
conductors are in the vicinity
Soft ground Filled ground not properly compacted Competent person to approve ground for
outrigger pressure
Site of demolition of old structures may have All old material to be removed, holes filled,
holes, loose blocks of concrete/steel/masonry ground made good and compacted
Trip Hazards Personnel injured by trips and falls Remove significant trip hazards from work
environment
Ensure people are aware of hazard
AA_AFRG_000008
ISSUE 0

Emergency Cranes or other lifting equipment blocks roads so Lifting plan to consider alternative routes
vehicle access that emergency vehicles cannot access other parts
of plant
Adjacent to Vehicles using road strike crane Lifting plan to specify closure of road or
public road, site barricading to protect crane from impact
road or haul
road Use of signage to warn road users
Vehicles strike Rigger or other lifting Crew Lifting plan to specify closure of road or
members barricading to protect persons from impact
Use of signage to warn road users
Use spotter to warn Rigger and Crew about
approaching vehicles
Rigging The Load

Rigging the Load incorrectly rigged or slung Use certified and competent riggers
Load
Slinging arrangement unstable Use certified and competent riggers
Lifting plan to be approved by competent person
Lifting tackle Incorrect lifting tackle used Lifting plan to specify tackle to be used.
used Identification of tackle to be checked prior to lift
Lifting And Slewing

Complex The lift is part of a complex sequence Ensure that the sequence is adequately detailed
Sequences in the risk assessment and lifting plan
Ready for lifting Improvising to place load when dunnage and Place dunnage and have chocks ready before
chocks are not in place ready to accept the load load is lifted.
People under Person under a slung load with no crushing Consider other options and choose method
slung load protection provided based on risk
Rigger under a slung load in an attempt to control Use tag lines for control or pre sling with tag lines
it and use hooks
Plan job to keep Rigger away from under slung
load
Slew load over Load dropped on or impacts plant containing Ensure that appropriate masks, showers, or
live plant dangerous or toxic gases or chemicals other measures are available in case of
accidental contamination
Ensure measures available to prevent
environmental contamination
Damage to plant under load leads to hazards Lifting plan with risk assessment to be approved
elsewhere (e.g. load dropped on conveyor belt by Plant Supervisor
breaks belt, releasing stored energy in belt
tension; load dropped on pipe breaks pipe Follow site isolation procedure, permit systems
releasing pressure; etc) and lifting over live plant procedure
Clearances of Crane component strikes adjacent structure during Check clearance of Counterweight, A Frame,
crane and load lift Masts and Gantries to Obstacles.
to objects during
the lift Load impacts boom during lift (“boom bound”) Check clearance of Boom to Obstacles.
Check clearance of load to Boom.
Load being lifted by EOT crane strikes crane Check clearance of load to crane beam and
beams / carriage carriages.
AA_AFRG_000008
ISSUE 0

Load being lifted by EOT crane strikes structures, Identify pinch points and crush areas.
other objects
Prepare scale drawings and Rigging Studies if
clearances are tight.
Limited High sling or chain loads due to shallow sling Use different lift arrangement.
headroom for angle
booms or loads
Barricading or Person impacted by counterweight during swing Identify tail swing area and barricade, tape or
taping and motion place warning markers.
restricting
access to Lifting Load drops on person below load Area below lift barricaded or taped with
Areas information tags, restricted entry tags, and / or
protected with spotters as per site procedures.
Person walks into area below lifted load and load Barricade, tape off area or control access to all
drops on the person the areas affected by the lift with spotter.
Working at Person in Lifting Crew falls from height Plan job to eliminate or minimise working at
Heights heights if practicable (use of accessible lifting
lugs, etc).
See
AA_AFRS_7 Provide safe access for lifting tasks with ladders,
scaffold, boom lifts etc.
Identify appropriate anchor points for fall
protection equipment.
Identify appropriate type of lanyard, inertia reel
and harness to be used.
Apply relevant site procedures.
Tool used by person at height falls and strikes a Barricade, tape off area below.
person
Use tool lanyards
Hand and Foot Hands caught in slip/ nip areas when chains or Keep hands clear of slip / nip areas when chains
Injuries slings are being put under tension or slings are being put under tension.
Bundled load shifts against itself and injures Never touch bundled loads with hands, use tag
Rigger’s hand lines.
Feet crushed when taking weight/ placing loads Keep feet out of crush areas.
Placing The Load And Shutting Down
Placing Loads Insufficient personnel and/ or support equipment to Plan adequately and identify personnel and
safely place the load equipment (e.g. boom lifts) required in the risk
assessment or lifting plan
Personnel are in crush areas as load is placed. Body positioning discussed in pre job planning if
confined areas are involved
Releasing Boom impacts structure above as weight is Confirm adequate headroom exists before lifting.
Loads released (due to boom deflection) Do a scaled drawing if necessary
Slightly lower boom to release weight ensuring
there is no contact with the obstruction above
Rigging accessories catch on structure during Rigger directs till rigging gear in sight of Crane
removal Operator
Load is placed in incorrect position on a truck Planning allows for truck driver to be involved in
discussions about orientation and placement of
the load on the truck
AA_AFRG_000008
ISSUE 0

Load is placed along grain of dunnage Place load correctly on dunnage and packing,
use steel plate if required
Pick And Carry And Travelling

Pick and Carry Crew embark on pick and carry task and improvise Crane operator and rigger walk and inspect the
as obstacles are encountered route to be used
Route with: Choose to use a truck to carry the load
 bumpy uneven ground, soft ground
 grades including side slopes
 power lines overhead or close to route
Rough terrain type crane used for pick and carry Only use Rough Terrain cranes for pick and carry
when ground is uneven over the front in accordance with the
manufacturer’s recommendations and only on
firm level ground
Improper tyre pressure causes load swing during Crane Operator checks that tyre pressures are
operation correct in pre start routine
Picks and Carries over a long distance and travels Choose to use a truck to carry the load
fast causing dynamic loading of slings
Wheel hits a pot hole or bump causing dynamic Operator engages Axle Locks if applicable and
loading of the sling uses low range.
Load swings and strikes surrounding objects or Use rigger with tag line to control the load or tie
crane the load to the crane using appropriate
accessories.
Load strikes other people in congested area Use a spotter in congested areas.
Clear the area of unnecessary people
Slings swinging on unloaded hook strike others or Stow gear after releasing the load
surrounding objects
Load drops on the Rigger and/or Assistants Rigger uses tag line, Load is carried low and
Rigger and Assistants are never under the load
Travelling Travels crane with boom in raised position Chooses to stow boom before travelling. If it is
necessary to travel with the boom up, ensure
load charts are used for planning the travelling
and that only a very short distance is travelled.
Engage necessary locks
Apply the pick and carry checklist and controls
above.
Interactions With Other Cranes
Interactions with One crane operates while passing its boom over Plan work and separate and mark “Arcs of
other cranes or under the boom of another crane. Operation” for each crane and do a risk
assessment of lifting plan for passing one crane
boom over or under another crane boom.
Two EOT cranes carry out a tandem lift Consider risks involved in disabling anti collision
devices and in loadings on supporting structures.
Do a lifting plan.
AA_AFRG_000008
ISSUE 0

Special Lifting Situations
Lifting with Lifting is carried out with a floating crane Specialist procedures for the particular type of
floating Crane lifting will be developed and used.
Sub Sea Lifts Lifting is carried out in a sub sea situation Specialist procedures for the particular type of
lifting will be developed and used.
Lifting Lifting personnel when other methods are Consider options and choose method based on
Personnel available to do the work risk.
Lifting personnel with a crane in other than a NOT ALLOWED.
certified man cage/ basket
Lifting personnel in a certified man basket The requirements detailed in the site procedure
for lifting personnel shall be applied.
Emergency Situations
Lightning, Load is to be suspended for an extended period of Check out weather forecasts before proceeding
Storms and time, exposing the lift to changes in the weather with the lift.
High Winds
Ensure Crew knows routine if it storms. If it
storms, Crew is to stop lifting and the boom is to
be retracted/ lowered if practical to do so. The
crew must understand that they are not to touch
rigging accessories while lightning is about.
If using an EOT crane, lower the load to the
ground. If unloaded, lift the hook to maximum
height. Check whether the crane beam needs to
be tied to the main girders.
Power Lines Crane contacts energised power lines Lift maintaining minimum clearances to lines and
structures/use spotter as per local regulations
and site procedures.
Remind Crane Operator and lifting Crew of
practices to be applied in case of contact before
undertaking the lift.
Environmental Considerations
Spills Oil spills from crane impact environment Crane carries oil spill kit.
Oil spill from load (e.g. gearbox) impact Crane carries oil spill kit.
environment
Other Other environmental impact? Address other environmental impact.
AA_AFRG_000008
ISSUE 0
APPENDIX 2: LIFTING EQUIPMENT MAINTENANCE AND INSPECTION
Applicable Legislation
South Africa: The Occupational Health and Safety Act (Act 85 of 1993) and Regulations.
Regulations, Driven Machinery, Lifting Machines and Lifting Tackle.
All equipment used for lifting operations shall be properly maintained, including relevant inspections
and load tests. The specific requirements, inspection intervals and discard criteria vary in different
countries, and should be obtained from applicable legislation or from the Manufacturers.
a. Cranes
 Operator Daily Inspections:
See typical “Daily Crane Operation Log Book”
AA_AFRG_000008
ISSUE 0
 Periodic Inspections and Testing:

 A competent person shall inspect all components of the crane at intervals not
exceeding one year, but preferably every three months.
 Cranes should be load tested up to 110 % of their SWL, or the crane chart rated
capacity, over the full range of operating conditions at intervals not exceeding one year.
 It is considered leading practice for cranes to be checked every two to three years by
an independent competent person.
 Major Inspection and NDT:
 A major inspection shall be conducted as specified by applicable legislation, by the
Manufacturer, or by a competent person. The crane or lifting equipment shall be
stripped down to allow access to all parts requiring tests or inspection. Inspection
methods may require visual inspection, NDT, or other means. The aim of the major
inspection is to ensure continued safe operation of the equipment.
 After 10 years or 10 000 operational hours all cranes and lifting equipment shall be
subjected to a major inspection.
 All cranes and lifting equipment that are to be modified or upgraded shall be subjected
to a major inspection.
 Any cranes or lifting equipment that has been involved in an accident, or has been
overloaded shall be subjected to a major inspection.
 Care of Cranes and Lifting Equipment:
 Never make any modifications, however small, without written approval from the
Manufacturer or competent person. The written approval shall be kept in the register.
 Never attach any brackets for any purpose whatsoever to cranes or lifting equipment.
Drilling, or tack welding, for attachment of brackets can substantially weaken the lifting
equipment.
 Register to be Kept:
 A register shall be kept on site for all cranes used on site.
 The register shall contain at least:
 The unique serial number of the crane.
 The purchase or commissioning date.
 The number of hours of operation of the crane.
 A record of inspections.
 A record of load tests.
b. Slings and Chains
 User Inspections:
 Inspect nylon slings on a daily basis or before each use for frayed threads, cuts,
tears, loose connections or other damage.
 Inspect steel wire rope slings on a daily basis or before each use for broken
strands, kinks, corrosion, or other damage.
 Check for distortion or corrosion of hooks and eyes.
AA_AFRG_000008
ISSUE 0
 Look for burn holes or damage from welding or other heat sources.
 Check that slings and chains have the proper tag showing the necessary
information.
 If the slings or chains are damaged or worn, do not use them.
 Competent Person Inspections:
 A competent person other than the user should inspect all slings and chains
periodically. These inspections shall be done at intervals complying with local
legislation. In the absence of specific applicable legislation, the inspections
should preferably be done every three months, but they shall be done at least
once a year.
 Care, Marking and Inventory:
 Store slings and chains in a dry, and safe environment; ideally in a locked storage
area.
 Maintain a register indicating the date of entry into service, and the nature of the
work performed or other relevant details.
 Ensure that tags remain firmly attached to slings and chains.
 Periodic Inspections:
 All slings and chains shall be load tested at intervals not exceeding one year.
 Tag in place,
showing all
necessary
information.
 Chains stored badly,

allowing onset of
corrosion.
A test certificate shall be obtained from the test authority. All test certificates shall be
kept in the register.
AA_AFRG_000008
ISSUE 0
c. Shackles
 User Inspections:
 Shackles should be checked on a regular basis and before each use.
 If sprung latches are not closing properly, they should be cleaned and lubricated
carefully, and discarded if the problem cannot be resolved. Check for damage,
deformities, or excessive wear.
 Damaged shackles shall be tagged and removed from service and the inventory
list.
 Care, Marking, Use and Inventory:
 Dirty shackles shall be cleaned with kerosene, WD-40, or similar solvent and
immersed in boiling water for 30 seconds to remove cleaning agent
 Dry with a soft cloth to ensure that the gate and gatekeeper operate properly.
 Shackles shall not be loaded along the gate side.
 Discard the shackle:
 After it has been damaged.
 Discard shackles and all integral components if any discoloration, deformation,
cracks, or abrasions are detected.
 If it has sustained any fall.
 If the spring brake and latch are bent, or not closing properly even after cleaning.
 If the gatekeeper no longer engages the slot cleanly.
 If it shows excessive wear, chemical damage, burn damage, and/or ultraviolet
deterioration.
 After 5 years of use.
AA_AFRG_000008
ISSUE 0
APPENDIX 3: LIFT PLANNING GUIDE
This flowchart is intended as a quick reference for the use Project Managers or Engineering
Managers who are in control of sites where lifts must be performed.
The flowchart makes reference to other sections of this guideline document, and is intended for
use together with this guideline. It is not intended as a stand-alone document.
L IF T P L A N N IN G G U ID E
Id e n t if y lif t p a r a m e te r s in c lu d in g :
 L if t m a s s
 A r e a o f lif t – In c lu d in g s ite p la n
 G r o u n d c o n d itio n s
 E n v ir o n m e n ta l f a c to r s IF A N Y I N F O R M A T IO N IS U N K N O W N – D O N O T L IF T
Id e n t if y L if tin g C r e w in c lu d in g : F o r a h e a v y o r c o m p le x lif t, th is m a y b e d o n e b y a
 R ig g e r S p e c ia lis t R ig g in g C o n tr a c t o r , b u t it m u s t b e d o n e .
 C r a n e O p e r a to r
 O th e r s IF A N Y P E R S O N H A S N O T B E E N F O U N D
C h e c k c o m p e te n c e a n d m e d ic a l f itn e s s C O M P E T E N T – D O N O T L IF T
Id e n t if y o r d e s ig n lif tin g e q u ip m e n t in c lu d in g : F o r a h e a v y o r c o m p le x lif t, th is m a y b e d o n e b y a

 C r a n e s , w in c h e s S p e c ia lis t R ig g in g C o n tr a c t o r , b u t it m u s t b e d o n e .
 L if tin g ta c k le , s lin g s , s h a c k le s , tu g g e r s
 B r a c k e ts , lu g s , lif tin g b e a m s , a n c h o r s
C h e c k a ll in s p e c tio n a n d te s t c e r tif ic a te s . IF A N Y E Q U I P M E N T IS N O T F IT F O R U S E O R S W L
C h e c k S W L a n d c r a n e c h a r t r a te d c a p a c it y . IS IN A D E Q U A T E – D O N O T L IF T
U s e lif t c o m p le x it y t y p e d e t e r m in a tio n in s e c t io n 2 2 “ R is k A s s e s s m e n t” s e c tio n to d e te r m in e lif t c o m p le x it y
R o u t in e S e r io u s C r it ic a l
Id e n t if y a p p r o p r ia te s ta n d a r d P e r f o rm r is k a s s e s s m e n t a n d P e r f o rm r is k a s s e s s m e n t.
p ro c e d u re p la n lif t p r o c e d u r e . P r e p a r e c o m p r e h e n s iv e lif tin g
OR p la n .
P e r f o rm r is k a s s e s s m e n t a n d
p la n lif t p r o c e d u r e .
O b ta in S u p e r v is o r a p p r o v a l f o r
lif t. O b ta in In d e p e n d e n t C o m p e te n t
P e r s o n a p p r o v a l f o r lif t.
P e r f o rm p r e - s ta r t in s p e c t io n o f
e q u ip m e n t.
P e r f o rm p r e - s ta r t in s p e c t io n o f
C h e c k th a t e v e r y b o d y
e q u ip m e n t. P e r f o rm p r e - s ta r t in s p e c t io n o f
u n d e r s ta n d s th e ir r e s p o n s ib ilit ie s .
C h e c k th a t e v e r y b o d y e q u ip m e n t.
u n d e r s ta n d s th e ir r e s p o n s ib ilit ie s . C h e c k th a t e v e r y b o d y
C h e c k C o n tr a c to r in d u c t io n s u n d e r s ta n d s th e ir r e s p o n s ib ilit ie s .
S e t u p lif tin g e q u ip m e n t a n d w h e r e a p p r o p r ia t e . C h e c k C o n tr a c to r in d u c t io n s
d e m a r c a te o r b a r r ic a d e w o r k w h e r e a p p r o p r ia t e .
a r e a , in c lu d in g d r o p z o n e .
S e t u p lif tin g e q u ip m e n t a n d
d e m a r c a te o r b a r r ic a d e w o r k S e t u p lif tin g e q u ip m e n t a n d
P E R F O R M L IF T S A F E L Y d e m a r c a te o r b a r r ic a d e w o r k
P E R F O R M L IF T S A F E L Y
P E R F O R M L IF T S A F E L Y

Aa Afrg 000008

Enviado por

Dados do documento

Título original

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Aa Afrg 000008

Enviado por

Direitos autorais:

Formatos disponíveis

AA_AFRG_000008

ANGLO FATAL RISK GUIDELINE

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 1 of 99

4 REASON FOR INCLUSION 11

7 SYSTEM AND PROCEDURAL REQUIREMENTS 37

APPENDIX B: RECORD OF AMENDMENTS 83

APPENDIX 3: LIFT PLANNING GUIDE 99

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 2 of 99

1. Anglo Safety Way - ASW

2. Anglo Fatal Risk Standards - AFRS

3. Anglo Fatal Risk Guidelines - AFRG

In addition to the manufacturer’s standard safety features, local statutory requirements

The purpose of this Guideline is to provide guidance and clarification on the

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 3 of 99

This is achieved through:

Installation and removal of conveyances in mine shafts is required from time to

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 4 of 99

Installation or removal of cages from mine

Pipes prepared for shaft slinging down mine shaft

These operations occur adjacent to open mine shafts, so the requirements of

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 5 of 99

Lifting crew : persons working directly with a crane operation.

Lifting equipment : any device which is used or designed to be used directly or

Workbasket : a personnel-carrying device designed to be suspended from a

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 6 of 99

Competence (Lifting : refers to a person’s ability to execute specific task/s in

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 7 of 99

Dunnage : soft material (usually timber) placed on the ground or on the

Lift complexity types : Three complexities of lift are defined:

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 8 of 99

Pad-eye : means a steel plate or bracket with a hole intended for

Register : a record of all important documentation related to each item of

Rigger : the competent person in charge of lifting operations. The Rigger

Shaft slinging : the process of lowering or raising long material or heavy

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 9 of 99

contact, or that cranes working where surrounding structures,

Tugger : means a mechanical lever device, usually attached to a steel

VLC : (a Vehicle Loading Crane) means a crane that is mounted on a

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 10 of 99

4 REASON FOR INCLUSION

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 11 of 99

6 PLANT AND EQUIPMENT REQUIREMENTS

Typical electrical switch boxes for cranes

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 12 of 99

Warning and lock out on access to overhead cranes

The operators and/or maintainers of the crane must have:

Unrestricted and safe access to the seating position

LIFTING OPERATIONS GUIDELINE

AA_AFRG_00000800.doc APPROVED 2 June 2009 Page 13 of 99

Access ladder extended Access ladder retracted

Guardrails on mobile crane