Method Statement for 400MT QMS Format: QSF - 8.5.

1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

Method Statement
For
400T Crawler crane unloading and
assembling

L&T Construction, B&F IC.

Project: IKEA Retail Store, Navi Mumbai

Prepared By Reviewed By Approved By

UNS / Ganesh
Name: DSS UKJ RS
Thakare

Date: 28.01.2019 28.01.2019 29.01.2019 29.01.2019

Signature:

Page 1 of 16
 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

REVISION RECORD SHEET

Rev. No. Date Section in which Change effected Description of Change

00 ---
01 29.01.2019 Clause no: 9 De-Assembling of crawler crane procedure has been
incorporated

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 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

INDEX

SR NO CONTENT PAGE NO

1 PURPOSE 4

2 SCOPE OF WORK 4

3 REFERENCE 4

4 RESPONSIBILITY 4

5 SAFETY PRECAUTIONS 4

6 EQUIPMENTS AND TOOLS USED 5

7 WORK PROCEDURE 5

8 ATTACHMENTS 10

9 De-Assembling of crawler crane 11

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 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

Method Statement for 400MT Crawler crane unloading and assembling

1. Purpose

The purpose of generating this method statement is to define the 400MT Crawler crane unloading
and assembling Procedure.
2. Scope
This Method Statement is applied for 400MT Crawler crane unloading and assembling Procedure at
proposed plant location, IKEA Retail Store –Navi Mumbai

3. Reference

 Proposed Location for 400MT crawler crane unloading.

 100 MT crane Load Chart
 Safety plan and Risk assessment
 User manual and manufacturer recommendations.
.
4. Responsibilities:
4.1 P&M Engineer-In charge:

 Concern Engineer-In charge & Supervisor shall execute the unloading & assembling work as
per procedure and maintain the checklist for the day
4.2. EHS Manager / Engineer:

 Ensure that all safety requirements explained adequately to the worker prior to the start of the work.
 Ensure that the work is carried out in compliance with safety manual and manufacturer
recommendations
 Monitor the work area for any unsafe conditions that may arise and make corrective actions to
ensure a safe working environment.
5. General Safety Precautions

 Ensure that only trained / authorised operator and rigging team will be deployed for unloading and
assembling work
 Traffic control, and one way movement to be ensured for vehicle, no reversing should be allowed
other than reversing zone.
 Flag man shall be deployed to regulate the transit mixer movement.
 The speed limit of transit mixer during movement shall not exceed 10 KMPH.
 Working under influence of alcohol and drugs shall not be allowed.
 All workmen instructed not to take rest under the parked vehicle
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 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

 Mobile phone use shall not be allowed to any operator.

 Ramp gradient should not be steep, Ramps for vehicle & pedestrian as per the slope mentioned
in the drawings
 Hard barricading shall be done all around excavated area if it is more than 1.5 meter deep.
 Prohibition on unauthorized occupancy in equipment shall be continuously reiterated
 Ensure that material handling shall be done in proper manner.
 Use of PPE’s like goggles, hand gloves, helmet and safety shoes.
 Tool box talk shall be conducted before start of the activity.
 All safety control measures to be implemented as per HIRA (Hazard Identification and Risk
Assessment)
 All the workmen shall enter the site through the designated walkways.
 Fitness of the vehicles / equipment shall be ensured.
 Fitness for the other equipment like mobile crane and other lifting tools and tackles etc. shall be
ensured.
 Area illumination shall be maintained as per the norms.
 Wheel stopper to be ensured while parking of trailer.
 Only tested, marked and required thickness pipe line should be used and routing should be
through pedestals and clamping should proper as per P&M SOP Requirement.
 Signal man to be deployed for coordination.

6. Tools & Equipment’s

 Crane-100 MT
 Web sling
 D shackles
 Tools & Tackles As per requirement.
 PPE
 Crane F-15 / F-17

7. WORK PROCEDURE:

7.1 Unloading Procedure:

 Mobile crane will be placed at levelled and compacted surface.
 Trained / experienced crew and operator will be engaged for unloading and assembling the
activity.
 TPIC lifting tools and tackles only to be used for lifting work.
 Lifting permit will be taken for the activity.
 Work procedure / HIRA will be briefed to the working crew.

Page 5 of 16
 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

 Area will be cordoned off to avoid unauthorised entry of workmen.

 Lifting tools and tackles will be placed in the given lifting points as per the manual.
 Safe lifting practice will be carried out with effective supervision.
 Double tag line will be used for hand ling the load.
 Proper packing will be given below the crane material.
7.2 Overview of Assembling Procedure for LIEBHERR LR 1400-2

 400 Ton Crawler Crane with 77 M – SDB configuration

 Equipment Description: LIEBHERR Crawler Crane
 Crane Model: LR 1400-2
 Crane Capacity: 400 MT
 Crane Configuration: SW (S – main boom, W – Luffing boom)
 Main Boom Length to be erected: 28 m
 Construction equipment’s to be used for assembly:
 (1) Assisting crane - 100 MT Capacity
 Lifting Gears to be Used:
 For Assembly Crane: 4 x 9 MT endless wire rope Slings
 4 no’s of 15 MT Webbing slings
 2 no’s of 17 MT Bow Shackles
 4 no’s of 12 MT D Shackles

7.3 Crane Assembling Procedure:

 The above mentioned LIEBHERR LR 1400-2 Crawler crane is going to be assembled at the
location near Weigh bridge area in front of Tower crane- 05
 Marked. The preparation works will be carried out as per the following sequence.
 Note: Area required: 15 x 20m hard stand required as per given specification, for positioning two
crawlers with under carriage excluding Main boom length (assembly area) required. Ground
bearing pressure must be ensured.

7.3.1. Preparation and Assembling of crawler Tracks:

 Prepare the ground, transport and off-load the Superstructure cabin with Centre carrier self-
unloading with hydraulic outriggers and place it on the solid timber blocks .Erect the A-frame up to
angle 75 deg.
Page 6 of 16
 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

 Clean up the flanges on the centre carrier which is going to fit on the crawler tracks.
 Transport and off load the container assembly tools, tackles with support crane and place it near
to the assembly area.
Superstructure cabin weight = 58 MT
Crawler weight = 28 MT x 2 nos.
 Self-assembly of crawlers tracks by using A-frame self-unloading hyd .cylinder.
 Off-load the two units of left and right side crawler tracks. Lift the right side track and match with
the centre carrier connecting holes.
 To push up the connecting pins connect all the hydraulic hoses and get the hydraulic power from
the power pack unit and push the pins inside the connecting holes.
 Upon completion of right side track, swing the superstructure & assemble the left side track same
as the right track.
 Disconnect the lifting slings from A frame hyd. Cylinder

7.3.2. Preparation and Assembling of central ballast & crane counterweights:

1. after completion of crawler tracks assembly, transport & off load central ballast & assembly with
support crane.

 Central Ballast weight – 8 MT x 2 no’s ( Right side )

 Central Ballast weight – 8 MT x 2 no’s ( left side )
 Central Ballast Base plate – 5.5 MT x 2 no’s
 Total Central Ballast weight – 43 MT

2. Transport & off load crane counterweight & assembly with support crane.

 Crane counterweight tray - 3.1 MT x 2 no’s

 Crane counterweight - 10 MT x 14 no’s
 Crane counterweight – 5 MT x 2 no’s
 Total crane counterweight – 155 MT

7.3.3. Preparation & Assembling of main boom & Luffing jib: Photo supports required

1. Transport the main boom bottom section and connect on the super structure with support
crane.
2. Make the connection of hydraulic hoses for pinning the bottom section.
3. Followed by the bottom section, bring SA frame to the front & connect the pendent’s to the
bottom section.
4. Offload & assemble 2 more intermediate section after the bottom section.

Page 7 of 16
 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

5. Upon completion slowly bring down the main boom and let the tip portion to Position on the
portable boom support / Timer supports.
6. Continue the rest of the boom section assembly and finally fix-up the boom top. Check all the
pin connections and safety lock pins. If everything is satisfactory release the SA frame pin
from the main boom bottom and connect all the pendent bars from the boom top to the SA
frame.
7. Main boom assembly completed, now transport & bring the Luffing bottom with upper & lower
luffing mast & connect to the main boom top.
8. Make the electrical connection from main boom bottom to luffing jib bottom.
9. Pull the luffing wire rope & do the reeving between luffing upper & lower mast using auxiliary
reeving winch.
10. Connect support crane to the lower luffing mast for erecting the luffing mast in 90deg.
11. Also pull & connect hoist winch 1 to the lower luffing mast on top.
12. Slowly lift the lower luffing mast with support crane simultaneously spool out the luffing wire
Rope, continue the procedure until the luffing mast pendent’s & main boom WU pendent
Connected.
13. Now pin the luffing backstop cylinder to the main boom top.
14. Disconnect the support crane & remove the hoist rope from the luffing mast.
15. Now transport & assemble the luffing jib inserts to the luffing bottom using support crane.
16. After the completion of luffing jib, lift the luffing top section & put boom boogie below top.
17. Pull the hoist 1 by using the auxiliary reeving winch up to luffing top.
18. Now connect the pendent’s from luffing top to luffing upper mast.
19. Do the electrical connection from superstructure to main boom top.
20. Slowly main boom up by spool in E drum & lower the luffing winch simultaneously, continue
the Procedure & roll the luffing jib as per the boom erection & take down.
21. Pull up the luffing jib top slightly above the ground level (about 2 m height) and place the hook
block under the luffing top. Pull out the H1 wire rope and perform the hook block reeving. Up
on completion of reeving slowly lift up the Main boom up to angle 87 deg.
22. Erect the luffing jib by spool in luffing winch W5 up to the operating range.
23. Perform the functional test for slewing, crawling and boom up & down. If the functional test is
satisfactory proceed to the next stage of Load test.

Page 8 of 16
 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

7.4 - LOAD TEST PROCEDURE FOR 400 TONS

CRAWLER CRANE (LIEBHERR LR 1400-2)

1. PROCEDURE

PREPARATION

Prior to load test, Ensure ground bearing pressure as per specification and place the steel plates. Prepare
and assemble the crane for the 28+77m SW configuration and ensure the risk assessment, crane check
list are completed. Ensure all the safety precautions are in place and presence of the witness for the
conducting the load test. Conduct tool box meeting and assign necessary personal to conduct the load
test.
 Make the marking of load testing Crane centre point, 50m radius from the crane centre, prior to
setting up the crane for load test.
 Rig up the assisting crane at the location of load test area and perform the daily check and fill-up
the daily checklist form.
 Transport the Test load by a trailer, Lift up and set the Load exactly 50m from LR 1400-2 crane
centre
 Barricade the whole Load testing area and place the Safety signboards.

2. LOAD TEST

 The Crawler Crane shall firstly be parked at appropriate area at the discretion of the client, and
load test shall be carried out according to the following sequence.
 Make sure distance between the test load centre and the crane centre is 50 meter.
 Prepare the rigging gears and hook up on the LR 1400-2.
 Lower down the crane hook block and rig up the test load.
 Slowly raise up the hoist wire and Tension the sling wires and check for the boom angle, hoist wire
verticality, shackles, sling wire and etc.
 Slowly lift up the Test load slightly above the ground and check the ground condition and the
stability. If the test is satisfactory, lifts up the load to a height of 500 mm above the ground.
 Keep the load at the same height for about 5 minutes and check the crane and slew right & Left.
Slowly lower down the Test load and check ground condition again.
 Minimum working radius of the crane is 26m.
 De-rig the test load from the crane hook and boom up until the hook block reaches the minimum
radius
 Check the back stopper limit cut off function and the stability of the crane then lower down the
boom.
 After getting inspected and approved by the respected inspection party, the load will be lowered
down and de-rigged.
 Upon completion of Load test take out all the test load by an assisting crane, and transport to
storage area.
 Get the relevant certificates from the concerned Authority for the further equipment lifting activity.

Page 9 of 16
 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

3. SAFETY

All Safety precautions shall be taken as per HSE requirements of the project and local and central
legislation requirements

III - CHECK POINTS / SAFETY DEVICES for SAFE LIFTING:

 Electronic Load moment Limiter (SLI)

 Boom & Hook Limit Switch
 Safety camera system
 Hydraulic boom backstops
 Anemometer
 Allowable wind speed: 9.8 m/s
 Ensure full compaction of road with 95% soil density.
 Operator competency

8. Attachments

 HIRA

Photos of assembling:

Reference for point Reference for point Reference for point

no: 1 no: 5 no: 6
Page 10 of 16
 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

Reference for point Reference for point Reference for point

no: 7 no: 10 no: 11

9. Dismantling / De-Assembling of 400T crawler crane as follow as:

1. Marching of crane to dismantling location:

A. 400t Crawler crane will go to the dismantling location at parking area (near ERM office) from its
current location.
B. MS plate will provided below the crawler chain during marching.
C. Flag man / area cordoned off will provided at location.

2. Overview of Dismantling Procedure for LIEBHERR LR 1400-2

400 Ton Crawler Crane with 28+77 M – SW configuration

Equipment Description: LIEBHERR Crawler Crane
Crane Model: LR 1400-2
Crane Capacity: 400 MT
Crane Configuration: SW
Main Boom Length: 28 m
Luffing Boom Length: 77 m

Construction equipment’s to be used for dismantling:

Page 11 of 16
 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

(1) Assisting crane - 100 MT Capacity

Lifting Gears to be used:

For Assembly Crane: 4 x 9 MT endless wire rope Slings

4 x 15 MT Webbing slings
2 x 17 MT Bow Shackles
4 x 12 MT D Shackles

3. Crane Dismantling Procedure:

The above mentioned LIEBHERR LR 1400-2 Crawler crane dismantling, The preparation works will be
carried out as per the following sequence.

Note: Area required: 15 x 20m hard stand required as per given specification, Ground bearing pressure
must be ensured 100% with available data & Test reports. For boom down total 115m open space required.

3.1 Boom down & Dismantling of main boom & Luffing jib:

1. March the crawler crane to the boom down location; place the crane on hard stand & before boom
down put the steel plates under the crawler.
2. After crane positioning Take down the luffing jib by spool out luffing winch W5 up to the end limit
range. Then take down the main boom until the luffing jib top slightly above the ground level (about
2 m height).
3. Remove the hook block reeving.
4. Put boom boogie below the luffing top. Slowly main boom down by spool out E drum & spool in the
luffing winch simultaneously, continue the Procedure & roll down the luffing jib till main boom on the
ground.
5. Provide the proper support to the main boom & luffing jib by wooden block or boom stand.
6. Now disconnect the pendent’s from luffing top to luffing upper mast.
7. Dismantle the luffing top & luffing insert with the help of auxiliary crane up to the luffing bottom.

Page 12 of 16
 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

8. Now connect the support crane to the luffing lower mast, also connect the hoist rope H1 to the lower
luffing mast.
9. Now unpin the luffing backstop cylinder to the main boom top.
10. Slowly lift the lower luffing mast with support crane & spool in the hoist rope H1 simultaneously spool
out the luffing wire Rope, continue the procedure until the luffing mast pendent’ s & main boom WU
pendent disconnected.
11. After disconnecting the backstay wu pendent’ s spool out the hoist wire rope & simultaneously spool
in the luffing wire rope till the lower mast lay down on upper luffing mast, till the support crane must
be attached with lower luffing mast.
12. Now remove the reeving of upper & lower luffing mast & spool in the luffing wire rope.
13. Disconnect the hoist rope from luffing mast & spool in the wire rope into the drum.
14. Now dismantle the lower & upper luffing mast with luffing bottom with the help of support crane.
15. Spool out the E drum & disconnect the boom pendent’ s from main boom top & connect the SA
frame to the bottom boom.
16. Dismantle the main boom top using support crane.
17. Dismantle the boom inserts till main boom bottom using support crane.

3.2 Preparation and dismantling of crane counterweights & central ballast:

1. After completion of boom dismantling, remove the crane counterweight & central ballast using support
crane
 Crane counterweight base plate - 15 MT x 1 no’s
 Crane counterweight - 10 MT x 14 no’s
 Total crane counterweight – 155 MT
 Central Ballast weight – 8 MT x 2 no’s ( Right side )
 Central Ballast weight – 8 MT x 2 no’s ( left side )
 Central Ballast Base plate – 5.5 MT x 2 no’s
 Total Central Ballast weight – 43 MT

2. Now remove the hydraulic hoses from boom bottom & dismantle the main boom bottom using support
crane.
Page 13 of 16
 Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

3.3 Preparation and dismantling of crawler Tracks & loading of crane cabin:

1. Position the crane for dismantling the crawler, place the solid timber blocks under the Centre
carrier self-unloading hydraulic outriggers & lift the superstructure with car body & crawler.
2. Disconnect the hydraulic & electrical connection from both crawlers.
3. Connect the lifting slings to the A frame hyd. Cylinder.
4. Prepare the rigging for left side crawler, take load of crawler by A frame cylinder and get the
hydraulic power from the power pack unit and remove the pins from the connecting holes.
5. After removal of crawler pins lift the crawler by A frame cylinder & load on trailer.
6. After completion of removal left track, sing the crane 90 degree & remove the right side crawler
by using A frame & load on trailer.
7. After dismantling the both crawlers remove the slings from the hydraulic A frame cylinder.
8. Now lift the superstructure carrier by using hydraulic outriggers & place the cabin loading vehicle
under the superstructure carrier.
9. De erect the A frame backside on the superstructure till the A frame rest on the superstructure.
10. After loading complete lash the superstructure carrier properly & transport the vehicle from site.

3.4 Photos of De-Assembling of 400T crawler crane:

Luffing and main boom lowered towards downward direction

Page 14 of 16
Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

Luffing jib dismantling

Page 15 of 16
Method Statement for 400MT QMS Format: QSF - 8.5.1 - F01 (00)
crawler crane unloading, M.S. No: L&T/P&M/MS-02
Rev No: 01 Date: 29.01.2019
assembling, De-Assembling

Removal of tie rods and main boom

Removal of counter weight

Gantry removal

**********

Page 16 of 16