AL HABTOOR LEIGHTON GROUP

Standard Project Instruction

INSERT PROCEDURE TITLE HERE

Lifting Equipment
Instruction No.: HLG/HSE/SPI/051

Issue
Date Revision Description By Checked Approved
Rev
03

02

01
 

00 09 Oct 08 First Issue LIL MK MAK

Copyright This Document is the property of Al Habtoor Leighton Group and all rights are reserved in respect of it. This
document may not be reproduced or disclosed in any manner whatsoever, in whole or in part, without the prior written
consent of Al Habtoor Leighton Group. Al Habtoor Leighton Group expressly disclaims any responsibility for or liability
arising from the use of this document by any third party.
Unless specifically stated otherwise, all printed copies are UNCONTROLLED and not subject to revision control

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1.0 PURPOSE
To clearly define the requirements relating to design, manufacture, repair, modification, registration,
inspection, use and removal from service of all lifting gear.

2.0 SCOPE
This Instruction applies to all areas of Al Habtoor Leighton Group work that use or may use lifting
equipment.

3.0 DEFINITIONS

Lifting All forms of Lifting Appliance and Lifting Gear

Equipment:

Lifting Is a machine or component that can raise, lower or suspend a load.

Appliance: Lifting Appliances include cranes, elevators/lifts for personnel and
materials, fork lift trucks, stacker trucks, mobile working platforms,
pulley blocks, runway beams with trolleys, davits and conveyors.

Lifting Gear: Components such as shackles, slings, hooks, chains and spreader
beams used to connect Lifting Appliances to one another or to connect
Lifting Appliances to loads.

Lifting Point: Components or features of loads such as trunnions, lifting lugs, eyes
and reinforcement pads designed for the attachment or bearing of
Lifting Equipment.

Purpose Made Lifting Equipment not available as a standard or proprietary item, which
Lifting the Works, Site or Facility requires to be designed and manufactured
Equipment: for a specific task or duty.

Safe Working The maximum load, determined by an approved person, which an item
Load: of Lifting Equipment may raise, lower or suspend under particular
service conditions.

Proof Load: Test load applied to Lifting Equipment after manufacture, or following
any repair, replacement or modification of any load bearing part. It is a
specified load, which is required to be withstood without the equipment
showing permanent deformation beyond a specified amount or other
defect.

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Working The maximum load which the Lifting Equipment is designed to raise,
Load Limit: lower or suspend under ideal conditions (the Safe Working Load will
usually be the same as the Working Load Limit but may be less).

4.0 PROCEDURE
4.1 Design, Manufacture and Ordering
The design of purpose made lifting equipment shall be approved by the Design Engineer.

Specification for purpose made lifting equipment shall be approved by the Design Engineer and or the
responsible Mechanical Engineer.

The recommended content of ordering specifications for Lifting Equipment is given in Attachment 1.

The ordering specification for standard or proprietary lifting equipment shall be approved by the
responsible Mechanical Engineer.

Materials for construction for lifting equipment should be selected taking into account the duty and
operating environment.

Where the use of materials previously unproven for a specified duty are being considered, such as
aluminium and its alloys or particular grades of steel, a materials specialist should be consulted.

4.2 Registration and Records

All lifting equipment shall be registered before being brought into use.

Registration of lifting equipment shall include:

• Allocation of a unique identification reference;

• Marking of each item with the identification reference and the safe working load, and
additionally for portable lifting equipment, affixing a label or coding which indicates the next
due examination date;
• Creating and maintaining a file for each lifting appliance containing documentation relating
to design, manufacture, testing, examinations, repairs and modification, refer Attachment
2;
• Retaining records for each item of lifting gear relating to testing and examinations;
• A notification system, which displays the next due examination date and any overdue
examinations.

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4.3 Periodic Examination Summary

All lifting equipment shall be given a thorough examination by an approved person within a prescribed
interval, with the exception that the responsible Mechanical Engineer may deem that lifting equipment that
is used infrequently need not be subject to periodic examination provided that it is stored in a secure
location and under conditions which will not cause deterioration. Such equipment should be examined by
an approved person before each use.

4.3.1 Examination Interval

Where examination intervals are not prescribed by legislation the intervals given in Attachment 3
shall be used. For equipment used in a aggressive environment shorter intervals should be
considered.

4.3.2 Scheme of Examination

The extent of examination is required to be such that the approved person is able to judge the
suitability of the equipment for further use and the maximum interval to the next examination.

A written scheme of examination applicable to each item of lifting equipment shall be used. For
lifting gear the lifting appliances such as pulley blocks and runway beams generic schemes of
examination will normally be appropriate. For major lifting appliances separate schemes of
examination for each item should be prepared.

4.3.3 Examination Reports

For Lifting Appliances the approved person is required to prepare a report of the examination and
any necessary repairs.

For Lifting Gear the approved person is required to record the date and result of the examination.

4.4 Modification, Repair and Taking Out of Service

4.4.1 Modification
All modifications to lifting equipment shall be designed and fabricated in accordance with national
standards and the modified design approved by the design engineer.

After modification Lifting Equipment is required to be tested by application of a Proof Load, as

specified by an approved person, and then thoroughly examined. A test certificate stating the Safe
Working Load and the Proof Load should be obtained.

The test certificate and a record of the modification should be placed in the registration file, and the
marking of the equipment suitably amended.

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4.4.2 Repair
Repairs to lifting equipment, other than the replacement of parts, shall be carried out by the original
manufacturer, the manufacturer’s agent or a fabricator approved by the responsible Mechanical
Engineer.

Replacement parts shall be identical to the original. Appropriate certification shall be obtained.

The load bearing components that are repaired or replaced with Lifting Equipment is required to be
tested by application of a Proof Load, as specified by an approved person, and then thoroughly
examined. A test certificate stating the Safe Working Load and the Proof Load should be obtained.
The test certificate and a record of the repair or modification should be placed in the registration
file.

Welding, unless approved by the Design Engineer, shall not be used to repair standard or
proprietary items of lifting gear e.g. rail clamps.

If Lifting Appliances, which have been given a final heat treatment after manufacture, are repaired
the same heat treatment is required to be applied after repair. A materials specialist is required to
be consulted for all repairs requiring the application of heat.

All repairs to Lifting Equipment are required to be carried out under the direction of an approved
person.

4.4.3 Taking Out of Service

Lifting Equipment which is worn or damaged to such an extent that in the judgment of an approved
person it cannot be repaired satisfactorily is required to be destroyed by cutting, and the Lifting
Equipment register and record file amended accordingly. Generally this will be 10% or more wear
from original specification / size.

4.5 Use of Lifting Equipment

4.5.1 Operation
Lifting equipment shall only be used if:

• The due date for examination has not been exceeded, and
• The operator has ascertained:
• by visual inspection that the equipment is in a satisfactory condition;
• the condition and design rating of lifting points on loads are suitable for the
intended duty;
• appropriate guarding is in place;
• the safe working load will not be exceeded.

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Lifting equipment shall be used only by operators trained in the use of the specific equipment and
only for the purposes for which it was designed.

In all lifting operations a single person shall have overall responsibility for the task.

Where lifting operations are not carried out in daylight, adequate illumination shall be provided.

Where the operator of lifting equipment does not have a clear view of the load being lifted,
assistance shall be provided by a specially trained signaller / dogger. Electronic signalling and
communications devices shall be protected from interference.

In the event of malfunction of lifting equipment, operation shall cease and the malfunction brought
to the attention of an approved person.

4.5.2 Access to Areas of Lifting Operations

Access to areas where lifting operations are carried out shall be restricted, protection provided or
procedures put in place such that persons in the vicinity are not subject to danger. Loads shall not
be lifted over persons.

4.5.3 Stability of Lifting Equipment

Lifting equipment shall not be used in circumstances where its stability is likely to be adversely
affected, such as on soft or uneven ground or on slopes, unless adequate precautions are taken to
ensure safe working.

4.5.4 Overloading
Any lifting equipment known or suspected to have been overloaded shall be withdrawn from
service. The equipment shall be re-tested under the supervision of an approved person and
thoroughly examined by the approved person before being returned to use. Records of the
incident, testing and examination should be entered in the registration file.

4.5.5 Failure of Lifting Equipment

All cases of failure shall be referred to the responsible mechanical engineer who shall ensure that a
failure report is prepared.

4.5.6 Use of Lifting Equipment in Potentially Flammable Atmospheres

Diesel engine lifting equipment shall conform to the appropriate national standard for explosion
protection and electrical components shall be certified as safe for the area classification. Air-driven
lifting equipment should be considered as an alternative.

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4.5.7 Maintenance
Maintenance of lifting equipment shall be separate from fault correction arising from examination.
There shall be a formal maintenance schedule for all items.

4.6 Hired Lifting Equipment Services

The responsible Mechanical Engineer shall ensure that the equipment, systems and methods of working of
the hire company shall be consistent with the requirement of this Instruction and comply fully with local
legislation.

For all hired lifting equipment current test certification and other appropriate documentation shall be
available, irrespective of the period of hire.

4.7 Auditing
Only approved persons shall conduct quarterly audits. The audits shall be recorded on
HLG/HSE/SPI/FM/051 - Lifting Equipment Internal Audit Checklist to check compliance with this
Instruction.

Plant Managers shall ensure that remedial corrective action plans are developed and progressed.

The Project or Construction Manager shall ensure that the quarterly audits are conducted and that
remedial corrective actions are completed.

4.8 Responsibilities
4.8.1 Responsible Mechanical Engineer
• The registration of Lifting Equipment.
• Approving ordering specifications for standard or proprietary Lifting Equipment and
for Purpose Made Lifting Equipment.
• Where permitted and appropriate, training and approving personnel to carry out the
periodic examination of Lifting Equipment.
• Where appropriate, establishing and maintaining a list of persons approved to carry
out the periodic examination of Lifting Equipment.
• Granting permission for infrequently used Lifting Equipment to be examined prior to
use rather than at a fixed interval.
• Ensuring that reports of Lifting Equipment failures are prepared and that the
appropriate persons and authorities are notified.
• Where appropriate, the approval of fabricators to carry out repairs, other than the
replacement of parts, to Lifting Equipment.

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 Lifting Equipment

• Ensuring that the equipment, systems and methods of working of the hire company
are consistent with the requirements of this procedure.

4.8.2 Design and Verification person / Engineer

• Approving the design of modifications to Lifting Equipment
• Approving the design and ordering specification of Purpose Made Lifting Equipment.
• The approval of fabricators to carryout repairs, other than the replacement of parts,
to Lifting Equipment.
• The repair by welding of standard or proprietary items of Lifting Gear.

4.8.3 Operator
• Checking that Lifting Equipment and Lifting Points are in a satisfactory condition
before use and for using the equipment in a safe manner.

5.0 REFERENCES
• Australian Standard AS1418 Crane Code
• Australian Standard AS1735 Lifts
• Australian Standard AS2550 Cranes Mobile Towers and Derrick
• Australian Standard AS2321 Chain Short Link
• Australian Standard AS2317 Collared Eye-Bolts
• Australian Standard AS3777 Lifting Hooks
• Australian Standard AS2741 Shackles
• Australian Standard AS2549 Cranes (including hoists and winches):
• Australian Standard AS2759 Wire Rope (Steel) Application Guide
• Australian Standard AS2076 Wire Rope Grips
• Australian Standard AS1666 Wire Rope Slings
• Australian Standard AS1380 - Fiber-rope slings:
• Australian Standard AS1353 - Flat synthetic-webbing slings:

6.0 ATTACHMENTS / FORMS

• Attachment 1 Recommended Content of Ordering Specifications for Lifting Equipment
• Attachment 2 Documents to be included in Lifting Equipment Record Files
• Attachment 3 Recommended maximum examination intervals for Lifting Equipment

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• HLG/HSE/SPI/FM/051 - Lifting Equipment Internal Audit Checklist

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ATTACHMENT 1

RECOMMENDED CONTENT OF ORDERING SPECIFICATIONS FOR LIFTING EQUIPMENT

1. COMPLIANCE WITH STANDARDS

The ordering specification should be in accordance with the appropriate standard.

2. CONTENT OF ORDERING SPECIFICATIONS

The ordering specification should state:
• The materials of construction and material specification
• The appropriate standard
• The Working Load Limit of the equipment and the Safe Working Load when appropriate.
• Full details of the Proof Load test, other operational tests and any special test equipment.
• Details of marking with the Safe Working Load
• the identification reference
• Details of guarding
• Documentation to be supplied by the manufacturer:
• material certificates
• Proof Load test and thorough examination certificate
• operating instructions
• documentation on correct maintenance, storage and limitations on use
• The requirements for inspection by or on behalf of Al Habtoor Leighton Group.

3. PURPOSE MADE LIFTING EQUIPMENT

For Purpose Made Lifting Equipment the following should be included in the ordering specification where
appropriate, in addition to the items listed in Section 2:
• A detailed description and/or drawing of the load to be lifted, giving all principal dimensions which
affect the lifting operation and the envisaged method of lifting including:
• headroom
• height of lift
• transport whilst suspended
• manipulation of suspended load
• centre of gravity

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The methods of lifting, means of attachment and any external obstructions likely to be encountered in the
use of the Lifting Equipment should be detailed, including:
• Details of any adverse environmental considerations such as heat, humidity, chemical attack,
corrosive atmospheres
• Details of frequency of operation and average loadings
• A request for provision of design calculations as soon as they are available.

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ATTACHMENT 2

DOCUMENTS TO BE INCLUDED IN LIFTING EQUIPMENT RECIRDS FILES

1. MANUFACTURE / EXAMINATION DOCUMENTATION

The records file should include the following to verify that Lifting Equipment has been manufactured
according to its drawing and ordering specification and has passed examination on completion:
• The equipment identification reference
• The order number
• The ordering specification
• The manufacturer’s specification
• The original test certificates
• The date of the initial examination and the frequency of subsequent examinations.

2. DOCUMENTATION ON SERVICE
In-service documentation to be added to that listed in Section 1 should include:
• Examination reports
• Test reports
• Details of repairs and modifications
• Records of changes of duty
• Overload and failure reports
Where it may be impractical to keep records in the file because of size, the file should contain a reference
to the location of such records.

3. LIFTING GEAR ASSEMBLIES

Where Lifting Equipment consists of an assembly of items of Lifting Gear not permanently attached to
each other, each item should be given an identification reference, which indicates the assembly to which it
belongs. The records file should be for the complete assembly.
Where items of Lifting Gear are permanently attached to each other an identification reference for each
item is not necessary.

4. RETENTION OF DOCUMENTATION
Where Lifting Equipment is taken out of service, documentation is required to be retained for a period of
two years after the date of removal from service, or for the duration of contract if this is longer.

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ATTACHMENT 3

RECOMMENDED MAXIMUM EXAMINATION INTERVALS FOR LIFTING EQUIPMENT

1 LIFTING APPLIANCES
1.1 Examination Interval 12 months
Block (general) Crane (general) Derrick pole and guy derrick
Hand operated chain Mobile crane
pulley block Rail-mounted crane Chain lever hoist
Power operated pulley Scotch derrick crane
Block Overhead traveling crane Winch or Crab
Pully block for use with wire rope
Pulley block for use with fibre
rope
Overhead runway beam Davits (general purpose) Jack
Trolley (traveling) Manway davits
1.2 Examination Interval 6 months
Hoist for passengers and materials Power-operated mobile working
(construction purposes - temporary). platforms
Hoist for materials only
(construction purposes - temporary)
Hoist/lift for passengers and goods (permanent) Lift truck (fork, platform, stacking).
Vehicle lift
Scissor lift

2. LIFTING GEAR
2.1 Examination Interval 12 months
Boatswains chair Eyebolt Intermediate bulk container
Bordeaux connection Girder clip or clamp
Bulldog (wire rope) grip Hook Thimble (for rope)
Plate lifting clamp Portable lifting beam or Wire rope
spreader
Rigging screw, stretching screw Removable lifting lug Fibre rope (natural and
and turnbuckle used for lifting (cleat or eyeplate) man-made)
purposes.
Shackle Socket for wire rope Swivel
Safety chair and cradle Suspended weighing Lifting box or skip for
(suspended type) machine (crane type) materials only.
Chain sling including ring and Pitched chain for use as load chain
link.
Fibre rope sling Hand chain for use in pulley blocks

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Wire rope sling Short link and non-pitched chain for general lifting
purposes
Wire flat sling Leafchain (plate link chain) used for lifting purposes
Man-made fibre flat sling

2.2 Examination Interval 1 month

Safety harness

Note :
Where equipment is subject to particularly heavy use such as railway line clamps or is operated in a
corrosive environment, more frequent examination intervals should be considered.

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