Headquarter Office, Churchgate, Mumbai-20 ufgerar Yer’ Western Railway No. W 68/0 (Policy) (W3) Date : 04.02.2019 ‘Sr.DEN(Cos) : BCT BRC RTM ADI RJT BVP Dy.CE(Briline)Dadar Dy.CE(Br)BRC Dy.CE(Br)ADI CWM(EW)SBI Sub : Dismantling / de-launching of Bridge super-structure Ref: ()) Railway Board vide letter No. 2015/CE-IV/ROB/206 dt.15.02.2016 (ii) Railway Board's letter No. 2015/CE-IV/RUB/206 dated: 11.08.2016. been unusual on one of the ROBs where a piece of concrete deck has dropped on the Supporting steel plates while dismantling. Dismantling of bridge has safety implications and therefore, it requires careful planning and execution. There are various methods of dismantling of the bridge decks like sawing, using Pneumatic breakers like Pavement breaker etc. The selection of method is to be decided by field Engineers depending upon the site conditions. However, Cutting the bridge deck with diamond cutter / wire cutters is widely used because of its efficiency, ‘safety and reliability as it causes no vibration and permits controlled dismantling making the operation safer. The method involves cutting of bridge deck into manageable small pieces which are being removed with over head cranes or lifting equipments. This in turn requires a detailed dismantling scheme indicating the size of pieces in which the slab is proposed to be cut, assessment of weight of each piece, ‘sequence of cutting of the piece with due fegard to main and distribution reinforcement, assessment of capacity of crane or lifting equipment and ear marking spaces for placing the dismantled piece after cutting Mobile cranes / Hydras are bei ing used for holding and disposing of the concrete blocks during dismantling. These lifting equipment are also used for launching / de- launching of steel ‘super-structure in case of FOBs, ROBs. Railway Board vide letter under reference have issued the detailed instructions for safe working cranes. These instructions are reproduced here under: @ No machine shall be selected to do any lifting on a ‘Specific job until its size and characteristics are considered against the weights, dimensions and lift radii of the heaviest and largest loads. bences)2 es (i) The contractor shall ensure that a valid Certificate of Fitness is available before use of Road Cranes. (ii) Contractors can utilize the services of any competent person as defined in Factories Act, 1948 and approved by Chief inspector of Factories (%) The laminated photo copies of fitness certificate issued by competent Person, the operators’ photo, manufacturer's load chart and competency certificate shall always be either kept in the operator cabin or pasted on the visible surface of the lifting appliances, (¥) All lifting appliances including all parts and gears thereof, whether fixed or Further, Railway Board vide the letter under reference (i) above have circulated instructions for Safe working of Road cranes for launching Girders. As per said instructions: 1. Based on site conditions i.e maximum boom length and operating radius, safe working load of crane shall be assessed which should be more than 1.5 times of 2. Before actually commencing the work near track, trial at site shall be done by actually lifting the heaviest segment to be tackled with required boom length and reduired operating radius. Once, the trial is successful, then only crane shall be brought to site of actual work. 3. The stability of slope under imposed load of crane prop under worst loading conditions and point nearest to edge of slope shall be checked. The location of Prop, {ocations of working of crane and other relevant factor shall be clearly indicated on plan. 4 At locations near crane propping, the strengthening of slope by driving the (ails/Sal Ball Piling shall be done to prevent any chance of slope fallure. Also, the proper compaction/strengthening of soil at prop location shall be done to Prevent any settlement of prop. 5. Stone/quarry dust may be filed by side of precast units with hand compaction before restoring train. These instructions should be scrupulously followed at the site of launching / de- launching of concrete / steel supérstructure. In addition to above, arrangements brought out in Annexure ‘A’ should be ensured for safe operation of cranes. Please acknowledge the receipt of this letter. eer Ofori 9 ( Manjul Mathur ) Chief Bridge Engineer Encl: As above&) 3 Ci CAO (C)-CCG : for kind information. It is requested that the construction sites may Please be sensitized about the issues brought out in this letter. C/- Director - MRVC Mumbai : for information & Necessary action. CI- Director ~ DFCCIL, New Delhi : for information & necessary action. C/- Director - RVNL, Mumbai : for information & necessary action. C/- Director ~ NHSRCL — New Delhi : for information & necessary action. Luna oHforfiq Chief Bridge Engineer C/-DRMs: BCT BRC RTM ADI RJT BVP - for information,Coe GOVERNMENT OF INDIA =, MINISTRY OF RAILWAYS (129 (RAILWAY BOARD) No.2015/CE-IV/RUB/206 New Delhi, dated 15.02.2016 Principal Chief Engincers, All Zonal Railways Chief Administrative Office(c), All Zonal Railways Sub: Special Conditions for working of Road Cranes Ir has been observed that large number of ROBs/RUBs/Subway works are in progress and launching of ROBs/RUBs/Subways are being done with the help of Road Cranes. But it has been observed that sometimes Road Crane with quitable capacity and having valid Certificate about safe condition of Rect Cranes are not being used and it is leading to unsafe conditions, In view of this, it is decided that the following condition should be incorporated in all future tender conditions: 1 No machine shall be selected to do any lifting on a specific job until its size and characteristics are considered against the weights, dimensions and lift radii of the heaviest and largest loads. 2 The contractor shall ensure that a valid Certificate of Fitness is available before use of Road Cranes * Contractors can utilise the services of any competent person as defined in Factories Act, 1948 and approved by Chief Inspector of Factories, ‘The laminated photocopies of fitness certificate issued by competent Pea operators photo, manufacturer's load chart and competency Certificate shall always be either kept in the operator cabin or pasted on the visible surface of the lifting appliances. 5 All lifting appliances including all parts and gears thereof, whether fixed or movable shall be thoroughly tested and examined by a competent ene at least in every six months or after it has undergone any alterations or repairs liable to affect its strength or stability. In addition, it is also advised that for all the works being executed by the Road Cranes, the above stipulations should be checked. These instructions should be strictly observed. Dae 16 (sc. Bath) Executive Director CE/B&S-IIws des ok) No.2015/CE-IV/RUB/206 All Zonal Railways of road cranes. of road crane issued by Railway Board above, following items shal modus operandi: radius, safe working be more be done by actually work. (i) The stability of slope GOVERNMENT OF INDIA 8 MINISTRY OF RAILWAY RAILWAY BOARD New Delhi, Dated 11.08.2016 ‘The Principal Chief Engineers “/| WR Sub: Safe working 6f Road cranés for launching of Girders/LHS. Railway Board vide letter No 2015/CE-IV/RUB/206 dt 15 02 2016 has advised to inchide special conditions in tender conditions for safe working e Recently, during launching of RCC box segments, an accident of toppling ‘occurred. Another accident ‘has taken place due to » subsidence adjacent to precast RC Units in service. Board (ME) has directed that strict compliance to instructions already shall be ensured by Zonal Railways. Besides also be ensured and properly incorporated in @) Based on site conditions i.e. maximum boom length and operati ting, load of crane shall be assessed which should f load to be handled. (i) Before actually commencing the work near track, trial at site shall lifting the heaviest segment to be tackled with required boom length and required operating radius. Once, the trial js successful, then only crane shall be brought to site of actual under imposed load of crane prop under worst joading conditions and point nearest to edge of slope shall be hecked. The location of prop, locations of working of crane and a ‘other relevant factor shail be clearly indicated on plan. xX Ext ‘ions near crane propping, the. strengthening of slope by OL & ing the rails/Sal Balli Piling shall be done to prevent any we ‘ance of slope failure. Also, the proper compaction/strengthening AX of soil at prop location shall be done to prevent any settlement of prop ais Xf () « Stone/quarry dust may be filled by side of precast units with hand ¥ compaction before restoring train. Railway shall confirm receii ipt of letter and action taken on the above. TO {A.K.Singhal) Executive Director. CE/B&S426 Annexure-A Protocol for Safe Operation of Lifting equipment and lifting gears 1. Purpose: The purpose of this document is to ensure safe working conditions during ‘Working with all kinds of Lifting equipment and Lifting gears. 2. Scope It is applicable to Re-girdering sites, sites for Launching/ de-launching of Superstructures at ROBs, FOBs, girder bridges, launching segments at LHSs and all other places where Cranes and Hydras are used for erecting/ dismantling 3. Definition: Crane — Any appliance equipped with mechanical means of raising and lowering a load or for transporting the load while in suspended condition. These can be crawler mounted, lorry mounted, tower types and wheeled telescopic. The cranes shall also include Hydras. Lifting Equipment — A derrick, winch, pulley blocks used for raising or lowering load. Lifting Gear — A chain sling, rope sling, ring or similar gear, and a link, hook, plate clamp, D-shackle, swivel or eyebolt. 4. Working of Cranes: () Cranes shall be installed under the supervision of a competent person as defined under factories Act 1948 or as approved by Chief Inspector of factories, (i) No structural alteration or repair shall be made on any part of the lifting appliances that affects the safety without the permission of the Competent person. (lil) Every Crane being operated outdoors should have a cabin for the Protection of the operator against weather. All panes should be intact to ‘stop rainwater. (iv) Crane shaill have load chart indicating safe working load at various radius of operations (Load Chart). — Limiting switch, Boom light, swing horn, flashing beacon. Safe Working Load (SWL) prominently displayed on the ‘crane body. This SWL should NEVER be exceeded (v) No lifting equipment shall be loaded beyond the SWL. (Wi) The lifting points on the load (girder or a dismantled piece) should be as stipulated in the drawing. (vil) Operators shall not leave Cranes/ lifting equipment unattended with power on or with a load suspended. (vill) Swing area of the crane shall be barricaded and no person should be allowed in this area when the crane is in operation (%) _ It should also be ensured that there is no object in the swing area of crane®) (xi) (xii) (xii) Annexure-A When more than one crane is required to lift or lower one load ie. Tandem Lifting arrangements shall be such that none of the cranes will at any time be loaded beyond its SWL or be rendered unstable in the lifting or lowering of the load and a competent person shall be specially appointed to co-ordinate the operation of the cranes working together. During lifting/ lowering operations, effective precautions shall be taken to prevent any person from standing or passing under the load. The crane must be operated on firm, level and fully compacted ground and additional support by way of steel plates must also be provided wherever required to ensure stability of cranes during its operation. Before actually commencing the work near track, trial at site shall be done by actually lifting the heaviest segment to be tackled with required boom length and required operating radius. Once, the trial is successful, then only crane shall be brought to site of actual work. Cranes shall not be used: - ()__~ To lift material during rains, heavy winds and bad weather which likely to endanger its stability. (ii) To dolifting operations close proximity to live OHE or live electric power lines. (ii) To pull out fixed objects. . Lifting gears: Lifting gear used in connection with cranes and lifting equipment's: ® wi (i) wy) w™ A competent person shall inspect all lifting gear before they are put in use. 4 Manufacturers shall issue a test certificate. Lifting capacity of gear ‘should be known beforehand. Slings with evidence of cuts, excessive wear, distortion or kinks shall be discarded. ‘Sharp bends of loads shall be padded by semi-circular metallic pipe pieces or rubber pads etc. ‘When multiple slings are used, load shall be equally distributed.Annexure-A (vi) Where double or multiple slings are used, the-upper ends of the slings shall be connected by means of a shackle or a ring and not be put separately into a lifting hook (vil) Eye splices should have sleeves and loops of wire ropes shall be provided with thimbles, (vill) Hooks shall be provided with a spring-loaded safety latches to prevent the load from slipping. + The wire rope sling shall not be used and shall be disposed if they are: Bird cages Kinks. Noma! Normal dana Reduced deter Abomal Surface wire are worn ‘Change of diameter of wire rope sling by 18 or more Check for wear and deformation Check for signs of “opening up" _ Check for cracks and twisting Check for wear and cracks ——>Annexure-A 6. Authorized Persons to Operate crane: Only Authorized person with valid Driving License in respective category, issued by Local Authority shall only be allowed to operate the Crane or Lifting ‘equipment. All Operators of lifting equipment must have received adequate training from 3rd party, for purposes of safety, including training in Load Charts and the Lifting methods which may be adopted when using the lifting equipment. The Operator must be conversant with hand signal communications during the operation of crane. Gr)