JSW Standard

Lifting and Handling Materials

Document Control Details

Revision Date Reason For Issue Compiled by Approved by

Lifting & Handling

1 09.01.2018 Corporate Standard Unit Heads
Materials Task Force

Next Review Date Format No

09.01.2020 JSW/SAFETY/STANDARD/30

User Notes: - The Apex Safety Committee (ASC) is the custodian of this document and is responsible for
the Administration and Authorization of this Standard. ASC is responsible for confirming the accuracy
and integrity of content and proposed changes to the Standard.

Controlled copy of the current version of this document is held at ASC and also available on its portal.
Any printed / electronic copy of this document is uncontrolled. It is recommended that users verify that
the version being used by them is the current version by referring to the controlled version
 Lifting & Handling Material Safety Standard

Acknowledgement The management acknowledges the contributions of the following individuals for
being a part of the Division / location workgroup and for their assistance in preparing this standard on
Lifting and Handling of Materials.

Division / Location Members

Vasind Mr. Chandrashekhar Ghatge

Vasind Mr. Rajendra Patil

Vasind Mr. Jainath Kushwaha

Vasind Mr. Vinod Mandot

Vasind Mr. Nilesh M Mankar

Vasind Mr. Sachin S Chabuk

Vasind Mr. Sanjay S Kumavat

Vasind Mr. A.K. Singh

Vasind Mr. Ashok Kumar Jain

Vasind Mr. Harsh Yadav

Vasind Mr. Nitin Tiware

Tarapur Mr. Chanchal Karmakar

Kalmeshwar Mr. Niraj Vithalkar

Kalmeshwar Mr. Shailesh Banait

Vijayanagar Mr. Hosigerappa

Dolvi Mr. Bhupesh Bhoir

Dolvi Mr. Sanjay Patil

Salav Mr. Sandip Dhapare

Salav M.r Millind R Joshi

Salav Mr. Sanjeev Agrawal

Salem Mr. Saravana K Kumar

Salem Mr. VM Manikandan

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Abbreviations

 JSW – JSW Group of Companies

 ASC – Apex Safety Committee
 DIC – Division Implementation Committee
 DSC – Department Safety Committee
 R&P SC – Rules & Procedure Subcommittee
 PPE - Personal Protective Equipment
 SMHSL – Site Material Handling Safety Leader
 HIRA – Hazard Identification & Risk Assessment

 ALARP – As Low As Reasonable Practicable

 OEM – Original Equipment Manufacturer

 EOT – Electric Overhead Travelling

 HOD – Head of Department

 SLI – Safe Load Indicator

 SWL – Safe Working Load

 S&FS – Safety & Fire Services

 RAGP – Recognized and accepted good Practices

 HSE – Health Safety Environment

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Table of Content
SL No Description Page No.

1. Purpose 8
2. Scope and Field of Application 8
2.1 Scope 8
2.2 Field of Application 8
2.3 List of Equipment for Lifting & Handling Materials and Tools & Tackles 8-9
3. References 9
4. Management Responsibilities 9
4.1 Management, leadership, and commitment 9
4.2 Site Material Handling Safety Leader 10
4.3 Line Management 10
4.4 Lifting & Handling Materials Coordinator 11
5. Definitions 11-12
6. Standards/Guidelines 12
6.1 Managing Hazards and Risks while operating equipment for Lifting 12-13
or Handling Materials
6.2 The purchasing or hiring of equipment for Lifting & Handling materials 13-15
6.3 Inspection of Equipment for Lifting & Handling Materials 15
6.3.1 Prior to use on Site/Unit 15
6.3.2 Functional 15-16
6.3.3 Frequent 16
6.3.4 Periodic 16
6.3.5 Equipment for Lifting & handling materials that is not in regular use 16
6.4 Crane operation 16
6.4.1 Rating changes 17
6.4.2 Safety precautions 17
6.4.2.1 Planning – Lifting Plan / Critical Lifting Plan 17
6.4.2.1.1 Simple Operation 17
6.4.2.1.2 Repetitive Operation 17
6.4.2.1.3 Critical Operations – Critical Lifts 18-19
6.4.2.1.3.1 Crane-suspended work platforms 19
6.4.2.1.4 Other Operations 19
6.4.2.1.4.1 Night Work 20
6.4.2.1.4.2 Adverse Weather Conditions 20
6.4.2.1.4.3 Working Near Hydrocarbon Pipeline 20
6.4.2.1.5 Documents required before a lift 20
6.4.2.2 Set Up 20
6.4.2.3 Operation 21-22
6.4.3 Avoid “Pick and Carry” load 22
6.4.4 Warnings, load charts, and operating manuals 22
6.4.5 Moving parts 22
6.4.6 Hand signals 22
6.4.7 Exposure to unsafe atmospheres 22-23
6.4.8 Exposure to electric lines 23-24
6.5 Maintenance, repairs, and modifications 24
6.6 Emergency preparedness 24

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6.7 Personnel Qualification – Lifting & Handling Materials 24

6.7.1 Equipment Operator Qualification – Lifting & Handling Materials 24
6.7.2 Riggers and Signalmen Qualifications 24-25
6.8 Training, Certification and Competency Assurance 25
6.8.1 General Awareness Training 24-25
6.8.2 Task-Specific Training 25
6.8.3 Refresher Training 25
6.8.4 Training Records 25
7. Management Systems 26
7.1 Support resources 26
7.2 Management Systems 26
7.3 Audits 26
7.4 Deviation process 26
7.5 Training & Communication 27
7.6 Contact 27
Appendix – 1 - Related References 28

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1. Purpose:

The purpose of this standard is to provide guidelines for carrying out material lifting and handling
work in a safe manner.

2. Scope and Field of Application

2.1 Scope

This standard establishes requirements for managing the safe operation by trained personnel of
equipment for lifting and handling of materials including the qualification of personnel and
encompassing employees as well as contractors/vendors.
“Shall” and “Must” and “Will” are Mandatory requirements in this standard, and are noted in italics.
“Should” and “May” - are non-mandatory in this standard and understood as “strongly recommended”.
Failure to follow strongly recommended practices which increases the risk to the safety of personnel
and/or creates a dangerous hazard at a JSW site can result in work stoppage to eliminate the risk
and/or hazard.

2.2. Field of Application

This Standard applies to all Material Handling Equipment and Tools & Tackles owned/hired and
operated by JSW and those operated by its Contractors and covered by appropriate contractual
arrangements.
Present equipment for lifting and handling materials shall be inspected & the ones not conforming
with this standard shall be upgraded within a time frame as directed within this standard or as
decided by APEX Committee
Manual lifting and handling of materials is NOT included in this standard.
Train locomotives, railroad cars, wagons, multi-axle trailers and Zephyr rail/road equipment,
Tractor, trucks and dumpers inspections are not included in these standard inspection

2.2.1 Manual Lifting : Factories Act Section 34 -,No person shall be employed in any factory to lift,
carry or move any load so heavy as to be likely to cause him injury. The lifting load is to be
followed as per the state factories rules as applicable.

2.3 List of Equipment for Lifting & Handling Materials and Tools & Tackles

The following equipment and tools & tackles are being used for loading, unloading and handling
of materials / jobs etc.
Equipment, such as:
 Hydra/Farahana / Pick & Carry Crane
 Tower Crane
 Pedestal Crane
 Tyre Mounted Crane
 Truck Mounted Crane
 Crawler Crane
 EOT Crane
 Goliath Crane
 Gantry Crane
 Multi Axle trailer (for loading/unloading aspect only)

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 Forklift
 Side Loader (Pay loader)
 Railroad car or wagons (for loading/unloading aspect only)
 Tractor (for loading/unloading aspect only)
 Material shifting Trolley
 Cherry pickers
 Scissors lifts (Ref OEM SOP)
 Winch Machine (Ref OEM SOP)
 Truck (for loading/unloading aspect only)
 Dumpers (for loading/unloading aspect only)
 Pipe Layers/Side Booms
 Slag Pot Carrier (for loading/unloading aspect only)

Tools & Tackles, such as.

 Chains
 wire ropes
 webbing slings
 Hooks, shackles, eye bolts, Swivels blocks, Snatch blocks
 Beam clamps and plate clamps
 Lifting beams / Spreader beams
 Hydraulic Jack
 Lever blocks
 Chain pulleys
 Lifting buck
 Coil grab
 Aerial coil tilter
 C-Hook and Tong

3. References

 JSW HSE Policy

 JSW Safety Standard
- Isolation and Lockout
- Working at Height
- Contractor Safety Management
- Permit-to-Work
 Standard guidelines for Lifting Tools & Tackles
 Factories Act 1948 under Section 28 &29, 34
 World Steel Associations

All operating and maintenance procedures regarding equipment used for lifting and handling
materials are included

4. Management Responsibilities

Line management has the responsibility to implement this standard.

4.1 Management, leadership, and commitment

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Effective management of Lifting & Handling Materials safely involves the focused application of
the following by JSW management:
 Providing resources and establishing procedures that focus on providing each Site with an
effective management process for safely lifting and handling materials.
 Committing adequate resources who will implement a safety management program to sustain
continuous improvement of safety in lifting and handling materials. Resources include the
provision of necessary tools, equipment, transportation and manpower to accomplish the program.
 Establishing accountability for performance to achieve specific safety goals and/or objectives as
decided by the APEX Safety Committee.
 Verifying (through first, second and third party audits) the degree of compliance with this standard
and related procedures including implementing appropriate corrective actions.
 Participating in activities that visibly demonstrate a commitment to safe lifting and handling of
materials at JSW.
 Timely arrangement and mobilization of competent persons for inspection and testing of Tools &
Tackles.

4.2 Site Material Handling Safety Leader (SMHSL)

The Site Leader for safe lifting and handling materials shall be qualified and recognized for his or
her material handling expertise and shall have the appropriate knowledge and experience with
this standard and the associated audit protocol. The Site Material Handling Safety Leader shall be
qualified to carry out the material lifting & handling safety responsibilities and accountabilities of
the position. This person shall be appointed and approved by APEX Safety Committee.
These responsibilities shall include, but not be limited to,
 Serving as a consultant to line management in fulfilling material lifting & handling safety
responsibilities.
 Monitoring material lifting & handling safety programs through reviews (e.g. serious incidents,
lifting technology upgrades, safety device applications, etc.)
 Monitoring site compliance with the elements of material lifting & handling safety as described in
Section 6 [“Standard & Guidelines”] as well as monitoring compliance with local regulations, as a
minimum.
 Coordinating exchanges (e.g., among sites, businesses, regions, and subsidiaries) of pertinent
material lifting & handling safety information, such as
- Recognized and accepted good practices. (RAGP)
- Changes in codes, standards, and regulations.
- Serious incident investigations.
- Incidents that occur outside JSW in the steel industry that involve lifting & handling materials.

 Assisting management by providing Site with access to the relevant resources for implementing
the requirements of this standard.
 Leveraging awareness tools and resources to other functions in the regions.
 Assisting the Site safety audit program manager with scheduling and providing resources for
audits of lifting and handling materials.

4.3 Line management

Each site operation or maintenance group or construction team or process unit that operates
and/or maintains material lifting & handling equipment shall develop and implement necessary
procedures for safety of its employees and equipment including contractors.

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Line management, within the operating areas for which they are accountable, shall be
responsible to ensure that
 All hazards are identified that are associated with material lifting & handling equipment
operations when operating the equipment at a Company facility and/or which are used
solely for the Company activities/work
 Risks are assessed; RISK = (Probability) x (Severity)
 Controls are applied to reduce the risks to acceptable levels (ALARP)
 The above activities must be done before lifting &/or handling materials is started.

4.4 Lifting & Handling of Materials Coordinator

Lifting & Handling of Materials Coordinator should be identified by the Site/Unit in Charge (HOD).
These coordinators are resources recognized for their expertise in the area of material lifting and
handling operations and maintenance and have in-depth knowledge of this standard, the
associated procedures and industry standards related to lifting & handling materials. Lifting &
Handling of Materials Coordinator should be made available to support the implementation of this
standard and continuous improvement effort within their unit.

5. Definitions

These definitions are provided to describe the intent of this standard. The terms may be defined
differently in other contexts.
Lifting machine - a crane crab which tangle pulley block, gin wheel, transporter or runway.

Lifting tackles - any chain sling, rope sling, hook, shackle, swivel, coupling, socket, clamp, tray or
similar appliances, whether fixed or moveable, used in connection with the raising or lowering of
persons or loads by use of lifting machines

Boom Angle – the angle above the true horizon of a line drawn through the boom hinge pin and
the centre line of the shaft of the main boom tip sheave

Materials- this includes any bulky or heavy supplies, equipment, pipes, machinery, parts, raw
materials, construction components, rubbish, debris, excavated soil, concrete, etc. that must be
lifted or moved or loaded/unloaded.

Acceptable Risk - A risk that is adequately safeguarded as determined by the local risk
assessment teams and in accordance with the local statutory requirements.

Anti-two-blocking device- an attachment to a crane that prevents the load block or hook
assembly from being drawn tightly to the boom point.

Anti-Collision Switch:- A device installed on the Crane Girder to avoid the collision between two
cranes when they approached closely.

Authorised Person - one who is resposible, accountable and authorised to perform job in his
premises and have knowledge &expertise concerning lifting and handling materials and aware of
hazards at work place and can be nominated by concerned HOD

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Competent Person - means a person or an institution recognized as such by the Chief Inspector
for the purposes of carrying out tests, examinations and inspections required to be done in a factory
under the provisions of Factories Act

Contractor- A firm or person employed under a contract to provide services to Company’s activities.

Designated Signal Man - an authorized person who is proficient in the use of signals for a
specific crane.

HIRA – Hazard Identification & Risk Assessment

Hazard – a condition, activity or situation which has the potential to cause damage, injury or loss.

Risk is the chance or probability that a person will be harmed or experience an adverse
health effect if exposed to a hazard. It may also apply to situations with property or
equipment loss, or harmful effects on the environment.
Risk – the combination of the likelihood of the occurrence of a harm and the severity of
that harm.
Likelihood – the chance of something happening.
{Note: In risk assessment terminology, the word “likelihood” is used to refer to the chance
of something happening, whether defined, measured, or determined objectively or
subjectively, qualitatively or quantitatively, and described using general terms or
mathematically (e.g., a probability or a frequency over a given time period)}.

Personnel- The term refers to all persons encompassing our own employees, employees
of Contractors and employees of third party service providers.

Line management- All executives or supervisory personnel such as, Foremen, Supervisors, Site
Engineers, Managers, General Managers, Vice Presidents, etc. in the line of command.

Operating radius—the horizontal distance from the axis of rotation to the center of gravity of the
freely suspended load
.
Safe Load Indicator (SLI) - an electronic device that performs load measuring and overload
limiting
Emergency Stop - Load Fall Arrestor for stopping a sudden "un-intended" drop of suspended load.
This shall be applicable in EOT cranes only
Safe Working Load – the maximum load capacity recommended by the original equipment
manufacturer (OEM)

6. Standard / Guideline

6.1 Managing Hazards and Risks while operating equipment for Lifting or Handling Materials

Hazards during the operation of equipment for lifting or handling materials shall be eliminated or
the risks controlled to an acceptable level.
Sites/units shall implement and maintain a risk management and reduction process based on the
following hierarchy (preferred order) of controls:

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1. Elimination of the hazard [Most Preferred]

2. Substitution of less hazardous processes, operations, or equipment
3. Engineering controls and Warnings (e.g. machine guards, barricades, fences, audible or
visible alarms, signs, tags, etc.)
4. Administrative controls (e.g. procedures and training of personnel)
5. Personal protective equipment (PPE) [Least Preferred]
The processes of risk assessment which enable a comprehensive hazard recognition and
safeguarding for the various task hazards involving lifting & material handling operations must
be in place. Unless the task/activity is eliminated or automated, the risk control provisions
shall employ multiple controls from engineering, warning, and administrative control options.
The management system as explained in this standard shall be designed to challenge and
improve operations and should be aligned with a continuing improvement cycle (i.e., Plan, Do,
Check, Act) to achieve an incident/injury-free workplace.
The primary hazards of concern are associated with those tasks and conditions that have the
potential to result in injuries caused by contact with the lifting & material handling equipment by
personnel in the operational areas, such as JSW employees, contractor employees and visitors

A risk assessment must be performed by an Authorised Person/s to identify the Hazards and
assess Risks associated with the material lifting & handling equipment in the work Site/unit.
Approved by the HOD Appropriate reduction of the identified risk through application of the
hierarchy of controls must be done. After the controls are in place, the lifting and/or handling of
materials shall commence.

The risk assessment must consider all operational areas.

Risk Assessment must be done for all lifts considering the following aspects and activities:

 Cultural, communication and language difficulties

 Weight, size, shape, angle of boom and centre of gravity of load
 Availability of approved lifting points on load
 Method of slinging/attaching/detaching the load
 Conditions of slings, chain blocks, shackles, etc.
 Overturning/load integrity/need for tag lines or ropes
 Suitability and condition of Lifting Equipment to be used
 Initial and final load positions and how it will get there
 Ground and underground considerations, such as stability and horizontal orientation
 Lifting over live equipment (avoid if at all possible)
 Proper use of hydraulic jacks
 Number and duration of lift(s)
 Conflicting tasks in area or incompatible activities
 Environmental conditions including weather (rain, wind, lightning, hail, etc.)
 Lighting in the pick-up and lay-down areas
 Proximity hazards, obstructions, path of load (e.g. potentially live electrical, hydraulic
or pneumatic lines, underground conduits, bridges and overhead structures)
 Access and emergency escape routes for the Signal man and other load handlers (e.g.
Banksman, Signal Man, Slinger/Riggers)
 Experience & competence of trained personnel (no untrained personnel shall be
involved in lifting & handling materials)

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 Number of personnel required for task

 Pre-Use Inspection of equipment by Operator
 Visibility of the load at all times by Signal man.

6.2 The purchasing or hiring of equipment for lifting & handling materials

Acquiring new equipment through a contract must be done after an inspection and prior to
purchase or hire. The supplier or contractor must be formally Pre-Qualified. (Refer to the
Contractor Safety Management Standard/Procedures. A risk assessment as described in
Section 6.1 should precede the purchase or hire and should also consider the requirements of
relevant Corporate Standards.
The purchasing or hiring of equipment for lifting & handling materials must be done according to
the unique requirements of JSW and local/national requirements which will be given by Site
Material Handling Safety Leader / Lifting & Handling of Materials Coordinator. These
requirements should address the following:
 Lighting arrangements
 Seat belts fitted for the operator
 Suitable access and egress for the driver/operator
 Suitable access to reach Trailer bed
 Provision of Safe Load Indicator (SLI) systems in all lifting equipment
 Provision of rear view mirrors for reversing and to avoid blind spots
 Reversing alarms (audio – visual as per standard)
 Safe working load – The Safe working load (SWL) shall be marked on each hoist or lifting
device and on the trolley if the hoist is hook-mounted (i.e., easily detached). These
markings shall be clearly legible from the operating floor.
 Proof Load test - All new hoisting systems and hoists or hoisting systems that have been
modified or altered shall be load-tested before being placed in normal service. The load
test shall be done by competent person as per legal requirement for twice in a year and
record shall be documented as per the respective State Factories Rules and All Lifting
Machineries and accessories must be inspected by competent person for every once in a
year and record shall be maintained as the respective State Factories Rules.
 All wire rope hoists shall have an Over Hoist Limit Switch device to stop the upward
hoisting motion beyond safe limits. For electrical hoists, this Over Hoist Limit Switch
device is typically a weight type limit switch.
 All required Limit Sensor, Limit Switches and Devices (i.e. Anti-Two Block device,
Emergency Stop, Boom limit switch, etc.) shall be suitably installed and in good working
condition before use of the crane.
 Geared limit device: All powered cranes (e.g. EOT /Gantry Cranes/Goliath Cranes) shall
have permanent end stops provided at the extremes of the bridge rail/track or structure to
limit the hoisting equipment travel
 Electric hoists shall have a dedicated electrical grounding conductor in the electrification
and control system to positively ground all equipment
 Anti-collision device is required for Goliath, Gantry and EOT cranes which are running in
the same track.
 All EOT/Gantry/Goliath cranes shall be fitted with both an audible and visible alarm that
indicates movement of the crane

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 All EOT cranes shall have entry and exit signal communication system

Specific requirements:
 Equipment for lifting & handling materials which operates under high walls must be fitted
with a roof which protects the operator from falling objects and was installed by the
Original Equipment Manufacturer (OEM) in compliance with national regulations.
 Rear view mirror(s) or camera
 Adequate fire suppression system or a fire extinguisher, as a minimum
 Bumpers to avoid head to tail damage from minor collision with other vehicles or stationary
structures.
 Fire resistant hydraulic hoses, sleeves and conduits

The arrival of new equipment for lifting & handling materials should undergo a thorough inspection
process with Subject Matter Expert -/ knowledgeable Lifting & Handling of Materials
Coordinator for acceptance of the new equipment, which includes:
 Confirmation of the specification of the equipment, as per purchase order; and
 Ensuring that all safety devices are in place and functional; and
 Confirmation the new equipment meets this safety standard requirement

A formal process must be established to ensure each equipment being introduced into service
for lifting & handling materials is in a safe operating condition. This process must address, at
least, the following:

 Pre-commissioning inspection is conducted by a competent person

 Periodic inspections of the equipment is done to maintain its basic operating conditions
 Formal inspection checklists are developed and applied for the above requirements
 The recording of all pre-commissioning and periodic inspection results and retention of
these documents for, at least One year
 Maintaining an up-to-date register or record of material lifting & handling equipment
approved for safe use within the operation site/unit.

6.3 Inspection of Equipment for Lifting & Handling Materials

There are four levels of inspections of equipment and tools & tackles for lifting & handling
materials. These inspections are conducted by three categories of inspectors.
Table 1 provides a mandatory guideline for the levels of inspection, categories of inspectors, and
frequency of inspection for equipment for lifting and handling materials.

Table 1. Inspections
Inspection Type Type of Inspector Minimum Frequency
Prior to 1st use Competent person Upon arrival and prior to acceptance
Functional Operator / User Before beginning work each shift / work
Frequent Authorised person Once in three months
Periodic Competent person Yearly/Half yearly

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An inspection checklist must be completed at the frequency shown in Table 1 for each unit and
must be kept on file for One year in the Department/Division where the equipment is utilised.
Lifts & Hoisting system must be inspected by competent person for minimum once in 6 months
and all Lifting Machineries and accessories must be inspected by competent person for every
once in a year

6.3.1 Inspections Prior to 1st use on JSW Site

Equipment for lifting & handling materials, including tools & tackles, shall be inspected by a
competent person(s) prior to 1st use on a JSW Site. A checklist shall be used to document the
inspection. Inspection records shall be retained for One year.
If Lifting & handling Material equipment is removed from a Site/unit and then returned, it shall be
re-inspected before it is used again on the Site/unit. Lifting & Handling Material equipment that
has been altered shall be re-inspected by undergoing a prior-to-1st-use inspection by a competent
person.

6.3.2 Functional Inspections

Before beginning work each shift, Operators of material lifting & handling equipment shall inspect
all controls and safety devices using a check list as guidance. The operator shall record his
observations on the check list. The operator shall submit the completed check list to JSW Unit
Supervisor at the beginning of the shift.
Similarly, before beginning work, all tools & tackles used for lifting & handling materials shall be
checked for any physical damage by the respective user for safe operation. Damaged, worn out
or defective tools & tackles shall not be used at any JSW Site/Unit.

6.3.3 Frequent Inspections

At least once in three months, an authorised person shall inspect all material lifting & handling
equipment in accordance with the manufacturer’s recommendations as well as national
regulations and/or Site/unit requirements. The frequent inspection shall be documented and
records maintained for three years.
In addition, inspection of Tools & Tackles used for lifting & handling materials shall be carried out
by site/unit authorised person, at least, once in three months.
Damaged, worn out or defective equipment, tools & tackles shall not be used at any JSW
Site/Unit. Refer the site disposal procedure.

6.3.4 Periodic Inspections

Inspection accompanied by colour coding of tools & tackles shall be carried out as per the
Site/unit requirements by a competent personmay be thrird party or any other recognised agency
which are approved by state factories inspector, and shall inspect at least every year.
Material lifting & handling equipment, including tools & tackles, shall receive periodic inspection by
a competent person at least once per year. This competent person may be a member of an
independent agency, such as indicated in the Factories Act. For JSW owned Material Lifting &
Handling equipment, the annual inspection records shall be retained on site for One year. For
equipment that is owned, leased or rented by a contractor, the periodic inspection records shall be
reviewed prior to use as part of Pre-Qualification [see Contractor Safety Management procedures]
and by an authorised person from the unit where the leased equipment shall be used.

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6.3.5 Equipment for lifting & handling materials that is not in regular use

Material lifting & handling equipment, including tools & tackles, that remain on site and are idle for
more than one month shall undergo a Frequent Inspection (see Section 6.3.3) by an authorised
person before being returned to service. Material lifting & handling equipment, including tools &
tackles, that are idle for more than six months shall receive a Periodic Inspection (see Section
6.3.4) by a Competent Person before being returned to service.

6.4 Crane operation

Crane operators must visually inspect all systems controls and safety devices each shift before
beginning work. Operators must inform JSW management of any systems, controls or safety
devices not functioning properly. The damaged &/or deficient equipment must be removed from
use at the site immediately, repaired prior to return and undergo a ‘Frequent Inspection’ by an
authorised person, if the equipment is returned within one week of removal from the site. If the
repair takes longer than one week, then the equipment shall be subjected to a ‘Periodic Inspection’
by a competent person when it returns to the site.
Before using a crane, the operator must also visually inspect the work location. Any unsafe
conditions must immediately be reported to supervision for correction.

6.4.1 Rating changes

No crane shall be re-rated in excess of the original load ratings without the crane’s manufacturer
written approval of such rating changes.

6.4.2 Safety precautions

Procedures shall be developed for Clauses 6.4.2.1 to 6.4.8, and, as a minimum, the following
points must be taken into consideration

6.4.2.1 Planning - Lifting Plan / Critical Lifting Plan

Lifting & Handling Materials Coordinator shall provide a Lifting plan / Critical Lift Plan for every
lifting operation which states:
 The competent person planning the lift
 Equipment required
 Personnel required and their particular roles
 Step-by-step instructions
 Communication methods to be used
 Contingency and rescue plans
All Lift Plans – simple or critical – shall be developed, reviewed and approved by Site Material
Handling Safety Leader (SMHSL) - Lifting & Handling of Materials Coordinator. This shall be
initiated by the executing department. (See Section 4.2)

6.4.2.1.1. Simple operation

For simple operations that do not require elaborate planning, then a note of the weight to be
lifted and the maximum radius that must be used from the centre of rotation of the crane
shall be prepared.
Information on the height to or from which the load is to be handled and an explanation of the
slinging arrangements shall also be included in the planning of simple operations.

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Category of Simple Operations:

- Gross load is less than 5 tonnes
- Gross load represents less than 75% of the load chart at working radius
- Within the normal operating parameters of the crane
- Lifting over non-sensitive areas
- Suitable environmental conditions
- Familiar, competent Crane Operators
- Load has known and evaluated weight, shape and centre of gravity
- Standard rigging arrangements shall be used

6.4.2.1.2 Repetitive operation

Straight forward repetitive operations will require to be planned once only. The Lifting
Supervisor shall monitor the operations to ensure no changes occur that requires a revision of
the method of work. Documented procedures of these repetitive operations are recommended
to be prepared by the supervisor and operators. (See Section 4.3)

6.4.2.1.3 Critical Operations – Critical Lifts

Critical operations shall require a Critical Lifting Plan- and more detailed planning and preparation.
The plan and method statement shall be accompanied by drawings, sketches or photographs, in
order to make it completely clear to the personnel concerned, exactly how the operation is to be
handled and the correct sequence in which the work is to progress (Protocol to be ensure).
The SMHSL – must approve all critical lifts and ensure that the manufacturer is consulted before
deviating, in any way, from the manufacturer’s instructions.
A crane lift shall be considered critical when any one of the following conditions exists:
• The load exceeds 75 percent of the manufacturer’s recommended crane capacity, as
shown on the load charts for the configuration to be used. This will apply to cranes with
an extendable boom.
• The load must be lifted by more than one crane
• Lifts with EOT cranes, gantry cranes, Goliath cranes, jib cranes and forklifts are not
included in this critical lift element. Lifts with these cranes should not exceed Safe
Working Load recommended by the OEM. Lifting personnel with a suspended “man
basket” is considered a Critical Lift. (Refer to Section 6.4.2.1.3.1)
• Multiple or Tandem lifting operations are NOT permitted inside the JSW plant
premises

An engineer, rigging consultant, or other authorised person must prepare a critical lift plan - that
contains at least the following information:

• A brief explanation of why the lift is critical

• The type, manufacturer, and model of the crane
• The boom length
• The boom angle
• The operating radius
• The load’s weight (the actual weight, including rigging, and not an estimate)
• The intended configuration of the crane (such as outrigger placement, amount and
placement of counterweights, jib usage, etc.), along with the resultant available capacity

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• The load’s dimensions

• The attachment points for rigging
• Any obstructions in the load’s path
• The type, size, and capacity of rigging hardware
• The ground-bearing capabilities and requirements for matting and/or pads.
If, during the course of a lift that was not deemed to be a critical lift, it becomes apparent that the
lift should be considered critical, then lifting operations shall be stopped and the load shall be put
down, so that a critical lift plan can be prepared before resuming the lift.
Examples of Critical Operations:
- Usage of Man Basket, irrespective of the load capacity of the crane or hoist
- Gross load represents more than 75% of the load chart at working radius, or
- Continuation of a lifting operation with different equipment (due to malfunction,
inadequacy or unsuitability)
- Within difficult or restricted spaces
- Over or in sensitive areas – active or energized hydrocarbon-containing process
equipment, near overhead electrical power lines, crane is standing above critical
underground structures such as cable trenches, water pipes, gas lines, etc.
- Tandem lift with two cranes or more
- Transferring the load from one lifting appliance to another
- In environmental conditions likely to affect equipment performance
- Load with unknown / difficult to estimate weight and / or centre of gravity
- Mobile crane on untested / uneven ground
- Non-standard rigging arrangements
- Load lowered into or lifted from a confined space
- Lifts conducted at night (Refer to Section 6.4.2.1.4.1)
- The lift requires deviation from the manufacturer’s recommendations, including but
not limited to the following:
o Using a boom configuration unlike that on the boom makeup chart
o Moving a crane with a longer boom than recommended
o Exceeding the capacities or restrictions shown on the load chart
o

6.4.2.1.3.1 Crane-suspended work platforms

When a mobile crane is used to lift personnel, the crane must be equipped with an anti-two-
blocking device that renders the crane’s controls inoperable when the anti-two-blocking device is
activated. Lifting personnel with a suspended basket or similar device should be done as the last
resort or when this option presents the least risk to personnel involved with the task.
In order to improve safety margins when lifting personnel:
 A critical lift plan - shall be completed and approved and shall take into account appropriate
load line and load chart capacity reductions to the crane and the tackle. Only after that, man
lifting operation shall be carried out.
 Obtain a permit or certificate or complete a checklist for a Crane Suspended Personnel
Platform (Man Basket). Permit or Certificate or Checklist shall be properly signed by an
authorised person and it shall be available onsite during the lift, as per procedure.
 In any case, total weight of all persons & man basket shall not exceed 50 % of SWL
 Do not perform crane suspended personnel platform (man basket) lifts in wind speeds
exceeding 25 km/h
 The crane shall be uniformly level and located on firm footing. Cranes equipped with
outriggers shall have them all fully deployed following the manufacturer’s specifications,
insofar as applicable, when hoisting personnel.

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Outrigger floats shall be placed on matting or oversized pads to further distribute the
ground-bearing pressure of the crane.
 Procedures for crane suspended work platform (man basket) shall be developed which shall
include :
- Design approval for fabrication of crane suspended work platform (man basket)
- Critical Lift Plan
- Load Line and load chart capacity reduction
- Emergency rescue plan
 A telescopic man lift is not included in this element of the standard. (The telescopic boom can
be powered by hydraulic, pneumatic, electric, etc. systems.) This includes “cherry pickers”,
“scissors lifts”, “telescopic ladders on a fire/rescue truck”, etc.

6.4.2.1.4. Other Operations:

Following precautions must be considered for the other operations are mentioned below:

6.4.2.1.4.1. Night Work:

As far as possible after the day light, erection shall not be conducted in the night. If an erection
activity is to be carried out in the night due to exigency, then the procedure for Night Work shall be
applied. Lifting & handling materials at night requires the approval of the Site Material Handling
Safety Leader and Head of the dept. (HOD) with protocol and illumination level minimum 100lux
minimum to be maintained. It shall be also authorised by Head of the Safety & Fire Services.

6.4.2.1.4.2. Adverse weather conditions:

Erection, including lifting and handling materials, shall be stopped in adverse weather conditions,
such as
 Storms, hail, sandstorm, lightning, fog, etc.
 When the wind speed exceeds 25 Km/Hr.

6.4.2.1.4.3 Working near Gas pipelines:

 Ensure the pipeline location is barricaded

 A banksman –/ Signal man is posted to notify the operator if the Lift or crane is brought
within 1 mtr distance from the pipeline.
 The concerned engineer ensures adequate precautions taken to avoid any damage to the
pipeline.
 Emergency procedures to be followed in case of any gas leak shall be developed and
discussed with the lift crew members before the job. Necessary rescue equipment shall be
provided at the job site.

6.4.2.1.5 Documents required before a Critical Lift:

Following documents shall be made available before a critical lift:

 Risk Assessment
 Critical Lift Plan
 Work Permit, Checklist &/or Certificate(s), Protocols
 Toolbox Talk (See Section 6.4.2.3)
 Emergency rescue plan

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6.4.2.2 Set Up

 Consider the hazard of flammable materials before using a crane in an operating area. Obtain
proper approval by permit for entering areas hazardous.
 Store loose items (e.g., tools, oil cans, and waste materials) in a toolbox or proper storage
container. Do not leave any loose items in the operator’s cabin.
 Before moving a crane into an area, evaluate ground stability and weather conditions for
hazards to crane stability and for the possibility of damage to underground facilities or injury to
personnel. Use mats to improve stability.
 Before set up consider all other cranes or equipment in the close vicinity when conducting risk
assessment.
 Barricade the swing radius of the superstructure (counterweight). Use other barricades
according to Site procedures. Keep the swing path clear by barricade and warning signs. At
no time, for any reason, shall a lift be performed over any personnel.

6.4.2.3 Operation

Communication of Lift Plan / Critical Lift Plan

 Prior to starting of lifting operations a competent person shall hold a Toolbox Talk with all
personnel assigned to carry out the lift. Lifting & Handling materials Coordinator shall ask
the ‘Questions for a safe lift’ to the lift crew during the Toolbox Talk. Proceed with the lift
when the crew members respond with the correct answers to the questions.
 The Lifting & Handling Materials Coordinator shall be clearly identified and made known
to all members of the lift team and personnel in the proximity.
 All personnel involved in the lifting operation shall have their individual responsibilities
clearly allocated. Individual responsibilities must be discussed with crew members.
 All personnel should have the opportunity to review the findings of the risk assessment and
the details of the Lift Plan/Critical Lift Plan – Lifting procedure/protocols to ensure that
everyone clearly understands and agrees with the methods and control measures to be
used.

An operator must always observe the following minimum safety precautions in addition to the
manufacturer’s recommendations and Site requirements:
 Maintain continuous contact, either visually or with two-way radios (Walkie Talkie system) with
a designated signal person. The methods of maintaining continuous contact are, in order of
preference:
– Visual (hand signals) 1st Choice
– Walkie Talkie system can be adopted to improve communication during operation

If for any reason contact is lost, the operator must stop all operations until full contact is
restored.
 Seat belts must be worn.
 Make sure the hoist line is vertical at all times.
 Know the radius of the load at all times.
 Operator and foremen – Signal man shall be aware of all the Lifting parameters during the
operation.
 Make sure the safety latches on the crane hooks are in good working order and are used
properly.

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 Follow the manufacturer’s instructions for entering and exiting the crane’s cabin. The only
acceptable alternative to these instructions is using a straight ladder that has been
permanently mounted to the crane.
 Under adverse weather conditions work shall not be started. If adverse weather conditions
develop after work has started, then cease lifting operations.
 The load must be controlled at all times by the crane operator and/or rigger. Tag lines (i.e.,
rope attached to the load) are strongly recommended as a means of control. The person
should be, at least, two meters away from the load. Personnel shall not use their hands to
control the suspended load at any time.
 Keep the loading/unloading areas clear of unnecessary personnel. When loading or unloading
trucks, the truck cabin should be unoccupied unless it is required. The key shall be removed
from the ignition and held by the loader-Driver/Operator. Chocks or wedges shall be placed
on the wheels of the truck to prevent movement.
 Do not leave the controls when the load is suspended or the crane is running.
 When leaving the control station
– Make sure the load is not suspended.
– Shut down the crane before exiting the cabin. Do not allow anyone to work, stand, or
walk under a suspended crane load. Never ride the hook or the load.
 Do not allow any other personnel on the crane when it is in use during normal operation.
 Follow the manufacturer’s recommendations for maximum allowable loads and maximum
boom lengths. Read and understand the manufacturer’s instructions for deploying and
retracting powered and non-powered pinned fly sections. Do not allow the fly section of the
boom to free fall or retract by elevating the boom.
 Make sure the equipment is shut down and a fire extinguisher is available during refueling.
 Any material shall be secured all the time during operation and before releasing the crane, it
shall be ensured that material is secured / stacked properly.

6.4.3 “Pick and Carry” load prohibitions – (Hydra / Farahana)

Handling “pick and carry” loads is not recommended and should be avoided. Use a truck or lorry
specifically designed for transport of the load, materials or equipment. Do not transport materials
with a crane, especially a hydra crane. As per JSW policy the maximum distance the materials can
be transported with a crane is up to 50 meters in the project areas or yard areas. Use a truck,
whenever possible for all materials transport.

 No Pick n Carry Crane will be allowed to travel(>50mts distance) with lifted load at working
site
 While working at site, two pick n carry cranes will not be used for lifting in tandem
 No Pick n Carry Crane/Hydra be allowed to move “with load” on roads
 On daily basis, a ‘Work Permit System’ will be followed along with hydra certificate
 Pick n Carry Crane will not be allowed to move on road with speed more than 8 KM per
hour
 No pick and carry allowed using mobile equipment on SLOPES/RAMPS
 No personnel shall be transported along with Material.
 No co-passenger will be allowed in the crane cabin/on the chasis
 OEM trained operators should only be used for operating the equipment

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 Before entering into the plant premises, the pick n carry crane is to be inspected and
certified by the representatives of Central Maintenance Department, Safety & Fire
Services and Concerned department.
 JSW approved pick n carry cranes must be used inside the plant premises such as
 Model F-15 of M/s Escorts
 Omega make 20T Pick n Carry crane
 Model 15X W-F pf M/s ACE
 Chowgule Truck Mounted Crane up to 2.5T capacity
 Palfinger Hydraulic Lifting and Loading up to 7.5MT

 TIL make Industrial crane 12.5T Capacity

6.4.4 Warnings, load charts, and operating manuals

Safe working load, recommended operating speeds, and special hazard warnings or instructions
shall be conspicuously posted on all equipment. Instructions, warnings, and durable load charts
shall be visible while at the control station. Load charts must be affixed to the crane cabin. Load
charts shall be those applicable to the specific crane for which they are being used. The crane
manual and legally required documents shall be available at site.

6.4.5 Moving parts

Belts, gears, shafts, pulleys, sprockets, spindles, drums, flywheels, chains, or other reciprocating,
rotating, or other moving parts of equipment shall have protective guards or panels in place during
equipment operation when these parts could contact personnel or otherwise create a hazard. If
any inadequately guarded moving parts are encountered, additional guarding shall be approved
by the manufacturer prior to installation or installed in guidance of Lifting & Handling Materials
Coordinator.

6.4.6 Hand signals

The purpose for using standard crane signals is to insure accurate communication between the
signalman and the crane operator. Applicable hand signaling standard should be used. An
illustration of the signals shall be posted on the job location.
Use of local, non-standard signals can be considered provided they enhance communication and
are reviewed and agreed upon by the crane operator and signal man.

6.4.7 Exposure to unsafe atmospheres

Whenever internal-combustion-engine-powered equipment exhausts into spaces with restricted

ventilation, then tests shall be made and recorded to ensure that employees are not exposed to
unsafe concentrations of toxic exhaust gases or to oxygen-deficient atmospheres.
Prior to equipment operation it is recommended that the work area should be surveyed to
determine the location and proximity to process equipment that may release toxic, corrosive, or
flammable chemicals, as a mist, fume or fog. Examples include, but are not limited to rupture
discs, relief devices, line break activities and process stacks.

6.4.8 Exposure to electric lines

When mobile cranes must travel or operate in the vicinity of electric lines or cables, the
requirements of electrical safety standard (recommended) must be followed in addition to these

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requirements. An Electrical Resource shall be engaged to help with ensuring that electrical safety
standard (recommended) is being appropriately followed.
For the purposes of this standard the following definitions of electric lines and cables shall apply;
Electric Lines – Electric lines are overhead electrical conductors that are not insulated for the
voltage at which they operate.
Electric Cables – Electric cables are overhead electrical single-conductors or multi-conductor
cables that are insulated for the voltage at which they operate.
A designated signal man shall monitor equipment clearance and give timely warning for all
operations where visual verification of the clearance by the operator is difficult, inconvenient, or
awkward.
All overhead lines or cables shall be considered energized unless and until the person owning
the line or cable or the electric utility authorities indicate that it is not energized. Crane operators
shall not rely on the wire coverings for their protection.
Table 2 provides the minimum clearance distances that shall be observed when the crane is in
transit with no load and with the boom lowered, as well as when the crane is working. An
authorized and signed close proximity permit shall be required for operating a crane closer than
the distances outlined in Table 2.
Table 2. Minimum Required Clearances

In Transit In Use (Not in Transit)

0 - 750 Volt 4’ (1.22 m) 0 – 50,000 Volt 15’ (4.58m)
750 – 50,000 Volt 6’ (1.83 m) 50,000 – 345,000 Volt 25’ (7.62 m)
50,000 - 345,000 Volt 10’ (3.05 m) 345,000 – 750,000 Volt 40’ (12.19 m)
345,000 - 750,000 Volt 16’ (4.88 m)

The use of cranes near electric lines or cables is not recommended. However, if work must be
performed in the vicinity of electric lines or cables and there is no alternative method for performing
the work, then work permit is required. The safe operating conditions to carry out the activity should
be well explained in the permit &/or certificate.

6.5 Maintenance, repairs and modifications

All maintenance and repairs shall be performed in accordance with the manufacturer’s
recommendations. Modifications affecting capacity or safe operation shall have the manufacturer’s
written approval prior to the modifications being performed. Records of maintenance, repairs, and
modifications shall be maintained for the life of the equipment. This is to be reviewed and tested by
competent person.
Procedures for maintenance repair & modification of Material Lifting & Handling Equipment and
Tools & Tackles shall be developed and implemented.

6.6 Emergency preparedness

Emergency preparedness shall be established for Lift ing and Mat er ial H andling operations.
Procedures must be developed for rescue and recovery of broken-down equipment, and extraction
of personnel from those equipment and others who are affected. Such matters should be
addressed as part of the operational risk assessment. Emergency response plan and rescue
equipment must be available.

6.7 Material Lifting & Handling Personnel Qualifications

6.7.1 Material Lifting & Handling Equipment Operator qualifications

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Operators of Material Lifting & Handling Equipment shall successfully complete a testing program
that meets country and/or site requirements. The testing program should consist of both a written
test and an operating test demonstrating proficiency in handling the specific type of Lifting &
Material Handling Equipment..
 Eye sight of persons operating or assisting operation of cranes, fork lift trucks etc has
been certified fit by an ophthalmologist and examined once in every 12 months up to 45
years of age and once in 6 months beyond 45 years of age. It is the requirement of
respective State factories rules.as applicable.
Site/unit management may elect to specify a more frequent medical examination.
Physical defects or emotional instability that could be a hazard to the operator or others may be
cause for disqualification.

6.7.2 Riggers/Operators and signalmen qualifications

 All riggers and Signalmen shall be certified by Site Material Handling Safety Leader (SMHSL)
- HOD
 Minimum age shall be 21 years for all riggers and Signalmen
 They shall be physically fit with regard to eyesight, hearing, reflexes and ability to handle
lifting gear and equipment. A person with any physical disability must not work as a Rigger.
 All Riggers and Signalmen shall be selected based on their qualification, experience and
they must be authorised by Site Material Handling Safety Leader (SMHSL).

6.8 Training, Certification and Competency Assurance

A detailed training, certification and competency assurance procedure must be developed for
all personnel including contractors involved in material lifting & handling operations (Such as,
equipment operators, [for example Lift & Carry Crane, mobile or hydra crane, forklift, etc.]
riggers, foremen, signalmen, banksmen, helpers, etc., including maintenance & other
departments like planning & designing, erection specialists, Lifting &Handling of Materials
coordinator).
Trainings shall be theoretical & practical and defined & designed for each & every job and
position. Competency levels also have to be defined for the positions.
A person can only work with full responsibility, after completing required training & certification
programs, and reaching required competency level.

6.8.1 General Awareness Training

Awareness information and/or instruction must be provided on a regular basis to personnel

who are involved in material lifting & handling activities, including contractor, to reinforce the key
safety issues such as:
 Critical aspects of safe operation
 Vision limitations (blind spots)
 Emergency procedures
 Requirements related to operating conditions
(Adverse weather, night operations, load conditions)
 Critical Lifting

6.8.2 Task-Specific Training

Training and certification shall be provided to personnel who are involved with material lifting &
handling operation. This may be in the form of training from OEM or Qualified Person or qualified
agency certified by the OEM.

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6.8.3 Refresher Training

General awareness and task-specific training shall be provided prior to work for people involved
in the following situations:
 Changes to the written program
 Inadequacies in an employee’s knowledge or use of the procedures

Refresher training should be provided at an interval of not more than one years from the
previous training.

6.8.4 Training Records

Training records shall be retained for three years or until retraining has occurred or as indicated
under local requirements.

7.0 Management systems

7.1 Support resources

Apex committee at corporate level and the Safety & Fire Services Department at Site level are
available to assist with the implementation of this standard.

7.2 Management records

Records shall be retained in compliance with the standards/procedures and Information

Management Policy.

7.3 Audits

Apex committee shall include the provisions of this standard in their second party safety audits
protocol. Site/units shall have a first-party audit program conducted that assesses compliance to
procedures and practices with the requirements in this standard. First-party audits shall also
address local laws, regulations, and situations unique to the Site/unit relative to machine safety

7.4 Deviation process

Deviations from this standard must be authorized by the Head of the Unit or Department after
consultation with the Apex Committee. Deviations must be documented, and documentation must
include the relevant facts supporting the deviation decision. Deviation authorization must be
renewed periodically and no less frequently than annually.
Emergency deviations must be authorized by the Site/unit Head when, as a result of an unforeseen
event or situation, there is inadequate time to process a formal deviation. Emergency deviations
shall be authorized only where it is not feasible to comply with a requirement in this standard.
Emergency deviations shall be short in duration, not to exceed the time to perform the task at hand.
Appropriate safety department resources shall be consulted. The deviation must be documented.
The documentation must include the relevant facts supporting the deviation decision and the interim
measures to be put in place to achieve acceptable levels. A copy of the deviation must be sent to
the APEX Safety Committee.

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7.5 Training and communications

Successful completion of initial Equipment training on Operation and Maintenance shall be a

prerequisite to becoming a competent person. Each Site/unit shall establish training systems that
require only competent persons to perform Equipment work. Trainees must operate and maintain
the Equipment only when under the direct supervision of a competent person. The competent
person must maintain vision of the trainee and maintain direct oral communication with the trainee
when he/she is working.

7.6 Contact

The contact for this document is the Corporate Safety.

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Appendix - 1: Related Standards

Indian Standards

IS3177-1977, Code of practice for EOT and Gantry Cranes.

IS 807-2006 Design, Manufacture, Erection and Testing (Structural Portion) of Cranes and Hoists -
Code of practice
IS 1804-2004 Steel Wire Ropes -Fiber Main Cores –Specification
IS 2266-2002 Steel Wire Ropes for General Engineering Purposes - Specification (Fourth Revision)
IS 2361-2002 Bulldog grips- Specification
IS 2758-1969 Specification For Mild steel point hooks for use with wire ropes thimbles
IS 2759-1969 Specification for higher tensile steel point Hooks for use with wire rope thimble
IS 2760-1980 Specification for steel chain slings
Specification For Short link chain grade M(4) (Part 1) - Non -Calibrated Load Chain For
IS 3109-1982
Lifting Purposes
Specification For Short link chain grade M(4) (Part 2) - Calibrated Load Chain For
IS 3109-1982
Pulley Blocks & Other Lifting Appliances
IS 3813-1967 Specification For 'C' hooks for use with swivels
IS 3822-2002 Specification for eye hooks for use with chains
Code of practice for heavy duty electric overhead travelling cranes including special
IS 4137-1985
servicing machines for use steel works
IS 4190-1984 Specification for eye bolts with collars

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