14.lifting Operations & Lifting Equipment

Power & Water Utility Company Document ID No: MSSM-1-SF-001
For Jubail and Yanbu (MARAFIQ) Page:190 of 363
Rev. No.: 00
MARAFIQ SAFETY MANUAL Valid Until : November 12 2010
14. LIFTING OPERATIONS & LIFTING EQUIPMENT

Reference Standards:
SASO - 325; 328
GS- 214 /1994; 80/1988
OSHA -1910-178; 179; 184
INTRODUCTION
Most workplaces have the need to carry out lifting and handling of
equipment and material, which creates a range of risks that need to
be assessed.
The use of mechanical equipment eliminates many of the risks

involved with manual handling. However when an object or person is
lifted or lowered by means of mechanical equipment there is a
potential for more risks to: -
a) Personnel / public involved in getting injured or killed or

b) Lifting equipment or plant and other equipment in the vicinity
of lifting operation getting damaged or
c) Combination of a and b
So, it is deemed necessary to control and minimize the risks imposed

by lifting equipment and related operations to employees and others
including members of the public, contractors, other users of the
premises, sites etc.
PROPRIETARY NOTICE IMPORTANT

THIS DOCUMENT CONTAINS INFORMATION PROPRIETARY TO MARAFIQ. ANY DISCLOSURE OR
USE IS EXPRESSLY PROHIBITED EXCEPT UPON WRITTEN PERMISSION BY MARAFIQ. Only document with stamps are considered official.
Rev. No.: 00
14.1 DEFINITIONS
Executing party:
The Contractor or MARAFIQ Department using cranes, hired cranes and/or forklifts or any other lifting
equipment.
Lifting operation:
Process of raising a load with a lifting appliance and
loose lifting tackle.
Lifting equipment:
A generic term used to indicate all lifting appliances and loose lifting tackles.
Lifting machine / appliance-

A machine / appliance which are able to rise lower or
suspend a load. It includes lifting appliance like crane,
forklift, winch, hoist, chain pulley block, etc.
Lifting tackle (gear) –

An item used to connect a load to a lifting machine but
which is not it capable of providing any movement to
lift or lower the load. It includes wire rope sling,
webbing belts, chain sling, shackles, eye bolts, lifting
beam and spreader, etc.
Rigger –
A competent person to inspect and connect lifting
tackles to a load and the lifting appliance
Signalman
The one who gives standardized hand signals to
crane operator.
Safe Working Load - SWL

The maximum allowable load to raise, lower or suspend a load safely under ideal conditions specified
by manufacturer of the lifting equipment

Rev. No.: 00
14.2 SIGNIFICANT RISKS

When an object or person is lifted or lowered by means of mechanical lifting equipment, there is
potential for more risks such as:-
 The overturning or failure of mechanical lifting appliances like a crane or forklift truck and getting
damaged
 Collapse of equipment or its components which fall onto persons causing injuries or fatalities by
being crushed, struck or falling
 Failure of loose lifting tackles that are connected to the load and the lifting appliances
 An object being lifted or lowered to fall and get damaged itself or damage other equipment on
which it falls.
 An object being lifted or lowered to fall injuring or killing persons beneath the falling object
 A person being lifted or lowered by means of man skips to fall and get injured or killed
14.3 SAFETY REQUIREMENTS

Any lifting equipment for use at work should be:
 Suitable, strong and stable enough for the particular use

 Marked with safe working load and if it is used for carrying people with the maximum number that
can be carried like man skips
 Positioned and installed to minimize any risks
 Used safely i.e. the work is planned, organized and performed safely by competent people
 Subject to ongoing thorough examination, testing and certification by third party inspectorate and
 Inspected by competent people prior to every use
14.4 RESPONSIBILITIES
Executing Party / i. Develop, implement and audit program for:
Maintenance Management  Periodic inspection of lifting equipment at least once in a
month and every time prior to use
 load testing, thoroughly examination and certification of
lifting equipment from third party inspectorate recognized by
Saudi Government once in a year
ii. Appoint competent and certified
 Competent crane, forklift and other lifting appliance
operators
 Competent riggers
 Competent signalman
iii. Complete Lifting Plan approved by Engineering Technical
Services and execute lifting operation safely
iv. Risk Assessment for critical lifts prior to obtaining permit to
Rev. No.: 00
work Certificate
Operations Department  Ensure compliance to “Lifting Operations” requirments within the

areas of responsibility while performing lifts
 Develop and implement program for the periodic inspection,
testing and thorough examination of all lifting equipment
periodically
Engineering department Review and approve all lifting plans prior to lifting operations
Safety Section – Loss  Inspect all contractors’ lifting appliances like mobile crane, forklift,
Prevention Division man lift, etc. as per the attached checklists, prior to entry or work at
MARAFIQ facilities or properties
 Affix safety inspection stickers on the lifting appliances that are

conforming to requirements as per inspection checklist.
Crane or Forklift operator Safely operate lifting appliances within the lifting machine
manufacturer’s or supplier’s instructions
Rigger cum  Inspect lifting equipment prior to every use

Signalman  Connect loose lifting tackles with correct practices to the load and
the hook of the lifting appliances
 Follow internationally approved signals to direct lifting appliance
operator during lifting operations
Authorized Permit Receiver Prior to obtaining Permit to work Certificate for carrying out
proposed lift,
 Verify that all lifting equipment (cranes and loose lifting tackles)
are tested, certified and again
 Visually inspect all lifting equipment prior to every use. See
appendix 4 for inspection checklists
 Verify certification of lifting appliance (crane, forklift, etc) operators
 Appoint competent riggers and signalman in lifting operation
 Complete lifting plan for critical lifts and make it available at site.
 Conduct lifting operation safely as per lifting plan, risk assessment
and taking necessary safety precautions

Rev. No.: 00

Rev. No.: 00
14.5 LIFTING PLAN

Lifting plan should be:
i. prepared for planned as well as unplanned critical lifting

operations involving:
 Two or more cranes

 A movable fly jib.
 Load equal to or greater than 5 Ton.
ii. Included with:
 Calculations of Load moment, maximum actual soil bearing

pressure i Drawings – side and plan view of crane set up
positions with load and loose lifting tackles showing;
 Crane basic configurations: - working radius, boom angle and
boom length for the propose lift
 Workplace details with a sketch showing:
- Access and obstacles within the working radius of the

crane(s)
- Underground pipes
- Overhead or underground electrical cables within the
working area
 Crane’s load chart

 Calculations of Load moment, maximum actual soil bearing
pressure indicated by the outriggers during lift and stress.
iii. Approved by Engineering Technical Services – Facility
Coordinating Engineer or call out Engineer
iv. Attached with a Risk Assessment and
v. Submitted to Operations Department prior to obtaining
“Permit to Work Certificate”.
LIFTING PLAN APPROVAL TIME LIMIT:
 Planned jobs – lifting plan shall be submitted to Engineering Department at least one week
before execution.
 Unplanned jobs (emergency work) - On call duty Engineer from Technical Services
Department should be called upon to approve lifting plan.
Note: Maximum allowable wind speed should not exceed 14 meters/sec during lift operation

Rev. No.: 00
14.6 LIFTING APPLIANCE OPERATORS
All operators of lifting appliances like crane (mobile / electric

overhead), man lift, forklift truck, etc, should possess following:
i. Appropriate operating license for crane / forklift / man lift

/other lifting appliance operation issued by Kingdom of Saudi
Arabia Government Traffic Division
or
ii) Appropriate driving license to drive crane on road issued by

Kingdom of Saudi Arabia Government Traffic Division
and
Certification from third party inspectorate recognized by Kingdom of

Saudi Arabia Government as competent person to operate specific
lifting equipment
Lifting appliance operators should: -
 Be provided with “on the job” and “refresher” trainings

 know to read, understand and use the load chart and working
range diagram of the lifting appliances
 know to read and understand the working of safe load
indicator and working within the limits.
 Be competent to operate the lifting appliances safely within the
manufacturer’s specifications and limitations.
 Remain in operator’s cabin when the lifting operation is in
progress and should not leave the cabin till the load is
disconnected from the lifting hook.
14.7 LOAD TESTING, THOROUGH EXAMINATION AND CERTIFICATION

All lifting equipment should be
 load tested, thoroughly examined and certified by Third Party Inspectorate recognized by Saudi
Government as per frequency given below and
 Tagged / indented with a) Identification number, b) SWL – safe working load, and c) date of test
and re-test
Frequency of Testing &

Type of lifting equipment Re-Validation of
Rev. No.: 00
Certification
Lifting Appliances - mobile / overhead Cranes, forklift trucks, hoists, Every Year
winches, chain pulley blocks, cherry pickers,
Loose Lifting tackles – Wire rope sling, chain slings, shackles, eyebolts, Every 6 Months
webbing belts, lifting and spreader beam, etc.
Man skip / basket Every 6 months
14.8 INSPECTION OF LIFTING EQUIPMENT

Inspections of lifting appliances prior to bringing on site
User Department / Contractor should ensure that any lifting appliances such as mobile cranes, man
lifts, forklifts, etc, intending to bring on to Marafiq premises are:
 In safe working condition as per the inspection checklist given in the appendices 1 & 2,
 Inspected by Marafiq Safety Section and affixed with safety inspection sticker
 Posted with entry pass/sticker from Industrial Security Department – ID Section completing
necessary documentation.
Inspections of lifting equipment prior to use
Lifting equipment including crane, slings and shackles that will be used for any lifting operations,
should be inspected by the user prior to its every use.
Periodic inspections
All lifting equipment (lifting appliances and loose lifting tackles), man basket and material basket should
be inspected periodically at least once in a month and records should be kept by the User Department.
(Refer inspection checklist – Appendix 1, 2 and 3)

Rev. No.: 00
14.9 GENERAL PURPOSE SLINGING PRACTICE

The following information is based on Section 1 – Appendix 1.5 of the LEEA (Lifting Equipment
Engineers Association) Code of Practice for the Safe Use of Lifting Equipment.* it should be read in
conjunction with the instructions for the safe use, given overleaf, of which it forms and integral part and
with any specific instructions issued by the supplier.
This information is of a general nature only covering the main points for the safe use of various types of
slings for general lifting purposes.
14.9.1 Mandatory Requirements
Always:
 Plan the lift, establish the weight of the load and prepare the landing area ensuring that it will take
the weight.
 Inspect and check slings and equipment are free of damage, use slings/slinging methods suitable for
the load and protect slings from sharp edges and corners.
 Attach the sling securely to the load and appliance and position hooks to face outwards.
 Ensure the load is balanced and will not tilt of fall.
 Keep fingers, toes etc clear when tensioning slings and when landing loads.
 Ensure that the load is free to be lifted.
 Make a trial lift and trial lower.
14.9.2 Prohibitions:
Never
 Use damaged slings or accessories.
 Twist, knot or tie slings.
 Hammer slings into position.
 Overload slings due to the weight of the load or the mode of use.
 Trap slings when landing the load.
 Drag slings over floors etc or attempt to pull trapped slings from under loads.
 Allow personnel to ride on loads.

Rev. No.: 00
14.9.3 Sling Configuration and Rating
Slings are available in single, two, three and four leg or endless form. In practice it will be found that
chain, wire rope and fibre rope slings are available in any of these configurations but that flat woven
webbing is limited to single leg and endless whilst round slings are only supplied in endless form. The
maximum load that a sling may lift in use will be governed by the slinging arrangement (mode of use)
and may vary from the marked SWL.** In the case of textile slings the SWL for the various modes of use
is usually given on the information label. In other cases it is necessary to multiply the marked SWL by a
mode factor.***
The following three simple rules will ensure that the sling is not overloaded. In some cases this will mean
that the sling will be underutilized although this is unlikely to hinder the user unduly. Where the
maximum utilization is required reference should be made to a Competent Person who understands the
factors involved and who can perform the necessary calculations.
 For straight lift never exceed the marked SWL and in the case of multi-leg slings the specified
angle or range of angles.
 When using slings in choke hitch multiply the marked SWL by 0.8 to obtain the reduced
maximum load the sling may lift ie reduce the safe working load by 20%.
 With multi-leg slings, when using less than the full number of legs, reduce the maximum load in
proportion to the number of legs in use. Simply multiply the marked SWL by the number of legs
in use expressed as a fraction of the total thus: one leg of a two leg sling = ½ marked SWL, three
legs of a four leg sling = ¾ marked SWL and so on.
Operative Training
Slings should only be used by trained operatives who understand the methods of rating and application
of mode factors.
14.9.4 Safe Use of Slings
 Good slinging practice must ensure that the load is as safe and secure in the air as it was on the
ground and that no harm is done to the load, lifting equipment, other property or persons.
 Establish the weight of the load, ensure the lifting method is suitable and inspect the sling and
attachments for obvious defects. Prepare the landing area making sure the floor is strong
enough to take the load. Follow any specific instructions from the supplier.
 Ensure the lifting point is over the centre of gravity. Any loose parts of the load should be
removed or secured. Secure the sling firmly to the load by hooks onto lifting points or shackles
etc. The sling must not be twisted, knotted or kinked in any way.
 Use packing to prevent damage to the sling from corners or edges and to protect the load.

Rev. No.: 00
 Do not exceed the SWL or rated angle. Any choke angle must not exceed 120 o and any basket
90o.
 Does not hammer, force or wedge slings or accessories into position; they must fit freely.
 When attaching more than one sling to the hook of the appliance use a shackle to join the slings
and avoid overcrowding the hook.
 Use an established code of signals to instruct the crane driver.
 Ensure the load is free to be lifted and not, for example, bolted down.
 Check that there are no overhead obstacles such as power lines.
 Keep fingers, toes etc clear ensuring they do not become trapped when lifting, lowering or
controlling loads.
 Make a trial lift by raising the load a little to ensure it is balance, stable and secure and if not
lower it and adjust the slinging arrangement.
 Where appropriate use tag lines to control the load.
 Except where special provision is made, do not allow anyone to pass under or ride upon the
load. The area should be kept clear.
 Make a trial set down, ensure the sling will not become trapped and the load will not tip when the
slings are released. Use supports which are strong enough to sustain the load without crushing.
 Never drag slings over floors etc or attempt to drag a trapped sling from under a load.
 Never use a sling to drag a load.
 Place the hooks of free legs back onto the master link and take care to ensure that empty hooks
do not become accidentally engaged.
 Never use slings in contact with chemicals or heat without the manufacturers approval.
 Never use damaged or contaminated slings.
 On completion of the lift return all equipment to proper storage.
APPENDICES
 Crane inspection checklist

 Forklift inspection checklist
 Inspection checklist for miscellaneous lifting equipment
 Standard Hand Signals for Crane Operators
MOBILE CRANE INSPECION CHECKIST

Rev. No.: 00
Department / Contractor: Date of Inspection:

Crane Details:
Make/Model:
Type:
Serial Number:
CHECK POINTS YES NO
1. Crane operator’s license/certificate - valid
Name of Operator: License Number:
Date of certification: Date of Expiry:
2. Crane’s current load test certificate from third party inspectorate - exists
Name of Third party inspectorate:
Test certificate No:
3. Tires - free from obvious defects
4. Electrical items including battery - safe and covered
5. Fire extinguisher – provided, inspected & in good condition
6. Engine, hydraulic, brake and fuel systems - free from leaks
7. Crane hook hoisting and auxiliary cables - in good condition
8. Audible reversing alarm - fitted and in working order
9. Main hoist operation - smooth with no binding / vibration
10. Spark arrestor - exists
11. Flashing visible warning light – available and in working order
12. Safe Working Load SWL – marked on crane
13. Load chart and working range diagram – available in the cabin
14. Automatic safe load indicator alarm – working a must
15. Hoist limit switches / anti-two blocking device - working
16. Wooden / steel blockings to place under outrigger floats Minimum 1 M x 1M - provided
17. Lifting hook safety latch – in good condition

18. Competency of crane operator–Understanding of crane’s load chart and limitations
Crane: Approved / Not approved
Comments:
Inspected by : Signature :

Rev. No.: 00
FORKLIFT INSPECTION CHECKLIST
Department / Contractor: Date of Inspection:
Forklift Details:
Make: Type:
Model: Serial Number:
CHECK POINTS YES NO
1. Forklift operator’s license/certificate - valid
Name of Operator: License Number:
2. Forklift’s current load test certificate from third party inspectorate - exists
Name of Third party inspectorate:
Test certificate No:
3. Safe working Load - clearly marked and or known by the driver
4. Flashing warning light - fitted and in working order
5. Lifting mast chain, brakes & hydraulic system - in good condition?
6. Dangerous moving parts - suitably guarded
7. Tires - free from obvious defects
8. Audible reversing alarm - fitted and in working order
9. Electrical (battery) connections - covered and free from obvious defects
10. Fire extinguisher - inspected & in good condition
Forklift: Approved / Not approved

Comments:
Inspected by : Signature :
INSPECTION CHECKLISTS FOR MISCELANEOUS LIFTING EQUIPMENT

Rev. No.: 00
Authorized Permit Receiver should ensure that all lifting appliances and loose lifting tackles are visually
inspected prior to their use and found in safe working condition.
Acceptable Not
OVERHEAD ELECTRIC CRANE / HOIST / WINCH acceptable
1. Safe Working Load SWL – legibly marked

2. Identification number – legibly marked
3. Wire rope in good condition –broken wires, kinks, corroded, worn,
damaged, etc.
4. Drum flanges – broken / damaged
5. Brakes - ineffective
6. Bolts holding members –missing / broken / loose
7. Frame - distorted
8. Electrical connections – unsecured, taped,
9. Limit switch - working
10. Guard / covers – missing / damaged
11. Hook safety catch – missing / damaged / ineffective / in good
condition
12. Hook – distorted / worn
13. Equipment safe to use
Trolley Acceptable Not

acceptable

3. Frame and side plates – loose / distorted
4. Wheels – worn / damaged / unsecured
5. Controls – damaged
6. Hand chain - damaged
Acceptable Not
Runway Beam acceptable
Rev. No.: 00

3. Structural defect –welds cracked
4. Structural defect – distorted members
6. End stops –missing / damaged
7. Track – even and leveled
8. Trolley –moving itself
Acceptable Not
Slewing Jib Crane acceptable

3. Structural defect –welds cracked
4. Structural defect –distorted members
6. End stops –missing / damaged
7. Jib –moving itself
8. Trolley –moving itself
9. Rings / hook – worn / damaged / twisted
10. Safety catch – missing / damaged / ineffective / in good condition

Rev. No.: 00
Acceptable Not
Wire Rope Sling acceptable

3. Wires – broken
4. Rope – Incorrect size / damaged due to heat or chemicals /
kinked / Corroded / worn / abraded
5. Strands - protruded
6. Master link - distorted
7. Ferrule – split / broken
8. Thimbles - distorted
9. hook – worn / damaged / twisted / in good condition
10. Safety catch – missing / damaged / ineffective

Rev. No.: 00
Acceptable Not
Chain pulley block acceptable

3. Chain – worn / links bent / notched / corroded / stretched / lack of
articulation
4. Frame – distorted
5. Slack and anchor - unsecured
6. Covers – missing / damaged
7. Hook – distorted / in good condition
8. Safety catch – missing / damaged / ineffective / in good condition
Acceptable Not
Chain Sling acceptable

3. Chain – worn / links bent / notched / corroded / stretched / lack
of articulation
4. Rings / master link – worn / distorted
5. Coupling components – distorted / cracked / pins insecure
6. Hook – distorted / in good condition

7. Safety catch – missing / damaged / ineffective

Rev. No.: 00
Acceptable Not
Polyester Webbing sling acceptable

3. Stitching – damaged / loose
4. Webbing – cut / damage due to heat or chemicals / frayed / solar
degradation / core exposed
5. Eye end fittings – cut / damaged
Acceptable Not
Shackle acceptable

3. Body – distorted, nicks, cracks, gouges
4. Pin – Incorrect, bent
5. Screw threads – damaged / incomplete
6. Nut - missing
7. Split pin - missing

Rev. No.: 00
Acceptable Not
Eyebolt acceptable

3. Screw threads – damaged / worn / incomplete
4. Shank – bent
5. Eye – distorted / worn
6. Underside of collar – not flat
Acceptable Not
Lifting Beam and Spreader acceptable

3. Welds - cracked
4. Bolts – loose / missing / broken
5. Beam – distorted
6. Suspension point – distorted / cracked / holes worn or elongated
7. Attachment point – distorted / cracked / holes worn or elongated

Rev. No.: 00
Acceptable Not
Wire rope grip / pull lifting machine (tirfor) acceptable

3. Casting – damaged / Shear pins – distorted / broken
4. Operating levers - distorted
5. Hook - distorted
6. Safety catch – missing / damaged / ineffective / in good
condition
Standard Hand Signals for Crane Operators
The signalman must:

 be in clear view of the crane operator, be aware of the standard signals for operators
 have a clear view of the load and the equipment
 keep persons outside the crane's operating area
 Never direct a load over a person.
 Hold hands away from body so that the operator can clearly see them.
 hold hands to side of body out of shadow if he is in the direction of the sun
 Always give signals according to the operator's right or left.
 Not give more signals than the operator can perform at one time.
 Use a middle-man to transfer hand signals when you can't see the operator, or a radio.

Rev. No.: 00

Rev. No.: 00

Rev. No.: 00
FORKLIFT SAFE OPERATION TECHNIQUES
1. Avoid
 loose objects, bumps or uneven floors
 rough surfaces 4. Driving forklift
 wet and oily surfaces  Drive at a slow and steady pace
 Observe speed limits
2. To increase forklift stability  Slow down for turns
 Space forks as far apart as possible  Drive in reverse if vision is obstructed
 Secure loose or slippery items  Yield to pedestrians
 Wrap or strap loads  Never drive up to anyone standing in
 Transfer loads on broken pallets to front
sound ones.  Do not ride people on forks or
counterweigh – no passengers
3. When working with load  Do not allow anyone to walk or stand
 Ensure area is clear of people under forks
 Stop before raising or lowering loads
 Rest the load against the mast
 Tilt the load slightly back with forks low
 Keep traveling position with load
maximum six inches above ground
 Never travel or turn with load elevated

Document ID No: MSSM-1-SF-001
Power & Water Utility Company for
Rev. No.: 0
Jubail and Yanbu (MARAFIQ) Valid Until : November 12 2010
MARAFIQ SAFETY MANUAL
PARKING FORKLIFT
----------------------------------------------------------Driving a forklift on slope
Page 213 of 28
Rev. No.: 0
FORKLIFT SAFE OPERATING TECHNIQUES

JUDGE YOURSELF
Page 214 of 28
Rev. No.: 0
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Power & Water Utility Company Document ID No: MSSM-1-SF-001

For Jubail and Yanbu (MARAFIQ) Page:190 of 363

MARAFIQ SAFETY MANUAL Valid Until : November 12 2010