Method Statement for Steel Structure Lifting Operation

Aktogay Copper Project Sulphide PlantMethod Statement for Steel StructureLifting Operation11250-ZB-NFC-3000-MS-S-0046B01-Dec-2015Re-Issued for Review/CommentYang DezhuangGe WanjiaGuan ChengmingA 28-Mar-2015 Issued forReview/CommentShi Yajun Chen Shehua Sun Yuanpeng Rev# Date Reason for IssuePrepared byReviewed byApproved byTable of ContentsI. Purpose (3)II. Work Condition (3)III. Scope of Work (3)IV. Material and Equipment (3)V. All the Personnel for the Project (3)VI. Operation Process (4)VII. Risk Assessment (7)VIII. Health and Safety (10)I. PurposeThis project is a newly-built project invested by Kazakhmys Copper Company, handling ores 25,000,000 tons / year. This method statement is used to describe the construction method for Kazakhmys Copper Concentrate Project’s steel structure hoisting operation.II. Work Condition1) The crane must have a reasonable position.2) The lifting operation should consist of three parts: the crane driver, the rigger and the lifting personnel, and special types of workers must hold certificates and qualification certificates of local place.3) The crane must have passed the annual verification and meet the requirements.III. Scope of WorkThis construction scheme includes the required personnel and the procedures which the workers need to observe in the process of lifting operation.IV. Material and Equipment4.1 The project includes 2 260-t crawler cranes, 1 TCT7527-20-type tower crane, 1 100-t auto crane, 2 80-t auto cranes, 2 70-t auto cranes, 4 55-t auto cranes, 6 25-t truck cranes. All types of cranes are equipped with corresponding slings, fixtures, etc.4.2 Inspection and maintenance：All lifting equipment shall be inspected monthly.A register of all lifting equipment is to be maintained slings, chains, hooks and shackles will be stamped with the approved load limitation. Lifting equipment that is damaged must be destroyed by cutting.V. All the Personnel for the ProjectThe operation staff of preliminary arrangement is shown in the table below:VI. Operation Process1）Crane operator and rigger must hold a job card ；each crane must be equipped with a fixed crane driver, and other people are not allowed to operate.2）Crane drivers must be trained, understand the structure and use of machinery, must be familiar with the mechanical maintenance and safe operation, and personnel not for installation or maintenance are not allowed to climb the tower crane without permission. The normal operating temperature of crane is -20 ~ 40 ℃, and the wind speed is less than 13 m/s. In case of thunderstorms, heavy rain, fog and other weather, the crane should stop working. Lifting job can only be carried out after the adjustment of unloaded, static, dynamic load tests and a variety of safety devices. Static load test hoist is 125% of the rated load, dynamic load test hoists with 110% of the rated load. After the crane stops working, we should check and ensure that the jib can rotate freely with the wind.3）Carefully check that the lifting hooks, rigging, etc are intact, and after they are confirmed to be reliable, normal operation can be carried out.4）Tower cranes,crawlers crane and under truck crane must be with good electrical ProfessionNumber of personsProfessionNumber of personsDecision-making layer Administrativestaff1Operation layerLifting worker18Executive layerTechnician1Crane worker 36The qualityengineer 1 Car driver18 Safety officer2Total77a tower crane or near the standard section is not permitted.5）Tower crane machines should be implemented with given set of people and a one-machine-one-person personal responsibility system, and non-crew personnel are not allowed to enter the driver’s cab without permission; when we deal with electrical hazards, there must be two or more full-time maintenance staff members.6）The crane driver should cooperate closely with the command staff, setting the same channel when using walkie-talkies, gently lifting up and down with noted signal, and preventing impact, drag or dumping.7）When lifting, please gently fetch up and put down, reduce noise and prevent the impact on the surrounding residential environment.8）After getting the command signal, the crane driver can start to operate. Before operation, the crane driver must whistle and concentrate attention when operating.9）Ten principles for not lifting of cranes: ①Hanging objects over the mechanical properties of the allowable range should not be hung;② When command signal is not clear; ③ There are people under the objects being hung; ④ When there are people standing on the objects being hung; ⑤Substances buried in the ground; ⑥Cable stayed and oblique pull; ⑦Fragmented small objects without container; ⑧Not strong and loose materials; ⑨Hanging weight is unknown, utensils hanging pull with non-compliance. ⑩When there are level 6 or stronger winds.10）Crane drivers must be in strict accordance with the magnitude of the crane characteristics specified in the table from the weight of the work, and should not be used with overload.11）Cranes shall not be operated with cable-stayed or oblique hanging items, and a similar ban for pulling piles operation.12）When a crane works, people are not permitted on the tower ladder, and adjustment or repairing machinery and other operations are not allowed during work.13）When a crane works, non-authorized person are not permitted to approach the range of activities for the crane.15）When a crane works and rotates, using brake to stop the crane is forbidden.16）When a crane works, swing mechanism is with a two-speed motor without disc brake. Operation should be manipulated by stalls, and shift can only be operated after a first speed stability. If reverse operation is needed, we must use handle to back to zero, and then by stalls. Disc brake is only for fixing the jib of tower crane under windy condition operation.17）The stress strength of all the poles, steel wire ropes, lifting power and anchoring facilities that bear force should be checked, and the safety coefficient should not be less than 3.0. The safety coefficients of wire ropes should be confirmed according to the use situation: the coefficient for wind cable ropes is 3.5, that for cable cranes and load-bearing machines is 3.75, that for manual lifting equipment is 4.5, that for motorized lifting equipment is 5-6, that for no-bending slings is 6-7, and that for bundled hoisting is 8-10 (due to abrasion or breaking, the stress strength of steel wire ropes should be reduced according to the standard until the steel wire ropes are discarded as useless.)18）All drag ropes (cable wind ropes) require more than φ12 mm wire ropes, and need to be set up with a dedicated ground anchors. They are not allowed to be bolted on electrical poles, trees or scaffolding. Anchors must be buried according to the standard size of the force with an appropriate position. The angle between drag ropes and the ground should not be greater than 45 °. If in a limited condition, anchors should be properly buried in deeper so as to increase the pressure in the vertical direction.19）Lifting steel ropes can be clamped, clip direction should be consistent, spacing should be 5-6 times, U-bolt is fastened at the tail end of the rope, and pressure plate should be pressed on the force rope.20）When we are using a few ropes for rigging or when we are lifting heavy objects with a rope rolled into several branches, every piece or each branch wire should be with a uniform stress, and the angle between the rope and the ground shall not be less than 45 °.21）The contact point between the rigging and heavy sharp edges should be filled by using sacks, rubber, wood and washer others, and we should reduce the breaking force according to the deformation of wire rope angle(breaking force is calculated according to the provisions) .22）The personnel who bundle up heavy weights and pull hooks should pay attention to the hook and see whether the wire rope are in a good condition. The objects being hung should be tied securely, the hook should be on the center of gravity, the objects being hung should be vertical, and oblique hanging or cable stayed are not permitted. When objects are being lifted, nobody is allowed to stand on top of or under the objects being hung.23）When the tower cranes, crawlers crane and under truck crane is in non-working condition, slewing gear brake must be loosened. When hook rises, the car stops at the end of the boom, which is the most significant place.24）Pay attention to the construction environment, and check whether there are hazardous locations, overhead power lines and other obstructions within the operating range. If necessary, we should set up forbidden zones and arrange special persons to watch and guard, and workers should wear and use protective equipment or appliances according to the regulations.25）Crane drivers should strengthen the routine maintenance on equipment to maintain good performance of the crane and keep it in a normal operation and should keep the body of the machine clean.26）The crane rental units should arrange technical personnel to check the tower cranes,crawlers crane and under truck crane every month. If problems are found, repair the machine timely. Operation with machines in a bad working condition is not permitted, and pay attention to material savings when doing the maintenance.27）Pay attention to those objects that can easily cause dust during lifting, prevent damage and pollution to the surrounding environment, stop the crane when there is a great wind(greater than or equal to level 6).28）When people are working at night, the tower cranes,crawlers crane and under truck crane itself should have lighting equipment, and the construction site should also be equipped with adequate lighting equipment. At night, whether the tower crane is in operation or not in operation, power supply for obstruction lights should be connected.There must be a construction permit at night.VII. Risk AssessmentWork Scope WorkPhaseIdentified RiskLikelyConsequenceControl MeasuresLiftingFailure to obtainpermits for liftingwork according to theregulationsOperatingagainst theregulations tocause accidentsApply for permit of work prior to every lifting work inaccordance with the regulations.Insufficient personalprotective equipment(PPE)Incidents andinjuriesWorkers should be equipped with PPE, safety belt,hamlet and life vest, and thorough checking shall becarried out.Operators are nottrained with safetyregulationsInjury to personsWorker training prior to lifting work and site trainingaccording to the regulation.Inadequate monitoringand supervisors not inpositionDealing withincidents nottimely, resultingin seriousaccidents.Constant monitoring by well trained personnel andoverall examination before start working.BeforeliftingInadequate fireequipment andimproper emergencyrescue measuresThe accidentbecomes moreserious, causinginjury to persons.Verify emergency supplies, such as fire equipment andmedicines are in place, make the authorized rescue plan,once accident happens, carry out the rescue work by theplan.Steel rope strings arebadly damaged, orsafety factor of theropes is unqualifiedFalling fromhigh positionsand injury topersonRegularly check the wire rope every month, if qualified,color coding according to different months, if anydamage is found, forbidden to use.Defective or Damagedmaterials and toolsThe accidentbecomes moreserious, causinginjury to persons.Overall examination before using strictly in accordancewith the regulations.No safety distancewith power facilities,operation site does notmeet the requirement.Injury to personsThe ground must be firm and reliable for operation andparking, and the operation site must has a safe distancewith the power lines.Lack ofcommunication withthe site, unclear signaland incorrectcommanding.Injury to personsand damage topropertiesEstablish contact with appointed person and commandusing unified signals.No safety cordons orwarning signs.Injury to persons Delineate cordons and set warning signs. Non-constructionpeople enter into construction site Injury to personsDesignate person to monitor and safeguard, or put upwarning signs.Lifting BeforeliftingNot strictly enforcethe lifting jobs "tenno-liftings"Injury to personsComply strictly with:Do not lift with unclear signals or incorrectcommanding;Do not lift overloads or when weights cannot be sure;Do not lift stayed weights;Do not lift under dark situation;Do not lift when persons stand under or on the weights.Do not lift buried objects;Do not lift when weights are not fastened, or ropes knot;Do not lift sharp-edged objects without cushions;Do not lift when safety equipments do not work;Do not lift when wind speed reaches 11m/s.Make the buildings orstructures as stresspoints of liftingInjury to persons Obtain the check and approval from authorization.Lift improperlyInjury to persons Do a short pre-lift with low angle.Lifted weights stay inthe air for certaintime.heavy objectsbreak ormachinerycollapseWell-training to operators, and violators must bepunished.Process the liftedheavy objectsInjury to persons Provide constant monitoringAdjust or repair thecranes in the lifting.Falling fromhigh positionsand injury topersonOverall examination to the cranes and make records.Leakage of hazardousmaterial or otherabnormalitiesInjury to persons Stop working and withdraw the personnel.AftercompletionNot clean up the site Injury to persons Clean up the site timelyVIII. Health and Safety1) All staff should comply with the provisions of HSE management plan.2) All construction personnel all should pass the physical examination, and special workers should have a special type of working certificates.3) The tools and equipment used in construction should be careful inspected before we use them, and they only can be used after being qualified, The tools and equipment need to check every month.4) The scaffolding used in construction shall be erected and dismantled by special personnel.5) We must carefully check whether the lifting eye’s welding is firm before lifting and check whether the rigging and shackle meet the requirements.6) Workers can work only after all the trial lifting of the cranes without mistakes before lifting.7) Environment protection is everyone's responsibility.8) The personnel entering into the construction site should correctly wear safety helmet, and wearing slippers and sandals, high-heeled shoes, or shoes with nails is strictly prohibited.9) Before construction, we must tell the real situation about the safety technical, and then we can start work.10) Entering into the construction site after drinking or quarrelling and fighting noisily on the construction site is strictly prohibited.11) There should be a special person responsible for connecting power supply for the construction. Connecting power source without permission is strictly prohibited, so as to prevent electric shock accidents.12) Irrelevant personnel are not allowed to go through the crane working radius or stay inside it. Warning ropes should be set up around the construction zone.walkie-talkie command crane, the crane should be equipped with spare batteries, the hook must have anti-unhooking device, the size of steel wires must be decided according to the object’s size. During hoisting, the wire ropes must undergo angle wrapping handling (or use the snap rings).14) When working at heights, we must use safety belts correctly. Safety ropes must be set up inside a flue, and they shall be firm and reliable. Safety belts are connected to the safety rope. The working position of the personnel should be lower than the connection points between the safety belts and the safety rope.15) When working at heights, we shall neither sit on the platform or edge of holes, nor ride on the railing, nor stand outside of the railings to work or by virtue of rail lifting objects.16) When we are working at heights, the objects of spot welding shall not move at will.17) The holes and groove channels around the construction site should be covered with a cover plate or enclosure, and warning signs should be set up.18) We should reduce the cross operation in construction as possible. When cross operation must be carried out, we should erect tight, firm protective isolation facilities between the layers.19) The channels of cross workplace should be kept clear; if there is a risk of entry and exit, a fence or warning signs should be set up.20) The crane must be equipped with the required fire fighting equipment and first-aid boxes.21) When the lifting operation is conducted at night, lighting should be adequate. It is necessary a work permit to use a crane at night.22) Smoking on the construction site is prohibited. We should keep the site clean and tidy, and do a good job in the way of civilized construction.23) When the wind is above level 6, no outdoor lifting operation is allowed.24) When there is fog or a thunderstorm, we should stop lifting operation.25) Access to areas where lifting operation are carried out shall be restricted.26) Areas where cranes and other lifting equipment operate which may endanger otherpersons shall be clearly demarcated and sign-pasted.27) Accessible areas within the swing radius of the rotating superstructurecounterweight of a crane will be fenced to prevent personnel being struck or crushed by the counterweight.28) In all lifting operations a single person shall have overall responsibility for the task.29) The lifting of persons shall only be done in a approved certified designated work box or basket, securely attached to the crane. A safety harness shall be used at all times for work platforms.30) The cranes must have in the work place the following documents:1. Crane passport;2. Inscription in the region (oblast).3. Operation and maintenance manual.4. Load chart.31) Crane operators must have certification for the type crane used.32) Riggers must show receipt certification by accredited company.33) Man lifts must have maintenance log.34) Man lifts operators must show receipt certification by accredited company.35) Lifting equipment must have valid inspection certification from a reputablecompany, include cranes, man lifts, forklifts etc.。