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इंटरनेट मानक

Disclosure to Promote the Right To Information


Whereas the Parliament of India has set out to provide a practical regime of right to
information for citizens to secure access to information under the control of public authorities,
in order to promote transparency and accountability in the working of every public authority,
and whereas the attached publication of the Bureau of Indian Standards is of particular interest
to the public, particularly disadvantaged communities and those engaged in the pursuit of
education and knowledge, the attached public safety standard is made available to promote the
timely dissemination of this information in an accurate manner to the public.

“जान1 का अ+धकार, जी1 का अ+धकार” “प0रा1 को छोड न' 5 तरफ”


Mazdoor Kisan Shakti Sangathan Jawaharlal Nehru
“The Right to Information, The Right to Live” “Step Out From the Old to the New”

IS 13367-1 (1992): Safe use of cranes - Code of practice,


Part 1: General [MED 14: Cranes, Lifting Chains and Related
Equipment]

“!ान $ एक न' भारत का +नम-ण”


Satyanarayan Gangaram Pitroda
“Invent a New India Using Knowledge”

“!ान एक ऐसा खजाना > जो कभी च0राया नहB जा सकता ह”


है”

Bhartṛhari—Nītiśatakam
“Knowledge is such a treasure which cannot be stolen”
,

IS 13367 ( Part 1 ) : 1992


(Reaffirmed 2003)

Indian Standard
SAFE USE OF CRANES- CODE OF PRACTICE
*
PART 1 GENERAL

UDC 621’873 : 614’8

0 BIS 1992

BUREAU OF INDIAN STANDARDS


MANAK BHAVAN, 9 BAHADUR SHAH ZAFAR MARG 1‘

NEW DELHI 110002

September 1992 Price Group 11


--- x

Cranes, Lifting Chains and Associated Equipment Sectional Committee, HMD 14

CONTENTS
PAGE
1 SCOPE ... .. . . ... I
2 REFERENCES ... ... .. . . .. 1
3 DEFINITIONS ... ... .. . ... 1
4 MANAGEMENTOF THE LIFTINGOPERATION ... . .. .. . 1
5 PLANNINGOF THE LIFTING OPERATION ... ... 3
6 SELECTION OF PERSONS ... ... .. . . .. 3
7 RECOMMENDEDMINMUM ATTRIBUTES ... .. . .. . 4
8 DESCRIPTION AND SELECTIONOF TYPES OF CRANES .. . ... 7
9 SAFETY ... ... . .. ... 8
10 SITING OF CRANES ._. ... . .. ... 10
11 ERECTION AND DISMANTLING .. . ... ... .. . 12
12 PROCEDURES AND PRKAUTIONS . . . .. . .. . . .. 13
13 OPERATING CONDITIONS . .. ... .. . ... 15
14 TESTING AND EXAMINATION ... . . . .. . .. 20
15 LEGAL REQUIREMENTS ... ... ... .. . 22
16 ROPES ... .. ... .. . *. . 22
17 SLINGINGAND HANDLINGOF LOADS ..* ... ... 31
18 RAISING OR LOWERING OF PERSONS ... ... .. . 32
19 BALLINGOPERATIONS ... ... .. . ... 32
20 SIGNALLINGSYSTEMS ... ... ... ... 33

TABLES
1 SEVERITYOF DETERIORATIONOF STEELWIRE ROPES *.. ... 30
2 TYPICAL EXAMPLESOF CUMULATIVE EFFECT OF DETERIORATION OF STEEL WIRE ROPES 30
3 WEIGHT OF MATERIALS ... ... ... . .. 31

FIGURES
1 EFFECT OF A SWINGING LOAD ON LOAD RADIUS . . . ... .. 2
2 RECOMMENDED
CRANE SIGNALS ... ... ... 5
3 TRAVELLINGUNDER OVERHEADELECTRICLINESAND CABLES ... ... II
4 SIDE LOADINGON JIB ... ... ... ... 16
5 CORRECTMETHODOF PAYING OUT ROPE ... ... ... 23
6 SERVINGOF ROPES( BEFORECUTTING) .. ... ... 24
7 TRANSFERRING
ROPE FROMREELTO DRUM ... ... ... 25
8 PARTSOF THE CRANE TO BE CONSIDEREDDURING THEEXAMINATION ... 28

FOREWORD

This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by
the Cranes, Lifting Chains and Associated Equipment Sectional Committee had been approved by
the Heavy Mechanical Engineering Division Council.

It is in the interest of all those involved in lifting operations to ensure that lifting operation are
carried out efficiently and safely. It is the aim of this code to assist crane users to achieve these
objectives.

It is felt that management and organization of such operations are the foundation stones 0; which
the successful operations may be built. These foundation stones are essential to all operations
regardless of the type of crane being used.
( Continued on third cover )
IS 13367 (Part 1) : 192

Indian Standard
SAFE USE OF CRANES - CODE OF PRACTICE
PAR? 1 GENERAL

1 SCOPE experience of the crane and the equipment used in


the lifting operation as is necessary-to- carry out the ,!
X,1 This standard gives guidance for the safe use of function to which the term relates in each particular !
i
all types of cranes. Subjects covered include safe context.
system of work, management, planning, general
recommendations for selection, installation, testing, 3.4 Driver ,
operation and maintetince of aan& and for the selection
of drivers, slingers and signallers. The person who is operating the crane for the purpose
of positioning loads.
1.2 Reference is also made to relevant legislation and
attention is drawn to statutory requirements for the Driver does not include any person who is operating
testing and examination of cranes. a crane for erection of the crane itself. f

3.5 Lesld Radius Indicator


2 KEFERENCES
A deviee fitted on a crane that shows the radius of the I
The following Indian Standards are necessary adjuncts
hook and the corresponding safe working load.
to this Standard:
IS No. . Title 3.6 Radius

808 : 1989 Dimensions for hot-rolled steel The horizontal distance between the point at which the
beam, column, channel and angle centre of rotation of the crane meets the ground, and
sections ( third revision ) the vertical centreline through the hook (see Fig. 1).
8324 : l“76 Code of practice for safe use and 3.7 Safe Working Load
maintenance of non-calibrated
round steel link lifting chains and The maximum load that can be safely handled by a
chain slings crane at a specified position and under specified
conditions.
3’ DEFINITIONS
3.8 Service Conditions
3.0 For the purposes of this code, the following
definitions shall apply. ai In-Service - With the crane handling loads
up to the safe working loads in permissible
3.1 qppointed Person wind pressures specified in the appropriate
Indian Standard.
The person appoiated by @e management or
organization requiring the lifting operation to be b) Out-of-Service - With the crane either not
undertaken who will be responsible for all aspects of required for use, or out of use when wind
the lifting operation. pressures exceed those permitted for in-
service conditions, and without load on the
3.2 Automatic Safe Load Indicator hook.
A device fitted to a crane, or incorporated in its
design, that automatically gives5visual indication to’ 4 MANAGEMENT OF THE LIFI’ING
the driver when the load being lifted pr carried by the OPERATION
crane approaches the safe working load, and that
also gives a continuous audible warning to the driver 4.1 Safe System of Work
and other persons in the vicinity when the load
being lifted or carried exceeds the safe working A safe system of work (see 9.3) should be established
load (see also 3.7 ). Under certain statutory and followed for every lifting operation. T%is should
regulations the automatic safe load indicator should include the planning of the operation, the provision,
be of a type approved ,by the Chief Inspector of selection, maintenance and examination of the correct
Factories (see also 3.5). equipment and the provision of properly trained,
competent personnel with adequate supervi,sion.
3.; Cliompetent
yet-son
The lifting operation should be taken to i&de any
A person who is deemed to be competent and has. necessary preparation of a site and erection and
such practical and theoretical knowledge and such #dismantling of the crane or cranes.

1
Always lift loa& gently and operate.cratre motions smoothly to avoid load swinging. ( A swinging load will increase the overturning moment
of the aanes.) Use steady lines where necessary and where tbe load presents a wind catching area. Always travel with the load near to ground *
level so load swinging can bk countrolled.
..
FIG. 1. E OF A SWINGING LOAD ON LOAD RADIUS

The same principles should be applied when a series of lifting gear and equipment, instruction and
lifting oKrations are being carried out at one site or the supervision as is necessary for the task to be
crane is a permanent fixture, for example, in a factory undertaken safely. This should include
or at a dock. consultation with other responsible bodies, if
necessary (see 9.3), and ensuring that where
4.2 Appointed Person different organizations are involved they
collaborate as necessary.
The management of the organization requiring the
lifting operation to be undertaken should appoint a b) Ensuring that there is an effective procedure
person with appropriate training and experience who for reporting defects and incidents (see 12.3)
should be competent. This person should be known as and that adequate maintenance of the
the appointed person. ’ equipment is carried out.

The appointed peion need not be an employee of the c) Responsibility for the organization of the team
organixation and will not normally undertake the duties involved in the lifting operation.
of crane driver, slinger or s&taller.
d) The nomination of persons to undertake the
4.3 Duties of the Appdmted Person duties required for the operation including
those listed in S or ensuring that this
The management of the organjzstion requiring the responsibility is delegated to an appropriate
lifting operation to be undertaken should specify the person or organization.
‘-duties of the appointed person which should include:
e) Responsibility for control 0; the lifting
a) The assessment of the lifting operation to operation. This duty may be delegated to
provide such planning, selection of crane(s) another person where considered appropriate
2
IS 13367 (Part 1) : 1992
by the appointed person. It is undesirable that 5.3 Planning for the Permanently Installed Crane
this duty should be undertaken by the crane
driver because of the need for the crane driver Where a crane is instalkd to carry out’ a number of
to be at the crane controls throughout the operations or is installed as a permanent fixture, the
operation. planning should be carried out prior to the selection
and installation of the crane. Account should be taken
The appointed person should be given the necessary of the continuing lifting requirements and the loads
authority for the performance of all these duties and that are likely to be lifted. The operations should be
in particular, authority to stop the operation reviewed periodically to check that the size and nature
whenever he considers that danger is likely to arise of the loads have not altered significantly and that the
should the operation continue. crane and equipment are still suitable for the duty
required of them.
5 PLANNING OF THE LIFTING OPERATION
5.4 Minimum Planning I
5.1 General
Lifting operations whose consideration shows that
Every lifting operation including crane erection and there are no hidden diffkulties with access, erection
dismantling should be planned to ensure that it is and dismantling, obstructions, hazards or other
- carried out in a safe manner. The extent of detailed complicationsshouldonlyrequire minimumplanning.
planning will depend on the complexity of the overall Following the selection of a suitable crane and range of
operation but no operation should be considered so lifting gear and equipment for the loads to be lifted,
simple that the planning can be ignored. The plan such operations may be delegated to the team of
should never permit exceeding the safe working load slinger(s) and crane driver after they have been fully
of the crane or equipment. briefed on their task.

5.2 Planning 6 SELECTION OF PERSONS

For a lifting operation where there are obs1ructions 6.1 General


and hazards, or where ground conditions are suspect,
or the load being handled is in any way unusual, a Safe lifting depends on the selection of suitable
high degree of detailed planning, including persons who are competent to carry out the required
. determination of the load and its characteristics duties. The appointed person should ensure that
(including centre of gravity), the investigation of the persons involved in the operation are efficiently
ground conditions, the nature of any obstructions and oganized to ensure good, team work in the
hazards and the method of slinging and of controlling working situation and that no member.of the team
the movement of the load throughout the lifting has his efficiency impaired because of alcohol or
operationshould be carried out. Anessential feature of otherdrugs. All persons inthe teamshould beaware
this planning should be the production-of plans and of their duties which should be as listed in 6.2.1
elevations of the lifting operation at all critical phases to 6.2.5. Responsibility should only be delegated to an
from the initial siting of the crane to the final landing extent that is appropriate, taking into account the
. of the load. A written statement outlining the duties of, ability, competence and authority of the person
and action required from, each member of the team concerned.
should be produced and all members of the team
should be fully aware of tbe contents of this statement. The appointed person should choose persons who
are fit and either competent or who are under
If the crane(s) called for by the planning, has to be appropriate training and supervision. The
erected before commencing work and dismantled recommended attributes for persons involved in lifting
after completion then these phases form part of the operations are given in 7.1 to 7.5.
overall operation and the appointed person should
ensure that all relevant factors including space, 6.2 Duties of Persons
suitability of ground and access are given due
consideration. In any case, safe access to the site of 6.2.1 Crane Driver
lifting operations is always an important The crane driver should be responsible for the
consideration. correct operation of the crane in accordance with
the manufacturers instruction book and the plan. In
Lifting operations involving the simultaneous use of some cases, the. crane driver may be responsible for
more than one crane carry a higher risk facior than erection and dismantling of the crane. The crane
those using only one crane so that additional care driver should at any one time only respond to the
should be taken in their planning (see 13.4). It is also signals from one slinger/signaller who should be clearly ,
essential that the drivers, slingers and the person in identified.
charge are thoroughly briefed with particular
emphasis on the effect that the operation of one crane 6.2.2 Slinger
has on the other(s). Three dimensional scale models t
should be considered a useful aid to the team briefing The slinger is responsible for attaching and detaching
for particularly complicated lifts. the load to and from the crane hook and for the use of

3
IS 13367 (Part 1) : 1992
the correct lifting gear and equipment in accordance 7 RECOMMENDED MINTMUM ATTRIBUTES
with planning of the operation.
7.1 Crane Driver
The slinger is responsible for initiating anddirecting
the safe movementof the crane [see 7.2(h)]. At any one The crane driver should:
time, dependent upon the physical position of the
slinger or slingers, only one slinger should have this a) be wmpeted;
responsibility.
b) be more than 18 years of age except when
under the direct supervision of a competent
Where this slinger is not visible to the crane driver,
person for the purpose of training;
another slinger or a signaller should be employed to
relay the signals to the crane driver. Alternatively, c) be fit, particularly with regard to eyesight,
other audio or visual methods should be used such as heating reflexes, tbe stature to operate the
telephone, radio or closed-circuit television. cranesafely, ability to judge distances, heights
and clearances;
To cover the possibility of failure of the audio or
NOTE- Evidencethatthedriverismedical~ tittodriveacrane
visual method, a separate system should be available should be obtainedat not more than 5 yearly intervals and should
to enable movement of the crane(s) or load(s) to be be made available to the appointed person.
safely halted. There should be no further movement of
the crane(s) or load(s) until means of signalling have 4 have been adequately trained in the type of
been restored. crane being driven and have sufficient
knowledge of the crane and its safety devices;
If responsibility for directing the crane and load is to
be transferred to another person, the slinger should 9 understand fully the duties of the slinger and
retain responsibility until such time as the slinger signaller and be familiar with the signal code
considers it necessary to transfer the responsibility. At shown in Fig. 2 and any alternative methods of
this time: relaying the signals which are to be used for
the operation being undertaken in order to
a) the slinger should clearly indicate to the crane $implement safely the instruction of the slinger
driver that this responsibility is being , or signaller;
transferred and to whom;
f) be familiar with the fire appliances on tbe
b) the slinger should clearly indicate to the new crane and be trained in their use;
slinger or signaller that this transfer is taking
place; g) have beenauthorized to operate the crane. The
appointed person in giving this authorization
c) the driver and new slinger or signaller should should take competence, training, recent
clearly indicate that they accept the transfer of experience and fitness into account.
responsibility. NOTE- It is also recommended that a record of the drivers
training and experience is maintained. Such records should be
.made available to the appointed persoa
6.2.3 S&taller

The signallet should be responsible for relaying the 7.2 Slinger


signalfromtheslingertothecranedriver.Thesignaller
may be given the responsibility for directing movement The slinger should:
of the crane and load instead of the slinger, provided
that only one person has the responsibility.
a) be competent;
b) be more than 18 years of age except when
under the direct supervision of a competent
6.2.4 Crane Erector
person for the purpose of training; ,
Thb cran’eerector is responsible for the erection of the 4 be fit, with particular regard to eyesight,
crane in accordance with the manufacturers lnsttuctions hearing, reflexes, agility, having the physique
(see 11). to handle lifting gear and equipment and be
able to establish weights, balance loads and
Where two or more crane erectors are required, one judge distances, heights and clearances;
should be nominated as ‘erector-in-charge’ to control
the operation. 4 have been trained in the techniques of sling-
ing;
6.2.5 Maintenance Personnel , e) be capable of selecting lifting gear and equip-
ment from that provided, suitable for the load
The maintenace personnel should be responsible for to be lifted;
maintaining the crane to ensure its safe and satisfactory
operation. They should carry out all necessary f) be able to understand the signal w&e shown in
maintenance in accordance with the safe system of Fig. 2 for the crane being operated and be able
work and permit to work (see 9.3 and 9.4). to give clear and precise signals;

4
IS 13367 (part 1) : 19J)2

d be capable of giving precise and clear verbal bearing, PE&X~S, mobility, rbil@ t? judge
instructions where audio equipment (e.g., distances, heights and clearances;
radio) is used and be capable of operatiag the
equipment; d) understand tbt signal code shown in Fig. 2
for the crar~e bei& operated aad be able to
h) be capableof initiating and directing the safe give clear and pre~ise.sig,nals; ’
movement of the crane and load; and
e) be capable of giving precise and clear verbal I
3 have been nominated by the appointed person instructions where audio equipment (e.g.,
to carry out slinging duties. radio) is employed and be capable of operat-
I
ing the equipment;
7.3 Signaller
f,) be capable of directing the safe movement of I
The signaller should: the crane and had:

a) be competent; g) have been nominated by the appointed per-


son to carry out signalling duties; and
b) be more than 18 years of age, exapt when
under the direct supervision of a competent b) be aware of the responsibilities allocated by
person for tbe purpose of training; the appointed person to the crane driver and
4 be fit with particular regard to eyefight, slinger.

OPERATIONS START

IN DIRECTION INDKATED 518 DOWN

l NOTE - Tbc sigualkr should stand in a secure pusitioa where HE CAN SEE THE LOAD AND CAN BE SEEN CLEARLY by I~G
driver. Facing towards the driver is possibk. Eac41signal should be distinct aud clear.

FIG. CRANESIGNAU
2 RECOMMENDED -Coned

5
IS 13367 (Part 1) : 1992

SIGNAL WITH ONE HAN0


OTHER HAND ON HEAD

EXTEND JIB RETRACT JIB TRAVEL TO ME TRAVEL FROM ME


TELESCOPING JIB (SIGNAL WIt!i BOTH HANDS 1

ROTATE WRIST
OFLEFT HAND

tAVEL IN DlRECTlON tNDtCATED TWISTLOCKS DN/QFF

OPERATIONS CEASE
( ~~sfd&X.X.T~s~OLUW MY

FOG.2 REcoMMpRlEDCRANESIGNAU

7.4 Crane Erector h) be capable of selecting lifting gear and


equipment from the that provided; suitable
The crane erector should:
for the load to be lifted;
4 becompetent; ’ ,
j) be adequately trained in the erection,
9 be more than 21 years of age except when dismantling and working of the type of crane
/ under direct supervision of a competent being erected, also in the safe use and setting
person for the purpose of training; up of any lifting appliance used in the course
of these duties; and
4 be fit with particular regard to eyesight,
hearing, reflexes and have the stature and k) be adequately trained in the setting and
agility to safely handle the loads involved in testing of the safety devices fitted to the crane
crane erection; being erected and those on any lifting
appliance being used for the erection.
d) be able to work confidently and safely at
heights; 7.5 Maintenance Personnel
e) be aware of personal responsibilities under
The maintenance personnel should:
the law (civil and criminal), for personal
safety and that of others; 4 be competent; )
f) be able to establish weights, balance loads
and judge distances, heights and clearances;
b) have adequate knowledge of the machinery
they are required to maintain; v
toslinging;
have been trained in the techniques of . cl have access to manufacturer’s relevant
literature; and
6
IS 13367 (Part 1) : 1992

d) be properly instructed and trained. Where The girders support a crab fitted with hoist and
special machinery is involved this should traversing motions. ,
include attending appropriate courses given The crane is normally operated fromanelevated cabin.
by the supplier of the equipment.
8.7 High Peck&al and Portal Jib Do&Me Cranes
8 DESCRIPTIOl’4 AND SELECTION OFTYPES
OF CRANES This type of crane is specifically designed for the
rapid loading or unloading to or from ships, barges,
This code of practice covers the types of cranes etc, of general or break bulk cargo. I
referred to in 8.1 to 8.10
These cranes are usually mounted near a quay
8.1 Mobile Cranes edge on rails or in a fixed position. The rails maybe at
quay level or be elevated to facilitate the movement of
Tkc cranes consist of a jib mounted on’ a purpose cargo and transport along the quay. The cranes are
designed chassis either road wheel mounted or usually of the portal type, having a structure which
crawler tracked. They may be pemritted, when allows transport to pass beneath. The elevated
specified, to move on‘their wheels or tracks when superstructtite gives better visibility for the driver and
carrying loads or may require the use of stabilisers or improved clearance for the crane jib. The
outriggers to permit the lifting of their design loads. Superstructure of the crane is capable of being slewed
Larger mobile cranes may consist -of separate units and, although the jib may be of the fixed type, it is
which when assembled for crane duties operate on a more usually of the luffing type with level lufftng
fixed base. Enhanced duties may be obtained in included in the design. Level luffing is an
special cases by the attachment of additional structural ammgement whereby the hook moves approximately
members and counterweight or by mounting the horizontally when the jib is derricked or luffed.
mobile crane on a special base or track, or by a
combination of both. Cranes of this type are characterized by their high
hoisting, luffing and slewing speeds.
8.2 Lorry Loaders (Jib Type) Cranes of this type range in size from those suitable
This type of lorry loader consists of a jib crane for light cargo handling to very heavy lift types.
mounted on a load carrying vehicle primarily intended
8.8 Manually and Power OperatedLight C&es
for handling loads on or off the vehicle to which it is
attached. These include manually and power operated light
, cranes which can be either complete units or those
: 8.3 Tower Cranes from which the lifting appliance can be removed from
its support. The jibs/runways/tripods/shear legs may
These cranes consist of a jib mounted at an elevated
level on a vertical tower, tne jib being capable of be cant&levered, horizontal, movable or fixed.
slewing through 3600 or more. I 8.9 Container Handling Cranes
Tower cranes may be mounted on a fixed base, These cranes are specifically designed for the purpose
crawler tracks, rails or wheels or may be mounted onto of handling containers and incorporate a purpose built
another structure. spreader in their construction.
8.4 Derrick Cranes 8.10 Rail mounted Low Carriage Cranes
These cranes consist of a jib which is supported by These cranes ire usualIy equipped, in basic form,
ropes from a mast which in turn is supported either by with a de&king. jib, <and may or may not be
guy ropes, stays or other means. capable of travelling under their own power with. a
suspended load. They are suitable for use at such
8.5 OverbeadlUnderbung Travelling Cranes locations as docks, shipyards, sidings, factories, etc,
These cranes consist of a bridge girder or girders .where railwaytracks are readily available. Cranes
mounted on end carriages housing the long travel -designed specifically for railway bcea kdown or track
wheels which travel along a gantry track. laying/maintenance purposes arc covered by this
Code.
The girders support a crab fited with hoisfing
machinery having a hook, maguet or grab and 8.11 General Considerations for Selection for the
traversing machinery. The crab may support a fixed Operation
or slewing underhung jib or mast.
Each af the types of crane referred to in 8:l to 8.10
.The crane is normally operated from a cabin either areavailable ina number of different fomrs and the
suspended from the main girders or attached to the characteristics of the various machines should be
crab. considered against the job requirements. Points to be
considered in making the selection include:
8.6 Goliath Cranes
4 weights, dimensiap and charaeteritica of
These cranes have the bridge girder or girders loads; * -
mounted on vertical legs. The crane may be fixed, b) operational radii, speeds of various opera-
rail-mounted or on steerable wheels. tions, heights of lifta and areas of movement;

7
IS 13367 (Part 1) : 1992
number, frequency and types of liftingopera- its place of work, a permit to work system may be
tions; necessary to achieve a safe system of work. This
requires a specially designed form or certificate to be
length of time for which tbe crane will be
issued only when the requirements of the safe system
required or anticipated life expectancy for a
of work have been implemented. Upon completion
Frmanently installed crane;
of the work the person(s) why have carried out the
site, ground and enviromnental conditions .or work should sign tbe form or certificate to certify
restrictions arising from the use of existing that all tools have been removed from the crane, that
buildings; all guards have been replaced, that all safety
space available for crane accessis, erection, devices are operating and that all persons working on
the crane have been advised that it is no longer safe
tnrve#ig,.operatisn and dismantling, and
to do so.
any special operationil rquirements‘or Ii&-
tations imposed. , : The wdrk, permits shall be given and received back
after completion by only one authorised person. The
Reference should be made to the relevant Parts of this crahe sh$I be declared safe for operation only by that
Code of Practice for details of the different tipes of authorised persoa. I .
crane and their operational characteristics.
Following the s,igning of the-certificate, the crane can
Having decided upon the type of crane to be used, on be restored to service.
the site or building and knowing tbe overall
requirements to be involved, a crane having ,an The essential details of a permit to work system are:
adequate working margin in respect both to load, a) the crane is clearly identified;
radius and maximum book big& should be selected.
It is important tbat the craw will meet all the b> the degree of power isolafion is adequate for
requiremenls of the planned lift. I the work being undertaken;
4 isolation remains secure against unauthorized
9 SAFETY restoration of power whilst the permit to work
9.1 General is in force;

Both the person or organization having over& 4 no work other than that for which the permit
specifies should be carried out unless the per-
control of the site and the employers of people
mit is endorsed for the extra work and all
involved in the lifting operation have responsibility
persons involved are notified;
for safety. In order that this responsibility may be
effectively discharged the appointed person (see 4.2) 4 where more than one group of people work,
should be given the necessary authority to ensure that eacbpersonshall begiventhe workpermita;.d
adequate systems to achieve safety are in operation. crane shall be declared safe for operation only
\ For safety matters relating to lifiing operations this after all work permits are returned to the
will include the use, maintenance, repair and renewal person authorised to issue work permits for
of safety equipment and the instruction and repairs;
responsibilities of various personneI in relation to the
equipment. 0 all special precautions are stated;
9.2 Identification of Person Directing Craae g) the s$fe working area around the crane is
clearly defined;
Movements
The person directing crane movements (slinger or
h) the safe working load is clearly identified; and
signaller) should be easily identifiable to the crane k) that the system be monitored.
driver by wearing high visibility clothing or by otber
means. 9.5 Personal Safety Equipment

9.3 Safe System of Work The appointed person should ensure that:
For every lifting operation and before any a) personal safety equipment such as safety
maintenance, repairsoradjustmentsoranyinspections gloves, helmets, safety spectacles, safety
are carried out on a crane, a safe system of work harness, safety boots, ear defenders, etc,
should be established to ensure the safety of all appropriate for the conditions of the Iocation
personnel. The system should prevent any inadvertent is available;
restoration of the power or movement of the crane. b) the equipment is inspected before and after
The safe system of workshould be clearly documented use and maintained in good working order;
as reliance on verbal instructions alone is not enough and
to ensure safety. c) a record of inspection and repairs is
Tbe system should ensure effective communication maintained.
between all parties concerned. NOTE - II should be noted that certain safety equipment
9.4 Permit to Work (for example helmeta) may deteriorate with age or@ damaged
by impact and should therefore be renewed periodilly or after
Where it is required to carry out work on a crane at impact even though no deterioration may be apparent.

8
IS 13367 (Part 1) : 1992

9.6 Use of Personal Safety Equipment installations. Any fire extinguishers at the location
including any mounted on the crane should be scheduled
Personal safety equipment appropriate to the conditions for periodic inspection and renewed as necessary.
pertaining to the location of the crane should be
provided to all personnel working on, or visiting the 9.9 Crane Safety Equipment
location of the crane.
9.9.1 Automatic Safe Load Indicator
All personnel working on, visitingorin the vicinity of
the crane, should be made aware of the requirements An automatic safe load indicator is required on certain
relating to their personal safety and to the use of jib cranes to give warning of an approach to the safe
personal safety equipment provided. working load and a further warning when an overload
occurs.
Persons should be instructed in the correct use of the
personal safety equipment provided and be required to 9.9.2 Load Radius Indicator
use it.
A load radius indicator is required on certain jib
9.7 Access and Emergency Escape cranes. It should be clearly visible to the driver and
indicate the appropriate safe working load and radius
9.7.1 Safe Means ofAccess and Emergency Escape for whatever configuration of the crane is used.

Safe means of access and emergency escape should 9.9.3 Motion Limit Devices
be provided and maintained in good condition :
Where motion limit devices are fitted to limit hoisting,
a j for the driving position(s) of the crane; travelling, slewing, traversing, climbing or any other
b) for inspection, maintenance, repair, erection crane motion, they should be regularly inspected and
and dismantling of the crane; and maintained in good working order.
c) suitable rope, wherever necessary may be
provided for emergency escape. 9.9.4 Overload Cut Out Devices
Switcks, or other devices, may be fitted to cut out any
9.7.2 .Boarding the Crane selected crane motion when the crane is in an overload
No person(s) should be permitted to board’ a crane situation. The devices should be maintained in good
without first obtaining the driver’s agreement. The working order.
driver shouid be aware of what precautions the driver
should take whilst the person(s) is/are boarding and 9.9.5 Level I@cator
should carry these out. Where fitted, level indicators should be used in
Where the point of access is out of sight of the driver accordance with the instruction manual and maintained
a system should be provided to ensure that the driver is in good working order.
aware of the other person’s whereabouts.
9.9.6 Anemometer
In the case of a crane with pendant control, a second
Anemometers, or other wind speed measuring
person should be made responsible for ensuring that devices, should have their indicators mounted in clear
the pendant is not operated whilst the person(s) is on view of the crane driver or where appropriate, the
the crane. person controlling the lift being undertaken. The correct
When only one person has to board a radio controlled operation of these devices should be regularly
crane, this person should switch the radio transmitter verified and they should be maintained in satisfactory
off, remove the key fro-n its keylock switch and retain condition.
possession of the transmitter while the person is on the
crane. 9.9.7 Machinery Guarding
Where more than one person is to board a radio All guarding should be properly fitted whenever the
controlled crane, a driver should be placed in charge of crane is in use and maintained in good condition.
the radio transmitter to ensure that the crane is only
moved with the agreement of all persons on the crane. 9.10 Documentation
Such movements should only be permitted for
maintenance and/or inspection of the crane and 9.10.1 Safe Working Load Charts
persons on the crane should only give permission to the Safe working load charts applicable to the various
driver for movements to be made, after they have specified operating conditions of the crane, with
ensured that they are in a safe position. appropriate de-rating for special applications such as
magnet or grabbing duties, should be prominently
9.7.3 Instruction of Personnel displayed to the driver. Operation of the crane outside
Personnel should be instructed to use (and should use) these parameters even in an unloaded situation may
only the proper means of access and emergency give rise to danger.
escape.
9.10.2 Instruction Manuals
9.8 Fire Extinguishers
Instruction manuals containing adequati information
These shall be provided in all the cabins on crane on the erection, use and dismantling of the crane

9
IS 13367 (Part 1) : 1992
should be kept regularly available at the location’ofthe The loads imposed by the crane should be obtained
crane. from the crane manufacturer or other authority on
crane design and construction. The loadings shall
9.10.3 Test Certificates include the combined effects of:
All current test certificates for cranes and lifting gear
should be kept readily available.
-4 the dead weight of the crane (including any
counterweight and/or ballasting);
9.10.4 Records b) the dead weight of the load(s) and any lifting
attachment(s);
a) Records should be maintained for each crane
that are sufficient to enable the condition of 4 dynamic forces caused by movements of the
the crane to & determined and its fitness for crane; and
further operation to be properly assessed.
4 wind loadings, resulting from wind speeds up
b) The records should include: to the maximum permitted (taking into
account the degree of exposure of the site).
9 technical information including
maintenance instructions and It is likely that in-service conditions will produce the
performance data provided by the greater imposed loading but out-of-service and erection/
manufacturer; dismantling conditions should be taken into
ii) test certificates, records of thorough consideration.
examinations and inspectioti including
ropes and brakes (see 16.7.1) (whether It should be appreciated that the vertical and
statutory or not) carried out on the horizontal forces are unlikely to be uniformly
crane; distributed and an allowance should therefore be
made for these and for any other unpredictable effects.
iii) records of significant repairs and
modifications to the crane including The appointed person should ensure that the ground or
renewal of major parts; any means of support is such that the crane can operate
iv) details of occurrences which are of within the levels and other parameters specified by the
more than short term relevance [see manufacturer.
12.3 (c), 12.3 (d) and 12.3 (e)].
10.3 Froximity Hazards
4 Except where specific forms are required by
legislation, the format in which records are 10.3.1 General
kept is not important. Whatever method is
used should be adequate to ensure that the Consideration should be given to the presence of
records allow a relevant and coherent history proxidty hazards such as overhead electric lines or
of the crane to be retrieved. The records should conductors, oil/gas,‘steam, etc, pipelines nearby
be clearly identifiable with the crane to which structures, cranes, vehicles being loaded, unloaded,
they refer. stacked goods, public access areas including highways,
railways, rivers, etc.
10 SITING OF CRANES
Where any part of the crane or its load cannot be kept
10.1 General clear of such hazards the appropriate authority should
be consulted.
During the planning operation the appointed person
should give careful consideration to the siting of the The danger to or from underground services, such as
crane. This should take account of all the factors that gas mains or electric cables, should not be
may effect its safe operation particularly: overlooked. Precautions should be taken to ensure
a) the crane standing and support conditions; that the crane foundation is clear of any under-
ground services or, where this is not possible, that
b) the presence of proximity and other hazards; the services are adequately protected to safeguard
c) the effect of wind during in and out of service against damage being caused.
conditions;
At any place where a crane or its load passes any
d) the adequacy of access to allow the placing or obstacle, the following points should be observed:
erection of the crane in its working position
and for dismantling and removal of the crane a) Where practicable the crane path should be
following completion of lifting operations. clearly defined by marking to ensure that it is
kept free from obstruction and a clearance of
10.2 Crane Standing or Support Conditions not less than 900 mm should be arranged
between the crane and any obstacle. Where it
The appointed person should ensure that the loads, is not reasonably practicable to achieve this
imposed by the crane can be sustained by the ground or clearance, effective precautions shohld be
any means of support and that these are assessed by a taken to prevent access to any trapping
competent person. hazards.
10
IS 13367(J%rt 1) : 1992
b) Where goods are regularly stacked near a When working parallel to overhead lines, a string of
crane, boundary lines for the stacking of warning markers should be erected at least 6 m
goods should be permanently marked on the measured horizontally along the ground from the
ground. outermost conductor at a tower or pole position -
where the minimum distance could be encroached by
103.2 Overhead Electric Lines and Cables ihe jib or the crane it should be extended. The actual
distance should’be agreed upon with the Electricity
Many fatal accidents have occurred due to some part of
Board.
a crane touching, or even coming near to overhead
electric lines or cables, without actually touching. In addition, a notice should be placed in the cab of all
cranes likely to work in the vicinity of overhead
The appointed person should ensure that the local electric lines giving the following information:
offices of the Electricity Board are consulted if the
crane is to be used within 15 m of overhead lines on If machine makes contact with live electric cable,
steel towers, or 9 m of overhead lines on wood, observe following precautions.
concrete or steel poles. This includes not only the
crane but also the jib at its maximum length. All a) Remain inside cab.
distances should be measured at ground level from a b) Warn all other personnel to keep away from
position estimated by eye to be vertically under the crane and not to touch any part of the crane,
outermost conductor at a tower or pole position. rope or load.
WARNINGNOTE c) Try, unaided, and without anyone approach-
iltg the machine, to move the crane until it is
‘TREAT ALL OVERHEAD LINES AND clear of power line.
0THERELECTRIcALAPPARATUsASLIVE
UNLESS DECLARED ‘DEAD’ AND ‘SAFE d) If the machine cannot be moved away, re-
BY THE LINE OPERATOR OF THE main inside the cab. If possible get someone
lXECIRICITY BOARD. IF IN DOUBT, SEER to int‘orm the electricity supply authority at
ADVICE’. once. Take no action until it has been con-
firmed that conditions are safe.
Whze a crane must travel underneath an overhead
line the crossing route should be plainly marked and e) If it is essential to leave the cab because of
‘goal posts’ erected each side of the crossing approach tire or some other reason, jump clear as far
to ensure that the jib or moving parts are lowered to away from the crane as possible. Do not
a safe position (see Fig. 3). touch the crane and the ground at the same
time.
The dimensions of the goal posts and their distance
from the nearest overhead conductor .should be t) Inform the responsible engineer of the works
decided in consultation with the Engineer of the or authority concerned of situation immedi-
.Electricity Board. Large notices should be posted ately and until assistance is received some-
stating: one should remain near the crane to warn of
the danger.
‘DANGER, OVERHEAD ELECTRIC LINES.

SAFETY CLEARANCE
/GOAL
,

FIG. 3 TRAVEUING UNDEROVWIEADELECTRIC


LINESANDCASLEX
11
IS 13367(Part1):1992
Devices
are available which are designed to be fitted dismantled fortransportation, particularly those which
on cranes to give warning when the crane comes areloadbearingorensure thestabilityoftheassembled
within a predetermined distance of the overhead crane, should carry a clear identification mark.
electric line. Such devices have limitations and should
not be considered as a substitute for a safe system of Diagrams and drawings in the crane instruction
work. manual, coveringerectionand dismantling in the crane
that show the correct location and orientation of
10.33Crane Control in the Vicinity of Airfieka3 components, should use the same system of marking.
The appointed person should consult the airfield NOTE - Under certain Regulations it is necessary IO identify
any part of a crane jib that can hc removed so as to indicate the
manager for permission to work whenever a crane is sane of which it is a part-
to be used in the vicinity of an airfield.
Care should be taken to avoid a mismatch of thread
NOTE - TheAir Navigation Order makes it an offence to reck-
lessly or negligently act in a manner likely to endanger aircraft formsoffasteners(nutsandbolts)forexampleimperia1
and conversely for any person likewise to permit an aircraft to or metric.
endanger persons or property.
1133 Materials
11 ERkTION AND DISMANTLING
Where components (for example Jib sections) have
11.1 j Planning been manufactured from special materials they
should be so marked. This is to enable the correct
Erection and dismantling of the crane should be repair procedures to be used, particularly where
thoroughly planned and properly supervised in the control of temperature during the repair is necessary.
same way as the lifting operation (see 5).
Nuts and bolts manufactured from high tensile steel or
NOTE- The planningshould take account of the need to other special steels should be clearly marked so that
dismantle tbe crane after use.
they can be distinguished from other nuts and bolts.
A cortectly planned erection and dismantling
11.4 Electrical Supply
procedure should ensure that:
The following points should be noted where the
. . a) erection of the crane does not commence until crane is electrically operated froma source external to
an instruction manual clearly understood by the crane.
erection staff, is available for their use;
W the erection/dismantling manual is appropri- 4 Electrically operated cranes should have an
_ ate to the particular crane and bears the crane effective earth connection. In the case of
manufacturer’s serial and type number and the cranes mounted on rails, at least one rail track
owner’s identification; should be electrically bonded at each rail
joint and the track should be effectively
4 the entire erection and dismantling operation earthed. Crane wheels should not be used for
is controlled by the erector in charge (see earthing the crane.
6.2.4);
all personnel involved have a sound
b>The crane structure, motor frames and con-
ducting cases of all electrical equipment,
knowledge of their part in the operation; including metal condujt and cable guards,
any departure from prescribed procedure is should be effectively and dirc:t.ly connected
approved by the designer or another to earth.
competent engineer; 4 The characteristics of the power supply and of
only correct replacement parts and ~mponents the crane equipment should be checked for
are used. comptability before connection.
4 Cables providing power to the crane should
11.2 Manufbcturer’s Erection and Dismantling be enclosed, positioned or constructed to
Instractlons protect them from mechanical damage:
The crane manufacturers instructions should be i) by running in conduit, trtmking or on
closely followed. Any departure from the specified trays; or
sequential procedure should be verified by the
ii) by being clipped to a structure in a position
designer or another competent engineer, to ensure .where they are protected from mechanical
stabilityofthecraneand thatstructuraland mechanical
damage; or
parts are not subjected to excessive loading.
iii) by being of armoured construction.
,11.3 Identification of Components and Materials
Where the method of protection is of
113.1 Components conducting material, it should be bonded to
earth at each end. In no case should the
All major components that form partof a crane and are protection be used as an earth conductor.

12
IS 13367 (part 1) : 1992

e) Where practicable, the power supply to a using caution in making checks in case of
travelling crane should be througb a cable maloperation.
winding drum or a properly installed,
Check proper functioning of all brakes.
insulated and protected collector system.
Check that the automatic safe load indicator is
Q Care should be taken to ensure that any correctly set for the condition of the crane.
trailing cable is not damaged during
operational movement or when the crane is Check that the load-radius scale is appropriate
travelling. to the jib combination fitted if this equipment
is separate from item (e).
The travel distance should be well within the
length of the trailing cable. ’ h) By varying the hook radius without load,
check the correct movement of 12.2.2 (f) and
s) In addition to any isolator within the crane 12.2.2 (g).
capable of cutting off the electrical supply to
the crane motions, there should be an identified Check lubricating oil level(s), hydraulic oil
isolation remote from the crane which can be level(s) and engine coolant level(s).
used to cut off tbe electrical supply to the Check that there has been no excessive loss of
crane itself. air pressure since the machine was last used.
Allisolatorsshouldbecapableofbeinglocked Check build-up time of air pressure for
in the ‘off’ position and should be identifiable efficiency of system (s).
witb the crane power supplies they control.
Check that ligbts, windscreen wiper(s) and
washers conform with the requirements of the
12 PROCEDURES AND PRECAUTIONS
Road Traffic Act.
12.1 Crane Operation P) Check visually the condition of tyres on wheel
mounted cranes.
Whenever a crane is moved anti whether it is lifting a
load or not it should only be driven by a competent 9) Check correct function of ail crane controls
driver (see 7.1) nominated by the appointed person. without load.
This should not inhibit the appointed person from r) Check satisfactory operation of audible
nominating a trainee driver provided thal such a driver warning device.
is under the direct supervision of a competent driver
who has also been nominated fnr that purpose by tbe s) In the interests of safety and fire prevention,
appointed person. ensure that the crane is in a tidy condition and
free from tins of oil, rags, tools, or materials
NOTE - Special arrangements may be necessary when carrying other than those for which storage provision is
out maintenance of repairs on the aane.
made.
12.2 Periodic Checks 12.23 Weekly
123.1 Generuf
Once a week, in addition to the checks in 12.23 the
The appointed person should ensure that the routine following additionalchecks as appropriate for the type
checks given in 122.2 and 12.2.3 are carried out. of crane concerned should be carried out:
NOTE - The crane driver may be authorized to carry auf a) Check the automatic safe load indicator in,
periodic chmks IO the extent that he is considered to be accordance with the operating instructions.
competent.
b) Visually inspect the hoist rope(s), trolley
123.2 Daily travel rope (tower cranes), derricking rope(s)
and static suspension ropes for broken wires,
At the beginning of each shift or working day, the flattening, bird caging or other signs of
following routine checks, as appropriate for the type damage, excessive wear and surfacecorrosion
of erane concerned should be carried out: (see 16).
Check all rope terminations, swivels, pins and
a) Checks as required by the manufacturers hand- retaining devices. Also check all &eaves for
book. damage, worn bushes or seizure. (see 16).
b) Clreck that all ropes are correctly positioned Inspect the structure for damage, for example
on their sheaves and have not been dis- missing and bent bracings on bridges and
placed. strut jibs, bulges, indentations and unusual
rubbing marks on telescopic jibs, cracked
Ensure, by visual inspection, that.no electrical welds, etc.
equipment is exposed to contamination by oil,
grease, water or dirt. e) Check hook(s), safety catch(es) and swivel(s)
for damage, free movement OKwear. Check
4 Confirm the operation of all limit switches or the hook.shank thread and securing nut for
cut outs and the dead man’s handle or lever, wear or corrosion.
13
IS 13367 (Part 1) : 1992
Check operation and adjustment of controllers. e>Tbe correct functioning of all the crane safety
limits should he c.hecked, in particular the
Check brake and clutch friction linings and automatic safe load indicator should be tested
drum paths for visible wear and reset, if by lifting a known weight.
necessary.

b) Check for creep of hydraulic rams in case of The result of all the tests in the programme should he
hydraulic machines. documented in the crane records (see 9.10.4) along
with details of any corrective action taken to
_OOn wheel mounted mobile cranes, check tyres overcome any defects prior to the crane being returned
for pressure as well as damage and wear on to service.
walls and tread. Also check wheel nuts for
tightness. 12.3 Repor-ting of Defects and Incidents
k) C&rrail mounted cranes, check rails, end stops The appointed person should ensure that there is an
and also ties where these are fitted. Check effective procedure for reportingdefects and incidents.
existence and condition of guards to remove This procedure should include notification to the
foreign material from rails. appointed person, the recording of action taken to
rectify any defects and clearance of the crane for
4 Check slew lock, if fitted.
further service.
4 On rubber tyred cranes check, steering,
This procedure shall include the immediate notification
brakes troth foot and parking, lights, indica-
tors, born, windscreen wipers and washers. of:

P) Generally inspect the crane to ensure that it is a) any defects found during daily or weekly
safe for use. periodic checks;

4) Enter results of checks in the records of b) defects found at any other time;
inspections.
c) incidents or accidents however slight;
12.2.4 ‘Crane Out of Use for a Considerable Period d) shock loads in whatever manner they occur; ’
and
If a crane is not to he used for a period exceeding three
or four weeks, precautions may have to be taken to e) dangerous occurrences or accidents (see 15).
prevent deterioration or damage.
Tbe procedure should include provision for an
In cases where a crane has been out of use for more examination by a competent person after any incident,
than three or four weeks, it may he necessary to carry whether a repair is necessary or not, to ensuIL that the
out a programme of checks in addition to those specitied crane is fit for further service.
in 12.2.2 and 12.2.3.
12.4 Leaving the Crane Unattended
The extent and thoroughness of this programme will
depend not only on the length of the period of out-of- In no case should a crane be left unattended even for
use, but also on the location of the crane during this short periods, unless all loads have heen removed
period. A crane standing under cover, or inside a from the book which should be left in a safe position,
workshop, may require very little in addition to the the power supplies to all motions switched off or the
checks detailed in 12.2.2 and 12.23, but a crane engine stopped, and appropriate motion brakes and
which has been out-of-use in the open, exposed to the locks applied to put the machine in a safe condition.
action of weather and atmospheric pollution, etc, will The ignition key and any other keys should be
require an extensive appraisal to ensure its fitness for removed from the crane whenever the driver is absent
work. from the machine.
For longer peiods and for out-of-service conditions,
In general terms the following points should he
isolation should he more permanent, that is, switches
covered as a minimum:
locked of, fuel supplies cut off and any doors giving
a>All crane ropes should be examined for signs access to machinery or control cabs locked to prevent
of corrosion and damage and thoroughly unautborised access. machinery should be left in the
Iubricated. out-of-service condition as described in the operating
instructions.
W All control linkages should be examined for
evidence of seizure or partial seizure and For details of methods to safeguard particular types of
correct lubrication undertaken. cranes, reference should be made to the appropriate
section of this Code.
4 Every crane motion should he tested for
several minutes without load, each motion 12.5 Maintenance
individually at first then by combination of
two or more motions simultaneously as 125.1 General
appropriate.
Provision should be made to ensure that throughout its
4 The test of all crane motions should he repeated use, the crane and other equipment used in the lifting
under load. operation are maintained in a satisfactory condition.

14
IS 133457 (part 1) : 1992
The appointed person should be satisfied that the 125.4 Use of Special Materials in Crane
maintenance is carried out by trained personnel who Construction
have adequate knowledge of the correct procedures.
The frequency and extent of such maintenance should Modem cranes make extensive use of high yield
take account of all factors that affect the crane in steels and if it is necessary to carry out any repairs to
carrying out its work. any part of the crane structure, it is essential that the
correct procedure laid down by the manufacturer is
12.52 Phnned Maintenance strictly followed. In particular excessive heat that can
change the properties of the steel should be avoided
To ensure safe and satisfactory operation of the crane and the use of special welding rods is required. It is
a properly planned maintenance system should be essential that the material is identified and the correct
established and used. procedure laid down by the manufacturer strictly
followed.
Manufacturers instruction books recommend that
specific tasks be carried out at stated intervals, and 12.S.5 Competence of Maintenance Personnel
these periods should not be exceeded. They will also
specify the lubrication points that require attention, Maintenance staff should have an adequate working
the interval or frequency of greasing and oil changes knowledge of the machinery they are required to
and the grades and quality of lubricant to be used. maintain and have access to the manufacturer’s relevant
They will also cover other essential maintenance such literature. Where special machinery is involved,
as the replacement of filters, draining intervals of personnel should be properly instructed, for instance,
air receivers, recommended tyre .pressures, the by attending maintenance, service and operating
frequency for checking the security of fixing bolts and courses given by the manufacturer of the equipment.
the recommended torque settings and other
adjustments, for example, clutches, brakes, etc. 12.5.6 Safety of Maintenance Personnel

The statutory examination of the crane requires the All maintenance staff should be fully aware of the
competent person to assess whether the crane is fit for hazards involved in working on cranes and the
service at the time of the exmination. This examination supervisor should be responsible for instructing the
does not cover the absolute legal requirements to staff in all aspects of safe working, including the use
ensure that the equipment is properly maintained. To of tools and equipment (see 9). Where necessary a
satisfy this requirement a more frequent inspection secure working platform should be provided to
should be carried out recognizing the frequency of use ensure the safety of maintenance personnel.
of the crane and the environmental conditions.
13 OPERATING CONDITIONS
An effective planned m&tenance system should
recognise the possible need to prohibit the use of the 13.1 Safe Working Load
crane until essential maintenance work is carried out. The safe working load of the crane should not be
exceeded other than for the express purpose of a test
In addition to any statutory regulations, a record of the crane under the supervision of a competent
(see 9.10.4) should be kept of every crane, giving person. The safe working load of any item used to
informationonthemajorcomponentsusedinthecrane attach the load to the crane should not be exceeded
manufacture, such as rope diameters, lengths, other than for the express purpose of a test of the
construction and breaking loads, tyre sizes and ply item under the supervision of a competent person.
mtings, make and model of motors, pumps, gear
boxes, winches, drives, electrical equipment and Care should be taken to prevent pendulum swinging
switchgear, etc. The availability and source of of the load, by careful control of the operating motions
replacement items should be checked and noted in the to match the swing of the load and to keep it under
record. Consideration should be given where control at all times as shown in Fig. 1.
appropriate to stocking certain expendable items and
Safe working loads apply only to freely suspended
otherpartsto minimize down time in the event of crane
loads. The crane hoisting, slewing, traversing, luffing
breakdown.
or travelling motions of a crane should not be used to
The record, together with the results of all drag any load along the ground with the hoist rope
examinations and inspections including those carried out of the vertical position. Before lifting a load, the
out to meet the statutory requirements, should form hoist line should be plumb (see Fig. 4). Failure to
the basis of the record for each crane. The record observe these points may hazard the stability of the
should contain details of hours worked, repairs carried crane or introduce loadings (stresses) into the crane for .
out as a result of defects found during the which it has not been designed, and, even with an
examinations and inspections. The record should automatic safe load indicator fitted, a structural failure
record the clearance of any defect noted and the may result without any warning being given.
signature of the person responsible for rectification.
13.2 Mode of Operation and Control
‘* 125.3 Replacement Components 133.1 Identification of Controls and,Direction of
Replacement components should conform with the Movement
manufacturer’s specification. To enstire safe use of the crane, each control should be
15
IS 13367(Part 1) : 1992

m - SIDE LOAD
AT JIB HEAD

SIDE LOAD
AT JIB HEAD

(a) Pulling a load sideways. (b) Travelling a- a slope.


Figures show typical operational conditions imposing a side loading on the jib of a crane. Jibs are not designed for high side loads in crane
service. Do not pull or drag loads sideways using &her the &wing motion or hoist line. The hoist line should always be in the plane of the jih
and hanging plumb.

AVOIDSIDELOADING
THEJIB
FIG. 4 SIDELCMNNG
ONJIB

marked to identify the motion cantrolled and the driver should ensure that the callittg sigtlal is
direction of movement. functioning satisfactorily and that verbal
messages can be clearly heard.
On no account should the driver tamper with any
controls, mechanisms or equipment either to enable 4 Where air or hydraulic systems are used the
the crane to function outside the operational range or driver should ensure that the gauges are
loads specified by the crane manufacturer or other functioning.
competent person, or to attempt to conect any suspected
defect. 4 Where air or hydraulic systems are used the
driver should ensure that the system(s) is/are
Before starting any lifting operation with a crane, the at the correct operating pressure(s).
following should be observed:
The hoist rope, or if applicable, the hoist chain should
a>The driver should be familiar with the controls be vertical at the commencennent of, and throughout,
and their layout. the hoisting operation. The load should initially be
Jifted just clear of the supporting surface and be
b) The driver should have a clear and brought to rest while the slings, balance of the load,
unrestricted view of the load and operational etc, are checked, before proceeding. Proper care
area. If not, the driver should act under the should be exercised by the driver at all times to avoid
directions of the slinger or an authorized shock or side loading on the jib or structure. Care
signaller who is positioned to have a clear and should also be taken to avoid the hook coming into
uninte.rrupted view; in some circumstances contact with the structure.
this may be a legal requirement. It is particularly
important that the driver should ensure that If it is necessary during normal operations to hold a
lifts can be carried out without causing damage. load suspended for any period of time, the driver
The driver should therefore ensure that loads should remain at the controls so that the crane is fully
and crane hoist- ropes are well clear of operational to meet any emergency.
obstructions. t
It is undesirable, where motion motors are to be 1.
, 4 Where telephone, radio or closed-circuit
television commnnications are being used, the reversed, to put the controller over the reverse position

16
I§ 13367 (Part 1) : 1992

before the motor has come to rest unless the control 13.4 Multiple Lifting
gear is specifically designed to allow this to be done.
It is undesirable, for safety reasons, to subject the 13.4.1 General
crane motion safety devices to continual operation.
Lifting a load with two or more cranes requires greater
Care should therefore be taken when approaching
attention to planning and supervision because the
the motion limits to avoid their frequent operation.
effects of the relative motion between the cranes may
In areas which are not adequately illuminated, all induce additional loadings on the cranes, the load and
travelling cranes which move close to where personnel the lifting gear in use.
have to pass or work should be distinguished at the
Because of this and the difficulty in monitoring these
leading end of the crave by a suitable warning lamp.
additional loads, multiple lifting should only be used
Before any crane is moved along its track, a warning when the physical dimensions, characteristics, weight
should be given by the person in charge of the lifting or required movement of the load prevent the
operation to all personnel whose safety is likely to be operation being carried out by a single crane.
endangered. A warning bell or klaxon may be fitted for
Multiple lifting should be planned with extreme care
this purpose.
(see 5) and should include an accurate assessment of
13.2.2 Radio-Controlled Cranes the portion of the load to be carried by each crane. It
is essential that the reason for and the extent to which
To prevent unauthorized use, the driver of a radio- the hoist rope(s) may come out of plumb should be
controlled crane should: evaluated. Additional forces may overload the cranes
causing thein to overturn or fail either immediately
a) retain the transmitter in his physical or in the longer term. The cranes should not be
possession; subjected to forces in excess of those which would
b) remove the key from its keylock switch and, occur were they handling their safe working loads as
for short periods, retain the key in his single lifts.
possession; and
13.4.2 Facmrs to be Cons&& in Planning the Multiple
4 for longer periods, or when the CKne is not in Lifing Operation
use, deposit the transmitter in safe storage.
If all the factors governing the distribution of the load
NOTE - Provision should be made for the security of the trans-
mitter when the crane is oot in use.
between the cranes can be accurately determined it
should be possible to use each crane up to its safe
When the radio transmitter is fitted with a belt or working load. In practice it may be difficult to evaluate
harness, the driver should be wearing the harness all the factors accurately and their effect on the
before switching on the transmitter so that accidental distribution of load between the cranes so it may be
operation of the crane is prevented. necessary to make a reduction in the load that each
crane is permitted to take.
The transmitter should only be switched otl when
operating the crane and should be switched off before The principle factors to be considered are as follows:
removing the harness.
a) Weight of the load - The total weight and its
The controlled range feature, where provided on a distribution should be either known or
radio controlled crane, should be tested at suitable calculated. Where the information is taken
intervals and it is necessary that at the beginning of from a drawing, due allowances should be
each shift, or where there is a change in driver, the made for casting and rolling margins and
controlled range should be checked to ensure that it manufacturing tolerances.
is in accordance with the limits specified for its
operation. b) PositiOn of the centre of gravity - Owing to
the variable effect of manufacturing toler-
13.3 Handling of Loads Near Persons ances and rolling margins, quantity of weld
metal, etc, the position of the centre of gravity
When loads have to be handled in the vicinity of
may not be known accurately and the propor-
persons, extreme care should be exercised and adequate
tion of the load being carried by each crane
clearances allowed. Drivers and signallers should pay
may therefore be uncertain.
particular attention to possible dangers of persons
working out of sight. 4 Weight of the lifting gear - The weight of the
lifting gear should be part of the calculated
All persons should stand clear of the load being lifted. load on the cranes. When handling heavy or
When lifting from a heap, all persons should stand awkwardly shaped loads, the deduction from
away from the heap in case other adjacent material or the safe working load(s) of the cranes to allow
objects are displaced.
for the weight of the lifting gear may well be I
Lifting of loads over highways, railways, rivers or significant. The weight of the lifting gear and
other places tb which the public have access should be its distribution should therefore be avrately
avoided. If this is not possible, permission should be known.
obtained from the appropriate authority and the area In cases where the crane ropes are reeved
kept clear of traffic and persons. round pulleys that are part of a specially
17
IS 133457 (Part 1) : 1992
designed piece of lifting gear, for example a may be 10 percent of the crane’s safe working load but
liftingbeam, it is acceptable to take the weight where stability of the crane(s) is likely to be affected
of the removed hook block and hook into the downrating may have to be 25 percent or mote.
consideration when determining the net
weight of the lifting gear. 135 Special Duties

4 Capacity of the lifiing gear -The distribution In all cases involving special duties, the designer’s or
within the lifting gear of the forces which will another competent engineer’s guidance should be
arise during the lifting operation should be obtained.
established. The lifting gear used should, unless
The weight of any special lifting attachments should
specially designed for the particular lifting
operation, have a capacity margin in excess always be included as part of the load to be lifted.
Attachment should be tested, certified and plainly
of that needed for its proportioned load.
marked with the safe working load and weight of the
Speeial lifting gear may be necessary to suit
attachment. They should only be used for the purpose
the maximum variation in distribution and
for which they were designed.
direction of application of loads or forces
which can occur during multiple lifting.
13.5.1 Grabbing and Magnet Crane Service
e) Synchronization of crane motions - If the
variation in the direction and magnitude of the 13.5.1.1 General considerations
forces acting on the crane during the multiple When using cranes for special duties such as grabbing
lift are to be kept to a minimum, it is essential or magnet crane service, allowance should be made
that the crane motions are synchronous intheir not only for the weight of the grab, magnet or other
effect. Thus, whenever possible, cranes of attachments,together withload,butalsoforadditional
equal capacity and similar characteristics loadings imposed on the crane resulting from fast
should be used. In practice there will always &wing grab suction effects, impacts, etc. Consequently
be some variation due to differences in response the weight of the grab and contents, or the weights of
to the activation of the motion controller and the magnet and load, will be less than the corresponding
the setting and efficiency of the braking system. safe working load for normal crane duty. Reference
The safe working load of a crane is based on should be made to the crane designer or another
the premise that the load will be raised and competent engineer for details of special duty ratings.
loweredina--vertical plane. The crane struc-
ture will have been designed to withstand 135.13 Grabbing service
any lateral loads imposed by accelerations in In the case of grabbing cranes, the load lifted is the
the various crane motions, but it is unsafe to weight of the grab and its contents; the latter weight
rely on this lateral strength to withstand hori- depends on the density of the material handled. It is
zontal components of out-of-plumb lifts. Since essential that any grab used is of appropriate capacity
it is unlikely, particularly if the cranes have forthe material, having regard to the safe working load
dissimilar characteristics, that the motions of of the crane. A weight check should always be made in
the two cmnes will be accumtelysynchro- case of doubt.
nixed, an assessment should be made of the
effect of variation in plumb of the hoist 13.5.1.3 Magnet service
ropes, which may arise from inequalities of
speed, together with a determination of the It should be appreciated that a load supported by a
means for keeping such inequalities to a magnet is not as secure as a load supported by a hook.
minimum. Precautions are therefore necessary to ensure that.
Instruments are available to monitor the angle thtXiSllDhi3ZdtopesOnnelCausedbyU~xpected

of inclination and load in each hoist rope con- release of the load.
stantly throughout the lifting operation. The The magnetic device should be marked with the safe
use of such instruments and the restriction of working load as determined by tests using weights of
the motion speeds together with the strict use the same characteristics as the load for which the
of one motion at any one time can assist in the device is intended to be used.
control of the loads on tbe cmnes within the
planned values. The power to the magnet should not be switched on
until after the magnet has been lowered on to the
13A.3 Recommended Safe Working Load During load to be lifted. The device should be carefully
Multiple Lifiing lowered on to the load and not dropped and should
not be allowed to strike a solid obstacle whilst in use.
If the person planning the multiple lift is satisfied that A battery back-up service of at least 10 minutes is
all the factors identified in 13A.2 (a) to 13A.2 (e) have essential for magnet service cranes (in case of power
been accurately identified or are being monitored, the failure). In such a case manual release shall also be
cranes may be used up to their safe working loads. provided for hoist brakes.
. If the person planning the lift cannot accurately evaluate
all the factors then an appropriate downrating should The device should not be used on ho; metal unless
be applied to all the cranes involved. The downrating specifically designed for this duty. When not in use,
.
18
IS 13367 (Part 1) : 1992
the power should be switched off to avoid the substantial repair, by applicationof a test load.
magnets becoming too hot. The test lozd surface should, as far as is
practicable, be similar to the worst type of
When not in use the device should not be deposited surface on which the device is intended to be
on the ground. It should be left suspended or, if used;
detached from the crane, it should be rested on a
wooden platform. b) bc inspected, particularly the hoses and
vacuum pads, before use at the beginning of
13.5.2 Vacuum Lifting Devices every shift or day, and the warning device
should be tested-at the begimting%f each
Vacuum lifting attachments should be regularly
week.
inspected to ensur? that adequate suction is maintained
over the required period.
13.4 Weather Conditions
Every vacuum lifting device should be fitted with a
device that gives a visual indication to the driver of the 13.6.1 General
crane of the state of the vacuum at any time and an
For cranes operating insituations where they are likely
audible warning to the driver and any person
to be affected by the weather careful attention should
working in the vicinity at ground level when the
be given to this aspect. Certain weather conditions
vacuum is 80 percent or less of the designed
such as strong wind, heavy rain, ice or snow can
working vacuum and/or in the event of the vacuum
impose loads on a crane and adversly affect the safety
inducing pump ceasing to operate.
or crane operations.
13.5.2.1 Every vacuum lifting device should: 13.6.2 The crane should not be operated in wind
a) be fitted with means that, in the event of speeds that are in excess of those specified in the
failure of the vacuum inducing pump, will operating instructions for the crane. Gusting wind
maintain sufficient vacuum to continue to conditions may have an additional adverse effect on
support the load suspended for a sufficient the safe handling of the lead and the safety of a crane.
time, together with a safety margin, for that Even in relatively light wind conditions, extra care
load to be safely deposited from the maximum should be taken when handling loads presenting
height of lift of the crane to ground level; large wind catching areas.
The limitations on wind speed for erection, testmg
b) be fitted witha suitable vacuum gauge; and dismantling the crane may be lower than the
limitation for normal operation and in cases of doubt
1) The gauge should be of sufficient size and the designers’ or another competent engineer’s
situated in a position where the gauge
reading may be easily read at the advice should be obtained. The testing of a crane
attachment and release position of the should not be carried out in an area which is known
load. to be subject to freak weather conditions.
Instructions issued by the crane manufacturer
2) The gauge should be distinctively marked
advising of the conditions under which a crane
with a red mark to indicate the lowest
vacuum below which the appliance should should be taken out of service and recommending
not be used. the conditions in which it should be secured, should
be strictly followed.
A vacuum lifting device should only be used to lift
loads that have a surface suitable fox vacuum lifting 136.3 Wind Speed Indication
pads.
In the case of high cranes, an anemometer should be
13.!!U.2 The vacuum device should be used in such a mounted at a suitable high point of the crane
way that: structure or at a similar height and exposed position on
the site.
a>each pad supports as far as is practicable an
13.6.4 Visibility
equal part of the load;

b) the contact surface of the load is suspended In poor visibility, suitable means of communication
horizontally as far as this is possible; should be provided to ensure the safe operation of
the crane. In extreme conditions crane operations
c) the surface of the load to be handled is clear of should be stopped until there is sufftcient
any loose material that would prevent any improvement in visibility to enable operations to be
vacuum pad from making an effective contact safely resumed.
with the surface.
13.65 Rain, Snow or Ice
135.23 It is recommended that the vacuum device
should: During adverse weather conditions, the appointed
person should ensure that adequate prec?rutions are
a) be tested by a competent person before being taken to avoid danger when the crane or the load are _
taken into use for the first time or after any affected by rain, snow or ice.
19
IS 13367(Part I) : 1992
14 TESTING AND EXAMINATION conditions of the site where the tests are to be
conducted. It should be remembered that the
14.1 General recommendations provided in the operating
instructions for the crane relate to operations within
14.1.1 Testing and Examination the safe working load and that more stringent
Various tests and a thorough examination by a requirements apply when loads are being applied for
competent person are required to ensure that a crane the purpose of testing.
is safe for use. Item 15 gives the legal requirements The following general requirements apply to all types
for the testing and thorough examination of cranes. of cranes. Further guidance is given in other parts of
Additional tests and thorough examinations are this standard covering specific crane types:
usually necessary following any substantial alteration
or repair to the crane. Any lifting gear to be used 4 The ground should be well consolidated
with-the crane in normal duties or forthe purpose of and capable of withstanding the loads that
testing the crane, should already have been tested will be applied to it. Care should be taken to
separately from the crane. ensure that there are no hidden dangers
such as cable ducts, drains, pipes, back-filled
14.13 Test Certificates and Document&m areas, cellars or other subterranean weak-
nesses.
Cranes are used under a wide variety of conditions
but the following minimum requirements generally b) The ground should be level to within the limits
apply: appropriate for testing the particular crane.
a) A crane should not be used unless it has the 4 The site should be of sufficient area and have
appropriate current test certificates. Tests will unrestricted overhead clearance to allow the
be required following substantial repairs or unobstructed movement of the crane and
alteration, and/or periodically as prescribed load throughout all its appropriate test move-
by legislation. ments, for example, slewing, de&king trav-
elling etc.
b) Periodic examination and inspections, sys-
tematic maintenance, repairs, renewals and 4 A test is designed to prove a crane and it
any necessary heat treatment (as applicable) must be borne in mind that the crane might
should be carried out and recorded. for some hidden reason not withstand the
loading. It is therefore necessary to ensure
c) The safe working load should. be clearly that all personnel not essential to the test are
marked on the crane or the charts affixed to it.
kept away from the area. Test personnel
d) Any lifting attachments should be clearly should be so positioned that they are
marked with their safe working loads. unlikely to be injured should there be any
mishap. It is recommended that the test area
e) A copy of the operating instructions should be
with the crane. be roped off and notices posted prohibiting
unauthorized entry. The test site should be
fl All test certificates and records related to the well clear of places where the public has
above should be available for inspection. (see access such as roads, railways etc. For similar
9.10.4) reasons the site should be clear of plant and
property which, as well as inhibiting the test,
14.13 Thorough Examination could also be damaged.
Athorough examinationshould be understood to mean
the following: 14.15 Weather Conditions

4 A detailed examination sufficient to ensure Apart from the obvious danger to personnel it
that the crane is safe for use. should be recognized that weather.conditions such
b) Whenever considered necessary by the as wind, ice and snow can impose loads on the crane.
competent person, visual examination can be For this reason test sites should preferably not be in
supplemented by methods of non-destructive areas which are known to be subject to freak weather
testing that determine the condition of any conditions. The limitations on wind speed for testing
part of the crane without causing any deuimental of the crane may be lower than the limitation for
change to the material; normal operation and in cases of doubt, the designer’s
or another competent engineer’s advice should be
4 Where considered necessary, parts of the sought.
crane should be dismantled by a skilled per-
. son to the extent -required by the competent The competent person in charge of the test should
person. ensure that adequate ,precautions are taken when the
windspeed exceeds the limit or the crane or load are
4 The examination should be carried out with
heavily coated with ice or snow.
the crane in operationand at rest.
Tests should never be undertaken when th: crane or
14.1.4 Test Site load cannot be clearly seen because of a limitation on
Careful consideration should be given to the visibility caused by rain, snow, mist or fog, etc. 1

20
IS 13367 (Part 1) : 1992 _
14.2 Test Requirements for the Crane e) travelling and traversing in both directions.

14.2.1. Conduct of the Test NOTE - Precautions should be taken to limit swinging of the
load. The crane should show itself capable of sustaining full
control of the load throughout these tests. There should be an
The tests should be carried out under the control of the adequate supply of known weights with meansof handling them.
competent person appointed for this purpose who
should clearly indicate when the tests start and when 14.2.3 Anchorage and Ballasting Test
they have been completed. The driver, signaller and/or
slinger should for the duration of the tests accept The security of the anchorage and/or adequacy of
instructions only from the competent person. ballasting should be tested after erection or any
alteration. This test requires the imposition of an
Immediately prior to the tests, the competent person overload above the appropriate maximum safe
should ensure, by thorough examination (see 14.2.2) working load as specified by the relevant Indian
that the condition of the crane is satisfactory for the Standard to be lifted by the crane at a position where
tests and that the site and weather conditions are there is a pull on each anchorage or by the imposition
suitable (see 14.1.4 and 14.1.5). of a reduced load at an increased radius to give an
equivalent test of the anchorage or ballasting
During the tests the load should be kept close to the arrangements. Care should be exercised to avoid possible
ground. Shock loading which may be caused by rapid overstressing of crane components (see 14.2.1).
acceleration of crane motions, sudden braking, erratic
or sudden steering movements or movement of the 14.2.4 Testing ofAutomatic Safe Load Indicator
crane controls should be avoided.
Automatic safe load indicators should be tested at the
time of testing the crane and in some circumstances it
At all times care should be exercised to avoid danger
should be noted that this is a statutory requirement.
to personnel and damage to plant and surrounding
property. The Construction (Lifting Operations) Regulations
1961 require automaticsafe load indicators to be of a
Precaution - Where safety devices have been
type approved by the Health and Safety Executive and
overridden or disconnected their correct function-
for them to be inspected once a week.
ing should be restored and checked.
NOTE - It should be noted that the test button provided on
14.2.2 Overload Testing certain indicators only confirms that the electrical circuit and
power supply aresatisfactory. Such test buttons cannot confirm
The testing of the crane requires the application of the correct functioning of the indicator mechanism which can
only be effectively checked by lifting a known load at the
loads in excess of the safe working load. Prior to the
appropriate radius.
application of overloads, it should be established by
reference toanauthorityonthedesignandconstruction
14.3 Thorough Examination After Test
of the crane, for example the manufacturer, that the
design of the crane will permit the imposition of the A thorough examination (see 14.13) should be
overloads at the appropriate positions at which they carried out by a competent person to ensure that the
will be applied.This is necessary because the overloads crane has satisfactorily withstood the test loadings
may be limited by the structural strength and not the without signs of structural damage that will effect the
stability of the crane. Under such circumstances, the safety of the crane, such as:
structure might buckle or collapse without warning
before the crane gives any sign of tipping. a) cracking;
b) permanent deformation,
Before commencing the overload test, the crane
should be thoroughly examined by a competent c) paint flaking, and
person for any significant defects or limiting condition d) loosening of or damage to structural connec-
of the crane, for example, insufficient falls of rope for tions.
the load under consideration, which require to be
rectified before application of the overload. The examination should confirm that all mechanisms
function correctly and are free from defect.
The crane should be operated through the motions for
whichit is designed to carry load. These motions will 14.4 Certification
include:
After any test or examination the results should ,be
a) hoisting and lowering; recorded.. Where a machine is used temporarily
undera different set ofregulations then the certificates
b) derricking in and derricking out;
issued for the prime use of the machine should bc
c) slewing in both directions through the maxi- considered as acceptable.
mum angle for which load carrying is permit-
Where, for any reason, the competent person
ted;
considers it necessary to restrict the use of 3 machine
4 telescoping through the permitted range of (for example site limitations prevent the testing of the
movement; and full range of duties of the machine) then the restrictions

21
IS 13367 (Part 1) : 1992
should be noted on the certificate and the use of the a) there is less than two turns of rope left on rhe
crane should be subject to these restrictions. The drum, and
markings/tables of safe working loads on the machine
should be amended to reflect these restrictions. b) the drum flanges project less than two rope
diameters or 50 mm whichever is less, beyond
15 LEGAL REQUIREMENTS theouterlayeroftheropeinallcircumstanccs.

15.1 General 16.3 Handling, Storage and Installation

Employers and the self-employed shall ensure, so far 16.3.1 Ofloading


as is reasonably practicable, the health and safety at
work of all their employees and that undertaking are To avoid physical damage, ropes should be oftloaded
conducted in such a way as to ensure, so far as is with care. The reels or coils should not be dropped. A
reasonably practicable, that persons not in their steel bar should be placed through the centre hole of
employment who may be affected are not thereby the reel and lifted by means ofa suitable sling. Coils of
exposed to risks to their health and safety. wire rope should not be lifted by their securing bands,
unless it is known that the bands are especially designed
I’his duty not only includes the provision and for this purpose.
maintenance of plant which is, so far as is reasonably
practicable, safe and without risks to health but also the 16.3.2 Storage
provision and maintenance of systems of work,
Ropes should be stored in a cool, dry building 4nd
information, instruction, training and supervision as
should not be in contact with the floor.
are necessary to ensure, so far as is reasonably
practicable, the health and safety at work of Ropes should never be stored where they are liible lo
employees. be affected by chemical fumes, steam or other corrosive
agents.
Employees have a duty to take reasonable care for
the health and safety of themselves and of other Ropes in store should be examined periodically and a
persons who may be affected by their acts or omissions rope dressing applied, if necessary.
at work. They also have the duty to co-operate with
their employers so far as is necessary, to enable the Ropes that have been removed from a machine Ibr
employers to comply with their legal duties. future use should be thoroughly cleaned and a dressing
applied before being stored.
15.2 Specific Legislation
Ropes having a length in excess of 30 m should bc
’ The following legislation contains provisions which stored on a drum.
apply to the provision, maintenance, examination and
use of cranes: 16.3.3 Uncoiling and Handling
The Factories Act, 1948
16.3.3.1 General
The Mines and Minerals Act. 1957
To prevent the possibility OCkinking or disturbance of
The Coal Mines Safety Act, 1939
the lay, ropes should be paid out without slack and in
The Merchant Shipping Act, 1958 a straight line.
The Indian Ports Act, 1908 Coils of rope should preferably be paid out from a
The Calcutta Port (Pilotage) Act, 1948 turntable. Alternatively, where the coil is short, one
end can be made free and the remainder rolled
The Indian Electricity Rules, 1956 along the ground. For ease of handling the inside end
should first be secured to an adjacent turn. A rope
16 ROPES should never be unwound by throwing cff turns with
the coil or reel flat on the ground. (see Fig. 5) The rope
16.1 Rope Replacement should be kept as clean as possible during this
operation. ’
Only ropes of the correct size, type, strength and
construction as specified in the crane manufacturers’
handbook should be fitted to the crane unless an Before any rope is cut it should be tightly served or
secured oneithersideofthe intended cut. Fig. Gsbows
alternative rope has the prior approval of the crane
a common method.
designer, rope manufacturer or other competent
engineer.
16.3.3.2 Mu!ti-strand rope,
16.2 Rope Length
Great care should be taken with multi-strand ropes to
The length of the rope used should be sufficient for the ensure that they are installed without imparting any
particular application for which the crane is to be used rotation to the rope. A free end will ,have no
pronounced tendency to rotate but caution should bc
I. but in no circumstances should it be such that in the
extreme positions: exercized to ensure that the lay of the rope is not

22
,

IS 13367 (Part 1) : 1992

(‘1

(2)

1
,i

Fro. 6 SERVING
OFROPES(BEFORECV~TING)

disturbed, either by turns in or turns out. If the strands at reduced speeds and loads to permit the new rope to
are disturbed, malformation of the rope may develop adjust to the working conditions. This is particularly
during subsequent use. important for multi-strand ropes.

16.3.4 Installation All new ropes when first installed will stretch due to
the wires and strands bedding in. This will normally be
The lay of the rope should not be disturbed during accommodated by the installation. If not it may be
installation, that is, turn should not he put in nor taken necessary to cut and re-terminate.
out of the rope. Ordinary lay ropes are usually
stable but special care should be taken with Lang’s
lay and multi-strand ropes. When winding a rope 16.4 Rollers and Guide Sheaves
from a reel to a drum, it should be bent in the same
direction. Re-reel from the top of the reel to the top of Rollersorguidesheavesaresometimesfittedonthejib
the drum. A tensioning load should also be applied to of the crane to ensure that the rope does not rub against
the rope to achieve good coiling. A simple brake such the jib structure. A siezed roller, or sheave will cause
as a plank rigged to bear against the reel flanges, may serious damage to a rope, leading to its premature
’ provide ample rope tension. The reel and the drum failure and they should therefore be checked at
should be spaced well apart to facilitate even coiling regular intervals [see i2 2.3 (c)] to ensure that they are
(see Fig. 7). free to rotate. .

16.3.5 Running-in 16.5 Rope Drums and Sheaves

After fitting a new running rope, it is advisable to run Where alternative drums and/or 1agging:can be fitted,
through its operating cycle for a number of operations it should always be ensured that the drum or lagging is

24
IS 13367 (Part 1) : 1992

Aiwaysreelfromtoptotoporbottomtobottem

ROPEmm REEI;TO Dim!


FIG. 7 ‘RAXSWRRING

compatible with the size of rope and the duty specif%d by the rope/crane manufacturer may be the
requirements. only solution to this problem.

Sheaves are usually manufactured from ferrous Rope terminations can be of permanent or non-
materials, but the use of plastics sheaves and sheaves permanent type and special attention should be given
with plastic inserts is increasing. For many uses, to the assembly and use of the latter which normally
plastics sheaves and inserts give an increase in rope take the form of a wedge and socket that can be fitted
life, but there may bc a change in the failure mode of to the rope at site. Guidance is given in 16.6.2 to the
the rope. Special attention should be given to the procedures that are necessary to ensure that this type
examination of ropes used,with plastics sheaves and of fitting is safely assembled.
inserts (see 16.8.2.3).
Wire rope grips as the sole means of temrinating a
16.6 Rope Terminations rope can be dangerous and they should not therefore
be used for tbis purpose.
16.6.1 General
Only rope termination as specified by the crane and/or 16.6.2 Wedge and Socket Terminations for Ropes
rope manufacturer should be used to attach a rope to a
drum, hook block or the structure of the crane. Care 16.6.2.1 Assembly
should be taken to ensure that anchorage .points are
securely fastened. The following points should be noted when
assembling wedge and socket terminations:
Terminations should be examined for mechanical
damage, for example elongation of the holes of clevis 4 It is essential that only wedge and socket as-
type fittings? for the presence of broken wires (see semblies of the correct dimensions and
16.8.2)and for evidence of the rope pulling through the strengtb for~tbe particular ropoare usad. Fail-
termination. Consideration should be given to the ure to do so may rbult in the rope pulling
possibility of internal corrosion: discard after a period through the fitting.

25
IS 13367(Part 1) : 1992

b) Wedges and sockets for a particular size of The clampor wire rope gripshould not be
rope should be matched to each other and allowed to encroach on the fused end of
should not therefore be obtained front differ- the rope.
ent manufacturers. T&e fit of the wedge (with
rope) in the tiket should always be checked ii) Where there is a possibility of the loop
at the time of assembly. Anoversize wedge, or interfering with an obstruction, such as !
a wedge of incorrect taper, will not enter the the working structure, which might
socket sufficiently to give a secure termina- cause the wedge to loosen and the rope
tion; too small a wedge will protrude too far to pull free, the tail-end length of the
through the socket and thehigh localised load- rope should not be looped back but
ing may cause the socket to crack and open should be fitted with a simple clamp or
out, allowing the wedge to pull through. wire rope grip and laid parallel to the live
rope. If a wire rope grip is used a 1
c) The rope should be fitted so that the live or distance pieee, or ashort length of rope of
loaded part of the rope is not kinked where it the same diameter, will be necessary to
leaves the socket, but pulls directly in line ensure that the rope, is adequately
with the point of attachment of the socket. griwd. If necessary the tail-end may be
Incorrect fitting will result in premature fail- lashed to the live part with soft binding
ure of tbe rope. wire.
4 When the termination is madeup, the tail-end NOTE- In both (i)‘and(ii). the clampis used to ensure that the ’
Iengthof rope left protruding from the socket ropecannot slip through the ad&wage. befotw t6r wedge has
should be long enough for the securing seated pop@.

method used [see 16.6.2.(h)].


i) Specipt care should be taken when tension
Multi-strand ropes tend to show distortion may be completely removed from the rope, for ’
wbentheyarebentaroundsmallradiiandmay example when a load is set dowt+ where there
require temporary serving, for example with is a possibility that the wedge may become
electricians’ tape during the fitting of the loosened.
socket. The serving should be subsequently
removed as far as possible to allow for rope 16.6.2.2 hspe&on
inspection.
When inspecting wedge and socket rope anchorages
After a wedge and socket termination has particular attention should be paid to;
been made orremade, it is essential that the ropedamage, for example broken wires or de-
wedge and rope are properly seated in the formation of the rope where it emerges from
socket before the equipment is put into the socket;
service. Failure to doso may allow the ropeta
pull through the fitting or particularly when the condition of the socket, for example’
the rope is new, the wedge to be sprung out of cracks, particularly if the wedge is seen to
the socket. protrude excessively. The socket lugs sbould
beexamin&l~forpossible.deformation,cracks,
s) Initially the wedge should be’lannnered or other defects;
home using a wooden packer to protect the
fitting and rope against’ damage and simulta- the security and tightness of the wedge fitting.
neously a second person should pull on the
ends of the rope. A substantial load should The wedge and socket and the part of the rope lyihg’
then be raised and left suspended (but not inside the fitting should be examined each time the
unattended) to seat the wedge and rope firmly termination is dismantled for any reason.
into the socket before the assembly is put into A wedge and socket termination found to be damaged
service. should be replaced.
h) There are two ways of securing the dead-end A length of rope that has previously been fitted with
lengths of rope protruding from the socket a wedge and socket termination should not be
depending on’the circumstances of use: straightened and use for load-bearing purposes.

0 The tail-end may be looped back on 16.7 M&teoari&~ Exnminatlon and Discard
,itself and secured by a wire rope grip or Cliteiill
clamp to form a loop. The loop should be
lashed to the live part of the rope by 16.7.1 General
suitabk means, sucLas seft bindingwire;
to prevent flexing of the rope in The continued safe operation of wire ropes depends
setvice.If this method is used, thetail- on the regular assessment of the condition of the ropes
end kngth of the rope shoald beabout and the equipment with which they are used.
15 times the diameter of the rope for Some cranes operate in conditions where the ropes and
example 195 mm tail-end length for a equipment are particularly liable to damage. In such
13 mm diameter rope. circumstances. the assessment of the condition ofthe

26
IS 13367 (Part 1) : 1992

rope and the equipment should be carefully carried b) the dressing should be re-applied at regular
out, and the rope removed from service when the intervals and before the rope is showing signs
damage is such as to affect its safe operation. of corrosion or dryness.

Good maintenance will, in general, increase the rope 16.7.4 Application of Dressing
life. Regular cleaning and service dressing is a necessary
part of good maintenance. There are several methods of applying dressings and
the most suitable for any particular rope depends
Guidance regarding rope maintenance, inspections upon the viscosity of the dressing and the length of
and examinations and discard criteria are given in rope involved. The methods of application include
16.7.2 to. 16.8.6. If the person inspecting the rope has brushing, spraying dripfeed or by automatic
any doubts about its safe operation, the rope should not applicators.
be used until it has been examined and declared fit for
further service by the competent person. For maximum effect the lubricant should be applied if
possible to the rope where it ‘opens up’ as it travels
Records should be kept of the maintenance, examination over a sheave or winds onto a drum.
and discard of wire ropes (see 9.10.4).
If the existing dressing on the rope is heavily loaded
16.7.2 Rope Maintenance witfrdirt, sand, grit, etc, or if loose corrosion products
are present, these should be removed with a wire brush
The maintenance of wire ropes is normally confined to or other suitable means.
cleaning and application of dressings. The dressings
are usually of mineral oil origin and are used to 16~8 Assessment OFRope Condition and Discard
provide lubrication of the wires and strands and to Criteria
provide protection against corrosion.
168.1 General
Corrosion is a common cause of deterioration of
ropes, esp&ially those working out of doors. Internal When carrying out inspections and examinations to
as well as external corrosion can occur. The former assess the fitness of the rope for further service, it is
is more dangerous because it can. lead to an necessary to consider lx@ general deterioration
appreciable reduction in the strengtb of the rope and localized detelioration or damage. It is’therefore
before the deterioration becomes apparent. necessary to examiue the whole length of the rope,
paying particular attention to the hope adjacent to the
The dressings used for these ropes should therefore: terminations, lengths which have been running or, .’
stationary over drums, sheaves and deflection pulleys,
a) psnetrate easiIy into rope, and any other areas likely to sustain damage (see
Fig. 8).
b) displace moisture from metal surfaces,
cl give good corrosion protection, The criteria in 16.8.2 to 161.6 should be considered
and are likely to occur in combination. The competent
4 be resistant to wash off by water, person should assess for each, the severity of
4 be reasonably reSiStant tQemulsification, and deterioration between the per-feetcondition and the
discard condition and the cumulative effect on the
f) not cause build up on surface so as to cause rope. A combination of two or more criteria should be
displacement of the rope. viewed more seriously than one occurring on its
own.
In certain environmental conditions, the application
ef a dressing might aggravate the wear, for example 16.83 Broken Wires
by retaining abrasive materials and in these situations
tbe application of dressings should be avoided unless it 1683.1 Generally distributed broken wires
is required to protect the rope against corrosion.
‘Ibe number oF generally distributed broken wires
The dressing should be compatible with the type of permissible before the rope is discarded are given in
lubricant applied during the manufacture of tbe rope the Construction(LiftingOperations) Regulations 1961
and in this respect the rope maker’s advice should be and the Shipbuilding and !Wp Re*iring Regulation
sought. 1960, which also specify maximum periods between
thorough examinationa.
16.7.3 Frequency of Dressing
This depends very much on the installation and In other cases that are not covered by these regulations
environment in which the rope is working. There are, the total tmmber of visible wipe breaks should not
however, certain general principles to be followed in exceed ten in any length oF rope of eight rope diameters.
. order to obtain the best rope life. These are:
Breaks that occur on the crown of the rope aae typical
a) wherever practical a dressing should be of deterioration by abrasive wear and bend fatigue,,. .
applied when the rope is fitted to the crane; breaksthat occur in tbe valley area between the strands

27
IS 13367(Part 1) : 1992

(6)
Points af attachment

- checkforwirebreaksandcorrosion;
- similarly, check se&on of rope
WhiChli6?SOIlOr
adjacent to compensating pulleys.

(11) L.ook for deformation ’


(12) Check rope diameter

‘(1) Examine termination of rope at drum.

(2) Examine for defect&e coiling, which causes deforma$ionu


(flattenedportions)andwear,$ichcanbesevereatcroas-
over positions. \
(3) Examine for wire breaks.
(43 Examine for co-ion
@) Look for deformations caused by snatch loading.

Examine carefUlly kr@h Lhich runs


through pulky block, particularly that
length which Iiea on the pulley when
the appliance is in a Wed condition.

(a) Examine for wire breaks or surface


LOAD wear.

(9) Fxamine for corm&n.

FK. 8 PARTS OF THE CRANETO BE CONSIDERED


Dmuw THE EXAMINATION
IS 13367 (Part 1) : 1?92
are typical of deterioration of tbe core by wear, fatigue 16.8.4 Corrosion and Chemicai Attack
or corrosion.
Corrosion and chemical attack may be external or
In the case of multistrands ropes wire breaks will internal, geneml or localized, and is significant when
frequently occur in the valley area between strands and the surface of the wires is severely roughened or
may become visible if the rope is flexed, or opened for pitted, or if the wires are slack within the strands due
internal inspection. to wastage. If any of these phenomena is present
either locally or generally the rope should be
16.8.2.2 Localized. broken wires in the vicinity of
discarded.
terminations
Slight rustingof the surface is not nomMlly detrimental
The rope should be discarded when there are three or but may be anindication that the rope is in need ol
more visible wire breaks in the immediate vicinity of lubrication.
termination. Detachable terminations such as a wedge
and socketsbould,be examined for broken wires within Internal corrosion OTchemical attack are not always
and under the terminations. easy to detect and are therefore particularly
dangerous. Indications are an unusual increase or
If the rope is shortened so that the broken wires are decrease in rope diameter, lack of gap between the
removed then it may be considered for re-termination strands, drynesss and deterioration of the lubricant,
and reuse. Wire breaks at or adjacent to the termination, discoloration in the valleys between the strands, and
even if low in number, are indicative of high stresses at increase in stiffness in bending. If a rope shows any of
this point and may be caused by incorrect fitting of the these signs it should & carefully examined and if not
termination. The causes should be investigated before requiring disca‘rd it should be re-dressed (see 16.7.2).
the rope is reterminated.
16.85 Localized Damage or Distortion
16.84.3 Ropes operating in plastics sheaves
Other forms of damage or distortion that may affect
When any rope operates either solely or partly with the safe working of wire ropes are:
plastics sheaves or metal sheaves having plastics lining, Waviness -Waviness js a deformation where
wire breaks may occur in large numbers internally the longitudinal axis of the wire rope takes the
before there is any visible evidence of wire breaks or shape of a helix. While not necessarily result-
substantial wear on the periphery of the rope. ing in any immediate loss of strength, the
deformation may transmit a pulsation which
Particular attention should be paid to any localized after Prolonged working will give rise to wear
area which exhibits a dryness or denaturing of the and wire breaks. In the case of waviness that
lubrication. affects the operation of the equipment, the
wire rope should be discarded.
The rope or crane manufacturers advise ibould be
sought regarding discard criteria but in any case this b) Basket distortion (or birdcage) - Basket
should be not less onerous than those applicable to distortion occurs in ropes when the outer
multistrand ropes working over metal sheaves. layer of strands has been dislocated or when
the outer layer becomes longer than the inner
16.83 Wear layer of strands. Such a condition may occur
as a result of abrupt (snatch) loading of the
Wear may be either general or localized and results rope from a slack condition, incorrect
from contact of the rope with sheaves, or drums, or installation or incorrect termination. A basket
other hard surfaces or rope to rope pressure. Wear formation is justification for discard.
may be uniform along or around the rope, or may
occur along one side of the rope only. cl Strand or core protrusion - Strand or core
protrusion is frequently associated with basket
When working over metal sheaves, the rope should deformationand is justification for immediate
-be discarded when the rope diameter anywhere is discard of the rope.
reduced to 90 percent of the nominal diameter in the
case of 6 and 8 strand ropes. , 4 Wire extrusion - In this condition certain
wires or groups of wire rise up on the opposite
In the case of multistrand ropes, internal wear or side of the rope to the sheave groove, in the
damage is frequently more critical than external wear. form of loopes. This feature usually results
This may also be accompanied by an accumulation of
from shock loading. If the condition is severe
internal debris. If the rope diameter falls to 97 percent
(3 wires), there is justification for discarding
of the nominal, or rises to 105 percent of the nominal, the rope.
a more detailed examination should be carried out to
ascertain the significance and discard may be e) Local increase in diameter of rope - Local
necessary. The rope should in any case be discarded increase in rope diameter may occur and
when the diameter has reduced to 90 percent of the could affect a relatively long length of the
nominal diameter. rope. The condition usually relates*to corro-
sion (see 168.4) or to swelling of a fibre core
If wear is not even, the cause should be ascertained ind owing to the effect of moisture. If the condi-
corrective action taken. tion is severe, the rope should be discarded.
/
29
IS 13367 (Part 1) : 1992

f) Local decrease in diameter ofrope - A local discarded. Indicators are dryness or loss of
decrease in tie diameter of the rope is fte- lubrication, bluing of the wire surfaces, fusion I
quently associated with fracture of the core.. of wire surfaces and the presence of weld
Posit&s close to terminations should be care- splatters.
fully examined for such deformations.
168.6 Cumuhtive Effect of Individual Criteria
If the condition is severe the rope should be
discarded. Clauses 16.8.2 to. 16.883 provide guidance regarding
individual criteria ‘that needs to be considered in
d Betufs and Kinks - Bends are angular deciding whether a rope should be discarded. The
deformation of the rope. competent person should also assess the cumulative
A kink is a deformation‘created by a loop in effect of-two or more criteria within each affected part
the rope which has been tightened without of the rope.
allow'ing for rotation about its axis. Unbalance The severity 6f deterioration should be assessed
of lay length occurs, which will cause excessive between Zero percent (perfect condition) and 100
wear, and in severe cases. the rope will’be so percent (discard condition). When a cumulative
distorted that it will have only a still pmportion intermediate condition of 80 percent *Ot more is
of its strength remaining. readed, the competent person should specify the
If the bend or kink is severe there is justifica- period of time for which the rope may be used and may
tion for immediate discard of the rope. recommend a reduction in time betweeninspections or
thorough examination of the rope.
h) Da&age due io heat or ele&ic arcing -
When there is evidence that the rope has been * Tables 1 and 2 show the estimation of the severity of
in any way affected by electric arcing or sub- deterioration and typical examples of the cumulative
stantially affected by heat, the rope should be effect.

Table 1 Severity of Deterioration of Steel Wire Ropes


(Clause 16.8.6)
Factor d I Emmated Percemtagc ofseverity of Ikterlolrtton 1
I-zic
D&riolrtiOIl

Intermediate Discard
condition I Cohdition
-
Wire breaks 20 40 60 80 100

Reduction in
rape diameter 20 40 60 80 100

External
corroaioxt 20 40 60 80 100
\
Deformations 40 40 40 40, 100

lDeforautions rate as either acceptable (40) or aevere and jastifyiag dishd of the rope (100).

Table 2 Typical
__ Examples of Cumulative El%& of Deterioration of Steel Wire R-sL
(Clause 16.8.6)

Wirt Reduction in EXtCXnal Deformations


BMkS RopeDi- Corrosion

1 0 20 Safe to use

2 20 20 Safe to nse

3 20 20 Safe to use

4 20 20 0 80 Discard within a
specified period

5 20 40 Discard within a
specl .f!led period
L

30
IS 13367 (Part, 1) : 1992
27 SLINGING AND EANDIJNG OF LOADS Another way of saying this is that the centre of gravity
is the point about which the parts of a body exactly
17.1 Load Estimatkm, Weight and Centre of ~balance each other.
-vlt3!
.. s 17.1.2.1 The Regularly shuped load
17.1.1 Weight of the Load
With a regularly shaped load (for example a rolled
It is important that the’weight of the load tobe lifted is steel joist) the position of the centre of gravity easily
known with reasonable accuracy. To .obtain this may be judged by measuring out the midpoint in each
information direction.

a) Look to see if tbe weight is marked on the 17.123 The more complex or irregularly shaped load
load. If it is checked to ensure that it is the
weight of all parts of the load (a machine For more complex shapes, it may be necessary to
tool for example may not include the drive estimate the centre of gravity of the various parts of the
motor). load and then combine them to get a cent&of gravity
for the whole.
b) Check the weight stated on any documenta-
tion. Wbea handling irregular shaped loadssuch~machine
tools where the position ofthe centre of gravity is not
c) ,I_ook at the drawingof the load. If theweight readily ascertainable it is essential to determine this
is marked check as in (a) above to elpun it ..by trial and error without lifting the load completely
includes all parts,of the load. 4: off the ground& Having established this the tackle
d) If the load is still on a trailer or truok, weigh it. should be adlusted to ensure that the load is evenly
~balanced for lifting without a tendency to topple over
e) Estimate theweightof the load by-usingtables and that no part of the load is subjected to
’ .of weights. In this respect ~S808 : 1989 gives excessive strain which might cause damage to the
the weight of.rolled steel sections. Table 3 load. Slings should be protected against any sharp
gives weights for other materials. edges on the load. The weight of all slings tackle and
lifting beams should be regarded as part of the load to
Table 3 Weight of Materials . be lifted.
[Clause 17.1.1 (e)]
173 Use of Lifting Gear
lkmuial Wc%at
4W Only slings and lifting gear for which a valid test
certificate has been issued and which have been
Ahninium 2700 thoroughly examined within the previous six months
Brass 8300 should be used. Slings and lifting gear should%
Brick 210 clearly marked with the safe working load and a#
Coal 1430 identification number (for test record purposes). All
-r 8800 slings and lifting gear should be visually inspected on
COaCrete 2400 each occasion before use. When not in use such lifting
Earth 1600 gear should be maint&ned in a serviceable
Iron, steel 7700 condition in a sunable store Lifting gresr should be
Lead 11200 released from the store only on the instruction of a ’
Magnesium 1150 responsibk person.
oil 800.
Paper 1 120 When use in,connection with the handling of molten
WPtU ldO0 metal or slag the safe working load of all lifting gear
800 should be de-rated to half the norma! safe working
NOTES ,
load.
1Insomecrsesthe~bovc~usrv~onlyandtbe~l Chain(s) should not be joined by means of bolts or wire
weight may vary accordingto the pticulat compositionAvaler
conten~etc.
and when shackles are used it is essential that the
proper pins be fitted. Under no circumstances should
2 Au f@fes have ken kooduJ for umvenience of use. chains be knotted.
,3 Wh dealing with a bol~ow body check wbther it contaim
anything and whether any such contents are liable to move. Chains and slings should never be dragged along the
ground or floor (see IS 8324 : 1976).
17.13 Centre of Gravity
173 Hooks and Hook Blocks
It is important to know the position of the centre of Hooks and hook blocks should be of adequate capacity
gravity. This is the point at which the total weight of a for the loads to be lifted and should never be loaded
body may be regarded as being concentrated. beyond their safe working load. It should be’noted that

31
IS 13367 (Part 1) : 1992
hooks can be readily overstressed by the application of machine for this service, thi: crane manufacturer will
a load to the point ofrhe hook. assume certain dynamic loading values, but in
practice the magnitude of these will vary widely
To prevent displacement of the sling or load the hook
according to the method of using the breaking ball, the
should be provided with a safety catch or other
skill of thedriver incontrollingthe ball and tbc impact
efficient device. Alternatively the hook should be of
resistance of the object being broken. Manufaclurcrs’
such a shape (for example, a c-hook) as to minimize as nx%munendations and working loads should. themfore,
far as possible the risk of the sling or load becoming beregardrde’donlyasaguide.Lesserloadsand/orshortcr
detached. jibs should be adopted in the light of practical
The @lacing of more than one slingon a hook should be experience of the driver in the use of the particular
avoided and the sling should be attached to a ring link machine in similar applications and according to the
or shackle which is then placed on the hook. This technique adopted and the proven skill of the driver.
prevents the danger of a book beingstrained due to the
NOTE - II should be noted Iha! certain manufacturers do not
spread of the slings and also the danger of a sling
recommend use of their machines for balling operalions or may
fouling the safety catch orslippingover the nose of the only approve this condilionally such as with restriction in lhr
hook. All links, rings or shackles should ride freely technique tobefoliowed, the maximumjiblength 10 bc wed. rlc.
upon any hook on which they are used.
The ball should never be swung by operalion of the
When setting the load down whilst using a single fall
derricking mechanism.
of hoist rope, consequently relieving the tension of the
rope, the hook may spin. The slinger should always
The drivers of cranes engaged in balling operations
exercise caution in approaching the hook when
should be skilled and experienced in the USC of the
disconnecting the slings.
equipnl,ent and techniques ofballing, familiar with rhc
machine in use and aware of the potential dangers and
18 RAISING OR LOWERING OF PERSONS
their possible causes. Operational methods should bc
used which do not overstrain the jib or hazard rhc
The raising or lowering of persons by cranes, should
stability of the crane.
oilly b carried out on cranes fitted with automatic
brakes such that when the controls are released the
The use of swinging techniques should be restricted to
motions are brought to rest (‘Dead mans’ handle type
machines designed for arduous or heavy duty service.
of control). It should only be possible to lower persons The weight of the ball should alwsys be less than the
under power controlled conditions (that is not under
capacity of the machine at the required radius and a
free fall).
maximum of 70 percent of the safe working load is
Per&s should only be carried in properly -desigtled recommended.
chairs or cradles provided with suitable means to
_,,prevent persons or tools from falling out (for A rope from the second drum of the crane should also
example with wire mesh or similar protection to a be attached to the ball to prevent an inadvertent increasr
height of 1 m). Means should be piovided to prevent in radius which might result in an overload situation.
the chair or cradle from spinni,ng (for example by The ball should be connected to the hoist rope by
the provision of a swivel or the use pf multi-fall means of a free running swivel if no method of prevetdng
ropes) or tipping and it should be clearly and the ball from turning is to be used.
permanently marked with the load that it can safely
carry.Thechairorcradleshouldbeinspected toensure When an old commercial vehicle type is used to
that it is still in a safe condition to carry persons, at minimize shock transfer to the crane a lazy chain or
intervals not exceeding three months. Where the strap should also be fitted so that if the tyre were to fail
chair or cradle is subjected to arduous usage niore the ball will remain attached to the crane.
frequent inspection may be necessary. The chair or
cradle should be thoroughly .examined by a Care should be taken to prevent the ball striking the
competent pp.rson at least every ,twelve months. A crane and jiborobject? otherthan that to be broken. As
record of all mspections and thotiugh examinations a protection against the jib spr’inging over the cab on
should be kept. release of the ball, jib angles greater than 60” from the
horizontal should not be used. Jib safety stops should
19 BALLING OPERATIONS always be fitted on the crane and adequate protection
against flying debris provided for the driver.
19.1 Genet-aI
In cases of free standing cranes the ball should be used
In balling operations a round or pear-shaped weight, only when the crane is standing stationary on firm and
known as a breaking ball, is suspended from the hoist level ground. A crane should never stand within a
rope of a crane and caused to move to strike the building that it is demolishing. When demolishing
building, structure or other object so that the impact masoruy arches, suspended floor slabs, etc., care should
causes collapse or breakage. be taken to avoid the ball becoming trapped, as a
During balling operations dynamic loadings are sudden collapse of the structure could c&erload ihc
.-imposed on the jib structure and other parts of the crane. If the ball does become trapped, it should bc
crane by movement and impact of the ball. In rating a lowered off before being freed as a dragging or liftiiig

32
.
IS 13367 (Part 1) : 1992

action might cause the structure to collapse on top of should be taken to ensure that the stability of the crane
the ball, so pulling the crane over. is not hazarded by allowing the ball to swing outwards
beyond the maximum safe working radius.
In practice the operational techniques given in 19.2
and 19.4 are used in balling operations. This method is limited to relatively low level objects as
the ball cannot be swung effectively when positioned
19.2 Vertical Drop Balling at much more than half!he available heightoflift. It is,
however, the most advisable method as it produces the
The breaking of objects by drop balling is achieved by
least strain on the crane.
raising the ball vertically above the object aud then
allowing it to drop onto the object by force of gravity. 19.4 Swinging the Ball by Slewing
The ball may be attached to the hoist rope of a crane By this technique the ball is suspended some three
with a free fall capability. It should then be raised a metres or more below the jib head and the slew motion
short distance, be held by the hoist brake then be isengaged causingthe ball toswinginanarcand strike
permitted to .fall until the object is struck. Sudden the object. The slew motion should be disengaged and
application of the brake while the ball is still moving the slew brake applied to stop the jib at a point in lint
should be avoided as shock loads which would be with the point of impact. Agaiu a second rope sh!)uld
produt5ed by such action may cause structural damage be used to prevent the ball swinging out of the safe
to, or overturning of the crane. The distancewhich the radius. Considerable torsional loadings can be applied
ball is allowed to drop should only be iucreased once to the jib and other elements of the crane by USCof this
the characteristics of the object bcingstrurk have been technique though these cau be reduced to almost nil by
determined and heavier impacts are con..idered to be good driver control. The actual strain will be governed
safe. Where the point of impact is above ground level by a number of factors including:
or above an underground void there is a possibility of
length of jib and operating radius,
the ball missing the intended point of impact, passing
through the object or bouncing off. In such circum$tanccs distance of ball below the jib head,
the drop distance should be kept to a minimum and at
the iniended point of impact there should be sufficient rate of acceleralion of slewing motion,
length of lope left on the crane to allow the ball to be speed of ball at impact and the impact resis-
brought to rest by the brake to avoid endangering the tauce of the ob.ject,
crane. In operations such as demolition it is often
advisable to effect a number of heavy impacts to cause e) position of the jib head relative to the ball
multiple cracking and IO follow with a number of when it strikes the object,
lighter impacts until part of the object is broken and
then to repeat the exercise. 0 rate of checking the slewiug motion, and

d weight of ball.
Where it is not possible or not desirable to use a crane
with a free fall capability, the ball may be dropped by 20 SIGNALLING SYSTEMS
application of a quick release mechanism often referred
to as a ‘Monkey’. The ball should be carefully positioned Copies of the code of hand signals shown in Fig. 2
above the object to be struck and then be raised as should be issued to all crane drivers, slingers and other
before. The mechanism is normally released by a persons concerned in the carrying out of a lifting
downward force on a light rope or handline which is operation to ensure that a standard signalliug code is
either pulled manually or is automatically tensioned as used.
the lifting hook is raised. Once the ball is released it is
permitted a completely free fall to the point of impact In those situations where speciai lifts arc involved or
and therefore great care should be exercised to ensure whcrehandsignalsalongare inadequate otherformsof
that the ball is contained in the working area and that communication should be used, either by means of
all persomlel arc outside that area and are suitably radio or telephone to supplement the hand signals
protected from flying debris. code.

Free droppingcanalso be carried out by lifting the ball When radio is used as a means of signallin& the
by use of an electro magnet aud then releasing the channel selected should be kept clear of all other
magnetic force or by use of a grab or similar device. communications. All personnel involved in the sigualliug
should be given a clear and unique call sign and all
19.3 Swinging the Ball in Line with the Jib communications should be preceded by this call sign.
The crane driver should not respond to any command
An additional rope from a second drum on the crane is
that is uot preceded by the given call sign.
attached to the ball and is used to pull the ball in
towards the machine. The pulling rope is theu released
During the carrying out of the lifting operation hand
allowingtheball topendulumoutwards,intheplaneof
signals and any voice instruction to the crane driver/
the jib, to strike the object. The second rope is used to
drivers should only be given by one person at any one
control and limit the outward swing of the ball. Care *
time.

33
( Continued,from second cover )

Accordingly, Part 1 of this code deals with management and organization and other common
features of cranes. Subsequent parts of the code would deal with specific features of the specific
type of cranes as follows:
Part 2 Mobile cranes
Part 3 Lorry loaders
Part 4 Tower cranes
Part 5 Derrick cranes
Part 6 Overhead/underhung traveliing and goliath cranes
Part 7 High pedestal and portal jib dockside cranes
Part 8 Manually operated and light cranes
Part 9 Container bandling cranes
Part 10 Rail mounted cranes

This code contains information which should provide means for reducing the present unacceptable
number of accidents involving the use of cranes.

This part of the code is based on Dot 85/72574 ‘DC Draft British Standard Code of practice for
safe use of cranes: Part 1 General ( Revision of CP 3010 and BS 5744, Section 1 )’ issued by the
British Standards Institution ( BSI ), UK.

Standard Mark

The use of the Standard Mark is governed by the provisions of the Bureau of Indian
Standards Act, 1986 and the Rules and Regulations made thereunder. The Standard Mark on
products covered by an Indian Standard coveys the assurance that they have been produced
to comply with the requirements of that standard under a well defined system of inspection,
testing and quality control which is devised and supervised by BIS and operated by the
producer. Standard marked products are also continusly checked by BIS for conformity
to that standard as a.further safeguard. Details of conditions under which a licence for the
use of the Standard Mark may be granted to manufacturers or producers may be obtained
from the Bureau of Indian Standards.
t

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