LH ACC SINDRRI EXPANSION –II PROJECT

Method Statement
Use Of Man Basket(By Crane)

LH ACC SINDRRI EXPANSION –II PROJECT

December 2020

Prepared By Reviewed By Approved By

LNVT LNVT ACC Limited

PROJECT: LH ACC SINDRRI EXPANSION –II PROJECT

Client: - ACC

Method statement Number:

Drawings Ref No:

SL NO. DATE Description of Prepared By Checked By

Revision ( SINOMA
LNVT )
 PURPOSE:
This procedure is intended to provide guidance and information for ensuring the safe hoisting
of workers using crane‐suspended work platforms (man baskets). All aspects of the procedure
must be followed to ensure hoisting equipment meets all testing, certification and design
requirements. Man basket workers are properly trained on the hazards associated with
suspended man basket work activities.
This Procedure applies to all ACC site planning to use crane‐suspended man baskets.

SCOPE:
This guideline applies to all new and sustaining projects where there are no possibilities of
using a Mobile elevated working platform/Scaffolding Platform or any other ways of accessing
the job.

REFERENCE DOCUMENT:
1) Man basket “TPI Certification”
2) Crane “TPI Certification”
3) Work permit
4) FLRA
5) Lift Plan

EQUIPMENTS:
1. Suitable Crane (3rd party certification)
2. Man basket (3rd party certification)
3. Retractable fall arrestor, Sling, Wire Rope & All necessary lifting tools & tackles (3rd party
Certification).
4. Safety accessories /PPE required

Definitions
Term Description
Crane A machine that lifts, lowers, and moves a load horizontally. The hoisting
mechanism is an integral part of the machine. Cranes (fixed or mobile)
are driven manually or by power.
Critical Crane Lift Any crane lift that requires a Critical Lift Plan
Crane Operator A person certified as per State Factory rules or as being qualified to
operate a specific type model and capacity of crane. The crane
operator must have transport license, trained and certified by OEM to
operate the crane.
Critical Lift Plan A Critical Lift Plan is a document that identifies a specific hazardous
load and method of hoisting, and the operating restrictions. Pertinent
information includes all weights on hook blocks and attachments.
Rigger A person having relevant experience certified to prepare a load for lifting
by site in charge or his authorized representative
Standard Crane Lift A standard crane lift is any lift not classified as a critical lift. Crane
configuration shall be with main boom only.
Suspended personnel Also known as a suspended work platform, man basket or man cage.
platform
Responsibilities:
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 Plant Manager/Project Manager is responsible for the assurance that all work is planned and
conducted according to the preplanning documents. If there is a conflict between
procedures/standards or requirements the more stringent system shall apply.
General Requirements:
ACC official will first ensure whether or not an alternative means of accessing the work
location is available, such as by scaffolding, stairs, ladders, man lifts, etc.
Note: Hoisting employees in a crane suspended work platform is strongly discouraged by
ACC. Crane suspended man basket use shall be authorized only when the use of
conventional means of accessing a work area (ladder, stairway, aerial lift, elevated work
platform, or scaffold) is infeasible because of structural design or worksite conditions, or that
use of conventional methods would create a greater hazard to the worker(s).
Man Basket Trial Lift Process

Prior to the start of the trial lift process, a pre-trial lift meeting shall be held. All personnel
including ACC Official, riggers, crane operator(s), workers, etc. shall participate in the pre-
trial lift meeting. The meeting shall be documented with all participants signing the meeting
roster. Meeting has to be chaired by a responsible officer from ACC.
Prior to hoisting any person in a crane‐suspended man basket, a trial lift procedure including
a trial lift of the un-occupied man basket, followed by a trial lift of the occupied man basket
shall be conducted. Following the trial lifts, a final inspection of all equipment shall be
performed by the competent person to identify deficiencies. The trial lift process will be
documented on the Checklist and the FLRA.
A trial lift of the un-occupied man basket with a test weight attached that is 100% of rated
capacity shall be conducted. The basket will be hoisted from ground level (or the level at
which employees will have to enter the basket) to each work location where it is to be
positioned.
The trial lift will be conducted prior to placing personnel on the platform. The crane operator
will determine that all systems, controls, and safety devices are in place and operating
properly. The ACC official will also verify that the man basket can be positioned to all
planned work locations without exceeding 50% of the crane’s rated load capacity (as
determined from the load capacity chart, based upon the crane’s lift radius, boom angle, and
boom length).
After the unoccupied trial lift inspection, and just prior to commencing work activities, the
workers will enter the man basket and the basket will be hoisted a few inches off the ground
and inspected to ensure that it is secure and properly balanced. Actual site lifting trial
Note: For the purpose of calculating the total weight of personnel occupying the man basket,
the Contractor shall presume each worker to weigh 100 Kgs minimum.
Note: The trial lift process must be performed each time the crane is moved.
Suspended Man Basket Checklist
Prior to any use of a crane suspended personnel platform, a Suspended Man Basket checklist
shall be completed by the ACC competent person and approved
A separate Checklist must be completed for each work area/crane setup location. WAH permit
will be taken for this activity. The Checklist & Permit is required to be posted at the work area

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 for the duration of the work activity, and a copy shall be made available to ACC H&S
department for review upon request.
Checklist & Permits shall be terminated when working conditions change, when crane
operators are changed out, when man basket or rigging deficiencies are identified by workers,
crane operators and ACC officials. Under normal conditions, the Permit shall be terminated
by the ACC Executor upon completion of the work activity. Working in a man basket to be
performed in day light only.
Man Basket Requirements and Criteria (Design)
 The basket should be designed with a 5:1 safety factor by a qualified engineer and welded
by a qualified welder.
 The suspension rigging system must be designed in such a way as to minimize tipping of
the man basket.
 The maximum rated load and maximum capacity shall be posted on a permanently affixed
plate on the man basket.
 The guardrail should be designed to fully enclose the platform on all sides. The toe board
must be minimum 150 mm in height from the deck and the top rail must be a minimum of
1100 m in height.
 The platform should be of chequered plate
 A grab rail must be provided inside the entire basket perimeter.
 Suitable anchorage point(s) for personal fall arrest systems must be provided.
 The access gate must be designed to open inward, and is positively prevented from
swinging outward while the man basket is in use.
 The access gate must have a positive locking system to prevent accidental
opening during operation/occupancy.
 The design must allow enough headroom for employees to stand upright.
 There should be no rough/sharp edges on any man basket surface.
 In addition to hard hats, overhead protection should be provided when employees are
exposed to falling objects.

Fig 1-Front View

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 Fig 2-Side View

Fig 3-Plan View

Pre planning
Precautions shall be taken to protect employees from any special hazards in the work area
where the crane and man basket will be operating. . The Contractor shall adhere to all
critical crane lift, communication, and other procedures applicable to work conditions
presented by special hazards.
Special precautions must be taken to protect personnel from electrical hazards. When the
suspended man basket is working near electrical lines or devices, the minimum allowable
working distance from energized electrical lines shall be 6 meters (20’) more than the
boom length
Man Basket Inspection
Following the trial lift process and prior to issuance of the Permit, the man basket must be
hoisted a few inches off the ground to verify its hang level. It shall then be given a final

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 inspection by the crane operator or Contractor designated competent person(s). Inspection
items include:
 Crane base, sheaves, drums, ropes
 Rigging and tackle
 Man basket
 All hoist ropes must be free of kinks
 Multi-part lines are not twisted around each other
 The hook must be cantered directly over the basket
 The hoist lines are laying properly on hoist drums and in the sheaves
 The crane bearing surface has been checked and crane levelled, as necessary

The inspector shall determine if the testing process exposed any defects or adverse
conditions. Any defects found during the inspection must be adequately corrected before
issuance of the Permit and commencement of work activities.
Following corrections, the Contractor shall re‐perform the trial lift process, re‐inspect all
equipment and verify that corrections made adequately addressed the issue(s). Upon
passing this follow‐up inspection, the Suspended Man Basket Permit shall be approved and
issued.
Man Basket Requirements

Fall arrester (Rope Grab & Retractable Block) has to be provided to each workman in the
basket.
Additional anchor point (rope knot system) has to be provided for anchoring the lanyards

Management

Fig 4-Fall Protection Arrangements

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Additional safety slings (1”) have to be provided to the crane block (safety pin) hole (in case
of hook failure the man basket will hang on the block).

Fig 5-Safety (Additional) Sling Arrangements

Workers in the Basket will not stand direct under the main member of the basket to avoid
them to be pulled by the basket when any anchor point of the basket fails.

Fig 6-Working Position of the workers in the Basket

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Rescue

 Crane drum hoists should have full control load lowering

 A spare man basket should kept onsite for rescue purpose by using it on another crane
 Rope ladders to be anchored and kept inside the basket for self-rescue
 Fall arresters to be fixed parallel to the rope ladder for a safe descending purpose

Fig 7-Rescue Arrangements

Fig-8 Spare Man Basket Fig-9 Rope Knot for Trauma

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Communications

The crane operator must be in constant contact with basket occupants by use of standard
hand signals or voice communications. Communication system(s) used must be adequate in
allowing basket occupants to quickly signal for assistance during an emergency event.
Radio or other verbal communications device is required when direct visual contact between
crane operator and basket occupants is not possible, as well as where the use of a signal
person is infeasible or insufficient.
All manuals, operating instructions, and load charts have been read and are understood by
the involved personnel prior to starting the suspended man basket work operation.
Competent person Certification

Ensure that all suspended man baskets and man basket rigging and tackle are tested and
certified by competent authority. Certification must be from a ACC approved agency.
Suspended man baskets and lifting tackle shall be competent person certified on an annual
basis, at a minimum. Ensure that crane operators training and certification includes use of
suspended man baskets with cranes. After any repair or modification of the suspended man
basket, the unit shall be re‐certified by the approved competent authority prior to being
placed into service.
Procedures / work steps for man basket using
Activities Hazards Control Measures
Work permit Unauthorized  Authorized work permit holders shall ensure obtaining
commencement and maintaining valid work permits.
of works  Inform all people regarding permit conditions before
work starts
 Supervisors must conduct daily toolbox talk about
nature of work and associated potential hazards and
their essential precautionary
Placing of Toppling or  Area assessment has to be made where crane has to
crane unbalance of crane be positioned, proper levelling, grading and dressing;
crane swing area clearance assessment has to be
done before placement of crane
 Ensure no overhead power cables shall be routed in
the vicinity of the crane, if found maintain safe
distance
 Crane shall be certified by a competent person and
physically checked at site before taken in operation
 SLI, Limit switches and wind sensor should be fitted in
the Crane and should be in working condition
 The crane will be assembled and after assembly of
crane the crane swing will be checked for any
hindrance or obstacles during swinging
 Crane outrigger should be placed on levelled surface
before lifting the load
 Crane operator should be trained with valid licence and
valid certificate
 Operator will not use crane in wind condition while wind

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 speed over 25mph
 The operator must ensure that the area surrounding the
man basket is clear of personnel, structures and
equipment before hoisting/lowering the basket.
 Communication to the Crane operator will be done
through Walkie-Talkie and hand signal not on mobile
phone
 A perfect signal should be given to crane operators by
trained rigging foreman
 Close supervision during placement of cranes and
during man basket operation
Using of man Personal Injury  Area should be barricaded
basket  Skilled person should be deployed to the job
 Use appropriate PPEs
 TBT should be conducted with identified team in every
shift
 There should be no rough/sharp edges on any man
basket surface.
 Adequate illumination arrangement in dark hour
Failure of lifting tools  Four lifting hook points should be on top of man basket
& tackles for slinging
 All lifting tools & tackles should be “TPI Certified”,
colour coded and physically checked before taken in
use
 Selection of lifting tools as per man basket total weight
 Always prefer lifting plan
 All rigging activities should be performed under rigging
expert
 Regular physical inspection to be done of attached
lifting tools & tackles
 If found any technical or physical defect in lifting tolls &
tackles, immediate replace it with right one
 Operators of cranes used for hoisting suspended man
baskets shall be adequately trained and experience in
this activity.
Failure of man basket  Man basket should be made by healthy materials
due to uncertified  The platform should be of chequered plate
basket or overloaded
 Load test should be done by putting sand bag/related
Capacity load.
 The guardrail should be designed to fully enclose the
platform on all sides. The toe board must be minimum
150 mm in height from the deck, mid rail of 550 mm
and the top rail must be a minimum of 1100 mm in
height.
 Test weights should be rated 1.25 times the capacity
for the basket
 Only “TPI certified-load test” man basket should be in
use
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  Max weight with person is allowed up-to Kg
 Safe Working Load(SWL) and TPI tested date must be
clearly marked on the basket
 Angle of wire rope sling to basket should be more than
45^ (because if angle is less, sling of the basket will
be subjected to maximum stress)
 No large gaps should be in basket
 4 lifting hooks should be used for slinging
 Guide rope should be tied with the basket for
movement control
 Man basket should be use according to SWL and TPI
Instruction
 It is mandatory to check the crane basket every time
before a lift is performed.
 Suspended man baskets shall be promptly lowered to
the ground/structure and vacated where/when there is
any indication of dangerous weather conditions (high
wind, lightning) or other impending danger.
 All activities from the man basket should be performed
in daylight.
 Operators of cranes used for hoisting suspended man
baskets shall be adequately trained and experience in
this activity.
 Only the numbers of workers needed for the task are
permitted in the basket while suspended.
Worker Fall from  Only skilled person is allowed to the job
height  All engaged workers should be passed through “work at
height training”
 Man baskets must be surrounded by a guard rail over
man waist height.
 Anchoring points/ Cleats should be welded inside the
basket for harness anchoring
 Before entering inside man basket, workers should be
worn “daily checked” full body harness
 Guide rope should be tied with the basket for basket
movement control
 All workers must be advised that they are not allowed
to exit the man basket before it has fully landed on the
ground/structure.
 Basket occupants shall never stand upon railings to
gain additional working height
 Suspended man baskets shall be promptly lowered to
the ground/structure and vacated where/when there is
any indication of dangerous weather conditions (high
wind, lightning) or other impending danger.
 All activities from the man basket should be performed
in daylight.
 Adequate illumination arrangement in dark hour, if
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 required
 Housekeeping shall be well maintained inside the
basket to minimize the potential for worker slips, trips
and falls.
 Only the numbers of workers needed for the task are
permitted in the basket while suspended.
 The crane operator shall also ensure that the basket is
hoisted /lowered in a slow, controlled manner with no
sudden rapid movement of the crane.
 Crane drum hoists should have full control load
lowering
 A spare man basket should kept onsite for rescue
purpose by using it on another crane
 Rope ladders to be anchored and kept inside the
basket for self-rescue
 Fall arresters to be fixed parallel to the rope ladder for a
safe descending purpose
Fall of material from  Workers shall load the man basket only with those tools
man basket required for the task.
 The guardrail should be designed to fully enclose the
platform on all sides. The toe board must be minimum
150 mm in height from the deck, mid rail of 550 mm
and the top rail must be a minimum of 1100 mm in
height.
 All surroundings guard rails should be covered by Jali
(net)
 Materials and tools which may be displaced during
hoisting/lowering must be adequately secured to the
man basket and the drop zone to be barricaded
properly to avoid unauthorized entry.
 If welding is to be performed by employees occupying
the platform, the electrode must be protected from
touching the metal components of the platform.
Landing of man Hitting to nearby  Guide rope should be tied with the man basket for
basket at existing properties movement control
desired point  Lifting slings should not be in sufficient length
 Guide rope should be continuously tightly hold by two
workers or tied with structure when worker doing their
job from man basket
 All activities from the man basket should be performed
in daylight.
 Adequate illumination arrangement in dark hour, if
required
 The crane operator shall also ensure that the basket is
hoisted /lowered in a slow, controlled manner with no
sudden rapid movement of the crane.

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Crane, man basket and lifting champion
1. Check & confirm suitability of crane given in request as per load chart and allot in availability
slot.
2. Conduct periodical audit to verify compliance to daily checklist.
3. To hold and/or check documents such as PUC/ RTO registration / Insurance
certificate/certificate from competent person/driving license of crane operator.
4. Repair & maintenance of all cranes for smooth & safe operation and to ensure that record is
maintained.
5. Predictive & proactive maintenance of all cranes for smooth & safe operation and to ensure that
record is maintained.
6. TPI certificate of man basket
7. Physical condition of man basket
Inspection of Wire Rope Slings, Hooks, Shackles and Winches Slings
Slings
Should be tested and tagged on a six monthly basis and marked with SWL and inspection date.
They shall be visually inspected by a competent person before all lifting operations.
Hooks and Shackles
1. Check that the SWL is adequate for the lifts
2. Use only hooks and shackles marked with the SWL
3. Check shackle and pin for excessive wear:
4. Make sure that the pin is free, but not loose in the tapped hole. Secure pins with wire to
prevent them vibrating free
5. Threads of the pin should be undamaged and without appreciable wear
6. Never replace the pin of a shackle with a bolt. Bolts may not be to the same standard and
could fail
7. Check shackle and pin for distortion
8. Check alignment of the pin holes; the untapped hole should not be too large.
CATEGORY OF SKILL REQUIRED
1. Rigger Foreman
2. Riggers
3. Fitter
4. Helpers
Emergency Rescue Plan:
 In case of any incident, call to emergency Control Room by calling: 9771497741
 For emergency 24hr ambulance facility & Paramedical staffs will be available nearby First
Aid Centre.
 In case of vehicle break down or in any incident contact to our Plant & Machinery In-
charge for rescue the vehicle/Equipment.
All emergency contact number is displayed at site for immediate communication around the clock.
Further Onsite Emergency response plan to be followed if any emergency situation is
occurred

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 Man Basket Checklist
Date: Inspector:
Crane make: Model:
Equipment Number: Crane Capacity:
Crane Type: Hydraulic □ Conventional □
SN Points to Verify Yes No SN Yes No
1. PRE-LIFTING MEETING 4. CRANE
1 This lift is the only way to do the job 1 Load line can support 7 times intended
load
2 Rules and checklist handed out 2 Load chart examined for maximum
pick. Cut the chart numbers in half
3 Operator 3 Wind speed indicator
4 Signal Person 4 Wind speed should be less than 10 kph
if there is no OEM guide lines
5 Workers to be lifted 5 Boom angle indicator
6 Supervisor 6 Extension boom marked for length
7 Limit switch/anti-two blocking device
installed on boom
2. BEFORE THE LIFT (Workbasket design) 8 Outriggers fully extended, cribbed up
1 Man basket should be certified by 9 Site ready for crane
Competent person
2 Basket can support its own weight and 10 Distances from crane to loads
5 times its intended load measured
3 Access gate is equipped so that door 5. TEST LIFT
won’t swing out
4 All surfaces are smooth 1 Man basket Inspected by competent
person
5 Standard guardrail (1.1 m) with toe 2 Lift to actual site with total load 100% of
guard 150 mm minimum rated capacity (no people)
6 Grab rail inside to hold onto 3 Hoist rope has no kinks
7 Sides closed off, floor to guardrail with 4 Multiple part lines not wrapped around
½ inch or less wire mesh one another
8 Room to stand up in basket 5 Primary attachment is centred
9 Overhead protection from falling objects 6 Load line is tight and lines reeved
properly
10 Label on basket of basket’s weight 6. DURING THE PERSONNEL LIFT
3. RIGGING 1 Body parts inside cage (except signal
person as required)
1 Basket Rigged so it won’t tip when lifted 2 Lanyards to be anchored from the load
block/ball
2 Legs of wire rope connected to the 3 Platform must be tied to the structure
lifting point when in the air
3 All hardware can support 5 times 4 Willkie-talkie to be used for
intended weight communication
4 Hooks capable of opening and closing 5 Crane operator in cabin at all times
5 Wire rope “eye” have thimbles 6 Other lifts or picks not made while
platform in air
6 All hooks have a positive locking type 7 Stop the operation in bad weather or
latch (Safety Latch) adheres conditions
7 Work area of the man basket is clear of 8 No travel with people
personnel, structures and equipment
8 Riggers shall use taglines at all times Body harness anchorage provided from
with suspended man baskets 9 the hook Retractable fall arresters and
Rope grab provided
Precautions have been taken to protect
employees from any special hazards in
10 the area where the crane and man
basket will be operating; for example,
power lines or areas where the man
basket will be out of the operator's
view.
11 Rescue arrangements are provided in
the basket (rope ladder)
12 rescuer available at site
13 Drop zone area barricaded

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