CORPORATE SAFETY, HEALTH AND

ENVIRONMENTAL STANDARD
Title: Standard for Material Handling and Lifting Document Number:
ABG/CB/SHE2010.40
Operations
Issue Date: April 07, 2021

Name and Title Date

Written By: Standard, Rules and Procedure Sub committee Sept 08, 2010
Owner: Corporate Safety May 13, 2013
Approved By: OH&S Board May 13, 2013

REVISION LOG
REVISION
REASON FOR CHANGE(S): DATE:
NO:
00 New Document Oct 01, 2010
10 To address issues raised during implementing the standard and Jul 15, 2013
changing criteria for NDT inspection of lifting tools & tackles
20 Revised to align with ABG TS 32 Feb 02, 2018
30 Revised based on inputs Mar 27, 2019
40 Manual Material handling included Apr 07, 2021

DOCUMENT MANAGEMENT
SHE documents released from Central SHE Function shall be numbered as XXXX.YY. The first “X” shall be a numeric
character and can vary from 1 to 4 indicating level of document. The first level document (starting from 1XXX) shall be
SHE Policy / Principles etc. The second level document (starting from 2XXX) shall be corporate SHE standards; third level
document (starting from 3XXX) shall be Corporate SHE procedure while forth level of document shall be represented as
“4XXX” indicating forms and formats. The other three X (XXX) shall be numeric character and will vary from 001 to 999
indicating document number.
The first “Y” after dot sign (.) shall represent current revision status of document while second “Y” shall represent current
page revision. Any changes in this document can be initiated from any individual as approved by SHE Board Standards,
Rules and Procedure Subcommittee Chairman and shall be issued from office of Business Safety Head Office in
consultation with SHE Board. The revised portion of the document shall be maintained in Italic and in red color.

Distribution: OH&S Board Members, Unit Heads & Safety Website

Document No: ABG/CB/SHE /2010.40

Prepared by: Standard, Rules and Procedure Subcommittee
Approved by: OH&S Board
(ABG Cement Business – Company Confidential Document)
 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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Material Handling and Lifting Operations

Table of Content
1.0 Introduction 3
2.0 Scope 3
3.0 Manual Material Handling 3
4.0 Material Lifting Operations using mechanical devices such as cranes, 13
hoists, chain pulley blocks etc.
5.0 Implementing Safe Lifting Program 14
6.0 New Projects, Merger and Acquisition 29
7.0 Stakeholder Engagement 29
8.0 Legal and Other Requirements 29
9.0 Emergency Preparedness & Response 30
10.0 Monitoring, Reporting and Verification 30
11.0 Compliance & Performance 31
12.0 Roles & Responsibilities 32
13.0 RACI 33
14.0 Training & Awareness 34
15.0 Deviation Process 34
16.0 Review 34
17.0 Annexures 35
Annex A Example of Lift Categorization based on Routine and Non-routine lifts 35
Annex B Common Types of Lifting Equipment 36
Annex C Technical Standards on Lifting Equipment 40
Annex D Sample of Basic Lifting Plan 44
Annex E Responsibilities of Lifting Supervisor, Equipment Operator, Signalmen 46
and Riggers
Annex F Example of Crane Inspection Checklist 48
Annex G Self-Assessment Checklist for Material Lifting Safety 51
Annex G1 Daily operator checklist 53
Annex H Annual Inspection records 54
Annex I Recommended run over protection for hydra crane 58
18.0 Appendix Appendix 1: Definitions 59
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1.0 Introduction
Material handling and Lifting operations are integral part of any construction, manufacturing or service
activity. Any kind of material handling or lifting - either manual or using machines or tools require careful
planning and execution to manage the associated hazards. All UTCL sites conducting material handling & lifting
activities are required to establish management and operational controls to prevent incidents during material
handling and lifting operations. This document provides minimum requirement for planning, execution and
management of material handling and lifting operation.

This Technical Standard on Material Handling and Lifting Operations supports the UTCL’s Safety Policy, Safety
Principles, Life Saving Rules and Safety Management System. This Standard describes structured approach to
establish, enhance and align existing safety management processes and system to achieve the goal of “Zero
Harm” along with other business goal of zero defects, zero legal non-compliance etc. in a systematic and
auditable manner.

There are many modes and methods of conducting material handling & lifting operation. This Standard
provides the requirements to establish systems, management control and operational requirements for the
planning and execution of lifting operations to ensure safety. Any UTCL site having an existing system,
standards and procedures on safe lifting operations, shall assess practices shared in the Standard and can
improve upon them as appropriate.
2.0 Scope
This Standard applies to all sites managed by UTCL, research and development facilities, new projects, merged
and acquired entities. The Standard is relevant to all UTCL company employees and contractors, UTCL owned
or hired equipment. Conformance to the requirements of this Standard is applicable to the entire lifecycle
(including planning, assessment, exploration, evaluation, design, development, operation and closure) of a
project/business. This Standard primarily covers work activities involving manual material handling and use of
handling and lifting equipment such as forklifts, hand trucks, other manual material handling devices, mobile,
crawler, Tower, overhead travelling, jib/lorry cranes and hoists (excluding man- lift equipment, elevators,
powered industrial trucks and stackers) but does not cover details on any specific lifting equipment. Until
unless specified Mobile cranes includes Hydra.
This Standard is also not intended to provide design and technical details on any specific lifting equipment as
referred above. Sites are recommended to consult the manufacturer or supplier when more technical details
are required depending upon the equipment selected and its application. The requirement and practices
indicated in the Standard does not intend to replace any national or local legislation. In case of dispute, local
laws shall prevail.
3.0 Manual Material Handling
3.1 Definition:
Manual material handling (MMH) means manually moving or handling things by lifting, lowering, pushing,
pulling, carrying, holding or restraining. This is also the most common cause of occupational fatigue, back pain
and lower back injuries.
The following activities are commonly carried out at sites that involve manual material handling:
• Lifting, pushing or pulling heavy bags
• Carrying large, heavy sacks
• Moving large, heavy drums
• Manually carrying objects such as sheet / rod/ pipe etc. by single or multiple persons
• Transferring heavy objects
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3.2 Statutory Provisions:

Section 34, Factories Act, 1948- Excessive weights.
1. No person shall be employed in any factory to lift, carry or move any load so heavy as to be likely to
cause him injury.
2. The State Government may make rules prescribing the maximum weights which may be lifted, carried
or moved by adult men, adult women, adolescents and children employed in factories or in any class
or description of factories or in carrying on any specified process.

Model Rule prescribed under sub-section (2) of Section 34, Factories Act, 1948
No woman or young person shall, unaided by another person, lift, carry or move by hand or on head, any
material, article, tool or appliance exceeding the maximum limit in weight set out in the following schedule: -
Person Maximum weight of material, article, tool or appliance
(a) Adult male 55 Kilograms
(b) Adult female 30 Kilograms

3.3 Potential hazards involved in manual material handling:

The weight and bulkiness of objects lifted are major contributing factors to human injuries. The awkward
postures (e.g., bending, twisting), Repetitive motions (e.g., frequent reaching, lifting, carrying), Pressure points
(e.g., grasping loads, leaning against parts or surfaces that are hard or have sharp edges), Static postures (e.g.,
maintaining fixed positions for a long time) cause back injuries. Other hazards include falling objects,
improperly stacked materials and various types of equipment.
3.4 Anatomy of human back & spine:
Overview: The human spine is made of 33 individual bones stacked one on top of the other. This spinal column
provides the main support for the body, allowing one to stand upright, bend, and twist, while protecting the
spinal cord from injury. Strong muscles and bones, flexible tendons and ligaments, and sensitive nerves
contribute to a healthy spine. Yet, any of these structures affected by strain, injury, or disease can cause pain.
Spinal curves:
When viewed from the side, an adult spine has a natural S-shaped curve. The neck (cervical) and low back
(lumbar) regions have a slight concave curve, and the thoracic and sacral regions have a gentle convex curve
(Fig. 1). The curves work like a coiled spring to absorb shock, maintain balance, and allow range of motion
throughout the spinal column.

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Figure 1. The spine has three natural curves that form an S-shape; strong muscles keep our spine in alignment.
The abdominal and back muscles maintain the spine's natural curves. Good posture involves training the body
to stand, walk, sit, and lie so that the least amount of strain is placed on the spine during movement or weight-
bearing activities. Excess body weight, weak muscles, and other forces can pull at the spine's alignment:

• An abnormal curve of the lumbar spine is lordosis, also called sway back.
• An abnormal curve of the thoracic spine is kyphosis, also called hunchback.
• An abnormal curve from side-to-side is called scoliosis.

Muscles:

The two main muscle groups that affect the spine are extensors and flexors. The extensor muscles enable us to
stand up and lift objects. The extensors are attached to the back of the spine. The flexor muscles are in the front
and include the abdominal muscles. These muscles enable us to flex, or bend forward, and are important in
lifting and controlling the arch in the lower back.

The back muscles stabilize the spine. Something as common as poor muscle tone or a large belly can pull the
entire body out of alignment. Misalignment puts incredible strain on the spine.
Vertebrae are the 33 individual bones that interlock with each other to form the spinal column. The vertebrae
are numbered and divided into five regions: cervical, thoracic, lumbar, sacrum, and coccyx. Only the top 24
bones are moveable; the vertebrae of the sacrum and coccyx are fused. The vertebrae in each region have
unique features that help them perform their main functions.
Cervical (neck) - the main function of the cervical spine is to support the weight of the head (about 10 pounds).
Thoracic (mid back) - the main function of the thoracic spine is to hold the rib cage and protect the heart and
lungs.
Lumbar (low back) - the main function of the lumbar spine is to bear the weight of the body. The five lumbar
vertebrae are much larger in size to absorb the stress of lifting and carrying heavy objects.
Sacrum - the main function of the sacrum is to connect the spine to the hip bones (iliac).

Ligaments: The ligaments are strong fibrous bands that hold the vertebrae together, stabilize the spine, and
protect the discs.

Spinal cord: The spinal cord runs from the brainstem to the 1st lumbar vertebra protected within the spinal
canal. The brain sends motor messages to the limbs and body through the spinal cord allowing for movement.

Any damage to the spinal cord can result in a loss of sensory and motor function below the level of injury.
3.5 Ill-effects of adopting wrong way of manual material handling:
• Strains, sprains and musculoskeletal disorders (MSD) from lifting loads improperly or from forceful
exertions while carrying loads that are either too large or too heavy.
• Fractures and bruises caused by being struck by materials or by being caught in pinch points, and
• Cuts and bruises caused by falling materials that have been improperly stored or by incorrectly cutting
ties or other securing devices.

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Work-Related Musculoskeletal Disorders:

Musculoskeletal disorders (MSD) are injuries or disorders of the muscles, nerves, tendons, joints, cartilage, and
spinal discs. Work-related musculoskeletal disorders (WMSD) are conditions in which:

1. The work environment and performance of work contribute significantly to the condition; and/or
2. The condition is made worse or persists longer due to work conditions.

Examples of work conditions that may lead to WMSD include routine lifting of heavy objects, daily exposure to
whole body vibration, routine overhead work, work with the neck in chronic flexion position, or performing
repetitive forceful tasks. This report identified positive evidence for relationships between work conditions and
MSDs of the neck, shoulder, elbow, hand and wrist, and back.
MSDs are musculoskeletal system and connective tissue diseases and disorders when the event or exposure
leading to the case is bodily reaction (e.g., bending, climbing, crawling, reaching, twisting), overexertion, or
repetitive motion. MSDs do not include disorders caused by slips, trips, falls, or similar incidents. Examples of
MSDs include:
• Sprains, strains, and tears
• Back pain
• Carpal tunnel syndrome
• Hernia
Musculoskeletal disorders are associated with high costs to employers such as absenteeism, lost productivity,
and increased health care, disability, and worker’s compensation costs. MSD cases are more severe than the
average nonfatal injury or illness.
Examples of common WMSDs are discussed below:
Carpal tunnel syndrome (CTS): CTS is defined as a disorder associated with the peripheral nervous system, which
includes nerves and ganglia located outside the spinal cord and brain. Carpal tunnel syndrome is the
compression of the median nerve at the wrist, which may result in numbness, tingling, weakness, or muscle
atrophy in the hand and fingers.
Back injury and back pain: Symptoms of back pain are among the top ten reasons for medical visits. For 5% to
10% of patients, the back pain becomes chronic.

Arthritis:
The term arthritis is used to describe more than 100 rheumatic diseases and conditions that affect joints, the
tissues which surround the joint and other connective tissue. The pattern, severity and location of symptoms
can vary depending on the specific form of the disease. Arthritis is a concern in the workplace both because it
may develop from work-related conditions and because it may require worksite adaptations for employees with
limitations or disabilities.
Common features of the occupations with high likelihood of arthritis are physically demanding/heavy labor
tasks, lifting or carrying heavy loads, exposure to vibration, high risk of joint or tissue injury, and prolonged
periods of working in awkward or unnatural postures such as kneeling and crawling.

3.6 Ergonomics:
Ergonomics is the science of fitting workplace conditions and job demands to the capability of the working
population. The goal of ergonomics is to reduce stress and eliminate injuries and disorders associated with the
overuse of muscles, bad posture, and repeated tasks. A workplace ergonomics program can aim to prevent or
control injuries and illnesses by eliminating or reducing worker exposure to WMSD risk factors using
engineering and administrative controls. PPE is also used in some instances, but it is the least effective
workplace control to address ergonomic hazards. Risk factors include awkward postures, repetition, material
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handling, force, mechanical compression, vibration, temperature extremes, glare, inadequate lighting, and
duration of exposure. For example, employees who spend many hours at a workstation may develop
ergonomic-related problems resulting in musculoskeletal disorders (MSDs). Working within the power zone
(above knee, below shoulder, close to body) is ergonomically recommended.

3.7 Risk Assessment:

A suitable and sufficient risk assessment is required when manual handling cannot be avoided. The assessment
should identify where the risk of injury lies and identify appropriate ways to reduce that risk. A checklist can
help in systematically examine all the possible risk elements. Involving employees and safety representatives
in the risk assessment process is a highly effective way of identifying hazards and developing solutions that
work. The following steps are recommended to carry out the risk assessment:

• Describe the task being assessed.

• Work through the list of factors and tick the level of risk you believe to be associated with each of the
items. Note down the precise nature of the problem and include suggestions about the remedial
action that may be taken. It may also help to write down the names of those you need to consult
about implementing the remedial steps, e.g., managers, trainers, maintenance personnel or
engineers and employees or their representatives.
• Decide whether the overall risk of injury is Low, Medium or High to prioritize remedial action among
many risk assessments.
• Summarize the remedial steps that should be taken, in order of priority. Record the assessor’s name,
the name of the person responsible for carrying out any remedial action and the date by which it
should be completed.
• When all the manual handling tasks have been assessed, the completed checklists can be compared
to help prioritize the most urgent actions. However, there are likely to be several ways to reduce the
risks identified and some will be more effective than others. Do not delay action on those that can be
implemented easily and quickly simply because they may be less effective than others.
• Check later to make sure that the remedial action to remove or reduce the risk of injury has been
effective. The checklists will help bring out a range of ideas on how the risks identified can be avoided
or reduced by making modifications to the load, the task, and the working environment.

3.8 Developing and Implementing Workplace Controls:

A three-tier hierarchy of controls is widely accepted as an intervention strategy for reducing, eliminating, or
controlling workplace hazards, including ergonomic hazards. The three tiers are: Engineering controls,
administrative controls and use of personal protective equipment.
• Use of engineering controls: The preferred approach to prevent and control WMSDs is to design the job to
take account of the capabilities and limitations of the workforce using engineering controls. Some
examples include:
1. Changing the way materials, parts, and products can be transported. For example, using
mechanical assist devices to relieve heavy load lifting and carrying tasks or using handles or slotted
hand holes in packages requiring manual handling.
2. Changing workstation layout, which might include using height-adjustable workbenches or
locating tools and materials within short reaching distances.

• Use of administrative controls (changes in work practices and management policies): Administrative
control strategies are policies and practices that reduce WMSD risk, but they do not eliminate workplace
hazards. Although engineering controls are preferred, administrative controls can be helpful as temporary
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measures until engineering controls can be implemented or when engineering controls are not technically
feasible. Some examples include:
1. Reducing shift length or limiting the amount of overtime
2. Changes in job rules and procedures such as scheduling more breaks to allow for rest and recovery.
3. Rotating workers through jobs that are physically tiring.
4. Training in the recognition of risk factors for WMSDs and instructions in work practices and
techniques that can ease the task demands or burden (e.g., stress and strain)

• Use of personal protective equipment (PPE): Using the following personal protective equipment prevents injuries
when manually moving materials: -
1. Hand and forearm protection such as gloves for loads with sharp or rough edges. If you wear
gloves, choose the size that fits properly. Depending on the material the gloves are made of and
the number of pairs worn at once, more force may be needed to grasp and hold objects. For
example, wearing a single pair of heat-resistant gloves can reduce your grip strength up to 40
percent.
2. Eye protection
3. Appropriate Steel toed safety shoes to avoid slips, trips, or falls.

3.9 Checkpoints / Precautions to be taken during manual material handling:

• Whenever possible, use lifting aids, cranes, forklifts or hoists to lift objects.
• Whenever possible, use trolleys to transport heavy objects.
• When moving materials manually, workers should attach handles or holders to loads. In addition,
workers should always wear appropriate personal protective equipment and use proper lifting
techniques to prevent injury from oversize loads.
• When Moving Chemicals and Hazardous materials (such as AFR):
i) Read and retain the relevant Material Safety Data Sheet (MSDS).
ii) Check that there are no leaks in containers.
iii) Wear appropriate PPE as advised in the MSDS.
• For maintaining good Housekeeping:
i) Return all moving\lifting gear to the correct storage location.
ii) When cleaning up ensure appropriate equipment and PPE is used.
iii) Leave the working area in a safe, clean and tidy state.

3.10 Kinetic way (Safe method) of lifting load:

A. Plan the Route.
• Where is the load going?
• Are there obstructions in the way?
• Is there somewhere to set it down?
B. One Person Lift
• Determine the weight.
• Look for sharp edges.
• See if weight is evenly distributed.
• Keep heaviest side to body.
• Decide how to hold the load.
• If it is too heavy use a trolley or get assistance

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C. Correct Positioning of Feet

• Comfortably apart
• One foot positioned in direction of movement.
• Other foot where it can give maximum thrust to the body.
• To maintain good balance feet should never be too close together on the ground.
D. Straight Back
• Lower the body by relaxing the knees.
• Keep your back straight (but not vertical)
• Keep load close to body.
• Keep chin in and head back.
E. Lifting
• If lifting from ground, make maximum use of legs.
• Keep back straight but inclined forward.
• As lift proceeds and the legs are straightened the back returns to vertical position
• Positioning of feet and bending of knees are the key factors in maintaining a straight back.
F. Correct Grip
• Take a firm grip by using the palms of the hands and roots of fingers.
• Taking weight on fingertips will create pressure at the end of fingers and could strain muscles and
tendons in the arms.
• A full palm grip will reduce muscle stress to the arms and decrease the possibility of the load
slipping.
G. Lifting Smoothly
• Thrust from back foot and straightening of knees will move body forwards and upwards – briefly
off balance.
• Immediately countered by bringing the back foot forward as if walking
• Lift now completed - forward movement results in smooth transition from lifting to carrying.
H. Carrying the Load
• Make sure you can see where you are going.
• Avoid twisting the body – move your feet instead.
• If you need to change your grip – set the load down – not whilst walking.
I. Setting the Load Down
• Use the correct stance for lifting and set the load down gently.
J. Two Persons/Team Lift
• Decide who will be caller and ensure that all team members are of almost same height,
• Assess the weight, ensure the route to carry the load is free from obstruction,
• Correct positioning of feet
• Straight back
• Correct grip
• Lift together
• The caller co-ordinates the lift and ensures each lifter knows what to do and when.

3.11 Use of Accessories for safe manual material handling:

A. Hand trucks:

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Hand trucks are for moving loads over short distances (typically less than 100m), and shall be specially designed
for lifting and moving packages or pallets e.g., hand pallet trucks. In the latter case, the facility to jack up the
truck shall be incorporated. Hand pallet trucks are suitable for loads up to 1500kg.
Hand pallet trucks must be clearly marked with their SWL and have an in-date certificate of inspection / test
from a third-party competent person as per Factories Act & Rules. Hand trucks must not be used on sloping
steel surfaces such as ramps and particularly not on long inclines (maximum recommended gradient 1:15). If
there is no alternative, consideration should be given to using trucks fitted with brakes. Hand trucks must not
be used on uneven or soft surfaces. Such surfaces, e.g., cracked concrete, distorted tarmac, sand and grassy
areas, increase both the physical effort required and the risk of toppling.
B. Forklift trucks:
Operations: Only forklift truck operators who have been properly trained and certified (valid license from RTO)
shall operate a forklift truck.
Before using a forklift truck, operators must check the truck and associated equipment to ensure they are in
safe and proper condition. Operators must ensure audible and visual warning equipment is working correctly
before using the forklift.
Parking: When unattended, forklift trucks must be left on even ground with the fork arms tilted forward and
lowered to rest on the ground. The engine must be switched off, the key removed, and the handbrake applied.
Ignition keys must be kept in a safe place and only issued to authorized operators for the duration of the duty
period or task. When not in use, forklift trucks must be parked in secure areas.
Operating Areas: Care must be taken at all times during forklift truck operations to avoid pedestrians, other
vehicles and hazards within their area of operations. Forklift truck operators must only drive-in areas where
they are authorized to do so. Forklift trucks must only be used in areas where there is enough room for safe
operation. Particular care must be taken to ensure that forklift trucks used in aisles have enough room to
circulate and maneuver either loaded or empty.
Forklift trucks must not be operated on excessive gradients. (In general, forklift trucks should be driven
forwards up a slope, backwards down a slope and in line with the incline. It shall be necessary to raise the forks
slightly at the bottom of a slope to avoid grounding.)
Stability of Forklift Trucks Loads and Handling: Forklift trucks must only be used to lift loads within their
certified capacity. Loads must be correctly placed and secured on the forks to avoid tipping forwards or
sideways. Wherever possible, forklift trucks must be driven with the forks in the lowered position and with the
mast slightly tilted back. The forks should be so adjusted that the fork heels should never touch the ground.
Movement with loads in excessively raised positions must be avoided to minimize the danger of toppling,
especially on uneven surfaces and while cornering. Forklift trucks must only be used for loads which can be
carried safely on the forks or attachments fitted.
General Operations: Operators must not carry passengers anywhere on the forklift truck. Operators must not
allow pedestrians to walk underneath the load. Forklift trucks must only be driven in a direction where visibility
is not blocked. Stacking and un-stacking on inclines must never be attempted. Rapid acceleration, hard braking
and sharp cornering which increase the risk of load tipping must be avoided. Operators must exercise caution
and drive slowly on slopes, uneven and damaged surfaces. Care must be taken when operating in proximity to
pedestrians and other vehicles.
C. Lifting Beams & hooks:
A lifting beam is a simple design of a long I-beam with a link or eye on the top to allow for connection to the
crane or other lifting machine's hook. It also has two or more connection points on the under where the load
is connected.

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Lifting beams are excellent for general purpose lifting, as well as for lifting weak or flexible loads that require
the additional support of other equipment. An additional benefit of a lift beam is the ability to lift more than
one load at a time since it is typically designed with two or more connection points.

D. Crowbar:
This is a metal tool used mainly to pry things open. It is usually hook shaped. Sometimes the bottom is slightly
curved to allow for better leverage. Some crowbars have a notched an end for removing nails. It is used as a
lever either to force apart two objects or to remove nails. Common uses for larger crowbars are removing nails,
prying apart boards, and generally breaking things.

E. Plate Clamp:
A plate clamp can be used to safely and securely move plates horizontally or vertically. Used with a crane hook,
the clamp’s cam and jaw mechanism locks the plate in place. Although one can be used to move certain
lightweight loads, plate lifting clamps are generally used in pairs in order to lift and transfer loads.

F. Wheelbarrow:
A wheelbarrow is a compound machine that is popularly used to carry heavy loads. It has two simple machines,
the wheel and axle and the lever that helps to makes the load lighter and simpler to move around. When you
pick up the handle of the wheelbarrow and raise it, you are applying effort to the lever. When you apply force
to the lever, the wheel will start rolling. The axle on the other hand, will increase the force — making it easier
to push the load. This enables the wheelbarrow to carry heavier loads and move easily from one place to
another.

G. Drum handler is a mechanical equipment that is used to handle and transport cylindrical module such
as steel drums, barrels, plastic drums and fiber drums. Unlike the forklift attachments, mobile drum handlers
have built in wheels so one can easily maneuver it anywhere.

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H. Gas Cylinder trolleys are to be used for handing and transporting gas cylinders securely in an upright
position.

3.12 Material Storage (Stacking and unstacking):

Stacking: When planning materials stacking, the following points must be considered:
The permissible floor loading and the design load-handling capability of storage racks and bins. The site layout
with adequate walkways and aisles. Materials routing in and out. Method of stacking to be used. Available
or required materials handling facilities and equipment. Area lighting with avoidance of shadow areas. Pallet
design and load bearing capacity.
Factors governing the size of stacks are volume and area available, and size, bulk, weight, type, rigidity and
fragility of materials to be stacked. Loaded pallets must not normally be stacked more than three high. Height
of stack to be restricted to prevent falling object hazard.
Stability of stacks must be determined by: A safe ratio of height to base area. Sound interlocking of the
materials, crossway stacking of bags for better stability of stack. How much of the aggregate weight is borne
by the components in the lowest tier of the rack? Good placement of every component in a stack, with no
overhangs. Heavy items of equipment stored in custom-built crates or containers must not be stacked on top
of the other (only the bases of these containers are designed to bear the load of the contents). Stacks must be
positioned at least 0.5m from walls.
Un-stacking: Most incidents involving the collapse of stacked materials occur when a stack is being taken
down. During this activity, the following must apply:
One person only is responsible for the manner in which the stack is reduced. If the person in charge had no
part in the erection of the stack, he has to familiarize himself before work begins. The stack is to be taken down
tier by tier (from top to bottom) without “taking bites” out of it.
3.13 Training & Awareness:
Proper training on manual material handling should always be imparted to avoid injury due to manual material
handling hazards and thereby ensure safe work performance. Whether moving materials manually or
mechanically, employees should know and understand the potential hazards associated with the task at hand
and how to control their workplaces to minimize the danger.
Because numerous injuries can result from improperly handling and storing materials, workers should also be
aware of incidents that may result from the unsafe or improper handling of equipment as well as from improper

Document No: ABG/CB/SHE /2010.40

Prepared by: Standard, Rules and Procedure Subcommittee
Approved by: OH&S Board
(ABG Cement Business – Company Confidential Document)
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work practices. In addition, workers should be able to recognize the methods for eliminating—or at least
minimizing—the occurrence of such incidents.

4.0 Material Lifting Operations using mechanical devices such as cranes, hoists, chain pulley blocks etc.
UltraTech company activities, projects and managed operations which undertake lifting operations shall
establish and maintain management system and procedures to ensure that:
A suitable lifting safety program/ safe system of work is developed consisting planning and execution of lifting
operations.
a. Risk assessments and permit to work are required for all lifting operation.
b. Lifting Plan with clear control measures is documented, communicated and executed.
c. The worksite is physically safe for the lifting operation e.g., there is no physical obstruction in the
path of the load.
d. The lifting equipment is correctly selected, tested and certified in accordance with legislative
requirements and technical standards.
e. The personnel deployed as part of the lifting team are suitably trained, competent and certified.
f. Only competent contractors are used, and all lifting work is appropriately supervised.
g. All lifting equipment and accessories are tested prior to commissioning and periodically by
competent persons for rated capacity and records are maintained.
h. All incidents, accidents, near misses, equipment failure or damage are reported in ENABLON or
MySetu.
The key functional aspects of safe lifting management program are schematically presented below:

Document No: ABG/CB/SHE /2010.40

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5.0 Implementing Safe Lifting Program

5.1 General Safety Requirements
Lifting by cranes, hoists, or other mechanical lifting devices shall commence only after meeting the following
conditions:
• An assessment of the lifting equipment has been completed.
• The lifting method and equipment is determined by a competent person(s).
• Operators of powered lifting devices are trained and certified for that equipment.
• Rigging of the load is carried out by a competent person(s).
• Lifting devices and equipment have been certified for use within the last 12 months (at a
minimum).
• Load does not exceed dynamic and/or static capacities of the lifting equipment.
• Any safety devices installed on lifting equipment are operational; and
• All lifting devices and equipment have been visually examined before each lift by competent
person.

5.2 Lift Categorization

To ensure that suitable controls are applied, lifting operations shall be categorized according to the level of
risk and complexity. Unit need to identify and get approval of Routine lifts. All routine lifts shall have SOP, Basic
Lifting plan and exclusion as per PTW.

Example: Lifting of Empty Cement Bags at Packing Plant

Handling of small loads at workshop

For further derails See Annex A: Example of Lift Categorization based on Routine and Non-Routine Lifts. Lifts
not listed and approved as Routine shall by default be Non routine activities.

5.3 Competency and Certifications

Only suitably trained and competent personnel shall be deployed as part of the Lifting Team. All persons
involved in planning and performing lifting and maintaining lifting equipment shall be trained and competent
for their role. The competency requirements shall consider the availability of certifications issued by the
competent agencies/ institutions, as may be applicable under the national and state regulations.
5.4 Hazard Identification and Risk Assessment
The hazards associated with lifting and hoisting activities include but not limited to a. Structural failure.
b. Crane collapse.
c. Crane overturning.
d. Contact or collision with other plant and structures.
e. Falling objects.
f. Falling from height.
g. Height restrictions with respect to the lifting plan.
h. Climatic conditions.
i. Electrical overhead cables in vicinity.
j. Stacking and de-stacking of goods; and
k. Striking people and equipment.

Document No: ABG/CB/SHE /2010.40

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 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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UTCL sites shall ensure that prior to undertaking any lifting operation; a risk assessment is conducted to ensure
the selection of appropriate control measures. Sites may not be required to conduct risk assessment for
routine lift operations every time as long activity is repetitive in nature and involves loads that are similar in
shape, size and weight. However, sites shall conduct risk assessment for all non-routine operations each time.

The risk assessment shall consider, but is not limited to, the following issues:
a. Competency requirements of operators/ signaller/ slingers.
b. Lifting equipment and accessories testing and certification requirements.
c. Unauthorized use of lifting equipment.
d. Failure of lifting equipment or lifting accessories.
e. A load being dropped whilst suspended.
f. Unstable ground conditions: collision of lifting equipment where two or more devices are
being used in close proximity to each other.
g. Visibility.
h. Lifting of people.
i. Communication.
j. Fatigue.
k. Employees being struck by the load or lifting equipment.
l. Striking overhead power cables or other services.
m. Falls during the erection of cranes.
n. Manual handling risks associated with lifting and moving heavy equipment.
o. Health risks from oils, solvents and greases; and
p. Contact with moving machinery parts during maintenance.
q. The results of risk assessment shall be considered in selecting the fit for purpose lifting
equipment and developing the safe lifting plan.

5.5 Selection of Lifting Equipment

The lifting equipment is available in a variety of designs, specification and forms. The selection of lifting
equipment is critical in developing safe systems of work. Sites shall consider the job requirements and results
of risk assessment while selecting fit for purpose lifting equipment. The lifting supervisor shall be involved in
the decision-making process. A number of relevant factors, which need to be considered on for the selection
process include:
Weights, dimension and characteristics of loads.
a. Number, frequency and duration of the lifting operations.
b. Length of time for which the equipment will be required or anticipated life expectancy, d.
Space available.
e. Site, ground and environmental conditions or restrictions.
f. Mobility of the equipment (will lifting operations be carried out in one place or several
different locations: and
g. Lifting radius.

Based on the above factors UTCL sites shall ensure that the selection of lifting equipment is carried out
following the principles of risk assessment and the best option for each lifting operation. Reference shall be

Document No: ABG/CB/SHE /2010.40

Prepared by: Standard, Rules and Procedure Subcommittee
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 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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made to the relevant International Standards/ Code of Practice for details of common types of lifting
equipment (cranes and hoists) and their operational characteristic. Refer Annex B: Common Types of Lifting
Equipment and Annex C: Technical Standards on Lifting. Sites shall ensure that the selected lifting equipment
meets the overall requirements of the planned lifting operations.

In addition to safety requirement in para 4.6 selection criteria following requirements shall be ensured before
hiring a Crane:
h. Meeting all the standard safety requirements
i. Healthiness of crane
j. Aging of crane 1) less than 20 years for crane below 50T & 2) less than 25 years for cranes
above 50T
k. Unit representative to inspect the crane before mobilizing.

5.6 Crane Safety Equipment

The minimum recommended safety equipment is as listed below:
a. Safe Load Indicator
All cranes (including Hydras) shall be provided with automatic safe load indicator with a visual warning to the
crane driver and an audible warning to those in the vicinity. In new installations of EOTs and Hoists above 10T,
site shall also ensure installation of SLI (Old installations before release of this standard will be allowed to have
EOTs without SLI).

b. Load Radius Indicator

A load radius indicator is required on certain jib cranes. It shall be clearly visible to the operator and indicate
the appropriate safe working load and radius for all configuration of the jib cranes used.

c. Motion Limit Devices

Where motion limit devices are fitted to limit hoisting, travelling, slewing, traversing, climbing or any other
crane motion, they shall be regularly inspected and maintained in good working order.

d. Overload Cut Out Devices

Switches, or other devices, may be fitted to cut out any selected crane motion when the crane is in an overload
situation. The devices shall be maintained in good working order.

e. Level Indicator
Where fitted, level indicators shall be used in accordance with the instruction manual and maintained in good
working order.

f. Anemometer
Anemometers, or other wind speed measuring devices, shall have their indicators mounted in clear view of
the crane (except Hydra) driver or where appropriate, the person controlling the lift being undertaken. The
correct operation of these devices shall be regularly verified, and they shall be maintained in satisfactory
condition.

Document No: ABG/CB/SHE /2010.40

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 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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g. Fire Extinguisher
Fire extinguisher shall be provided in the operator’s cabin.

h. Cabins for Drivers

The driver of every power-driven lifting appliance shall be provided with a suitable cabin and the cabin
shall:
• Provide an unrestricted view for proper operation.
• Provide protection from weather; and
• Allow access to the machinery for maintenance work.

i. Brakes and Controls

All cranes, crabs and winches shall be fitted with brakes capable of holding and controlling their maximum
loads. The mobile crane shall be fitted with suitable horn, head lights, side lamps, rear and stop lights and
flashing direction indicator.

j. Rear and Side run over Protection.

All Hydras crane shall be provided with run over protection as per the Annexure I.

5.7 Lifting Plan

The Lifting Plan is a set of plans that are created for use in any crane lifting operation. Lifting plan is
supported by a risk assessment, a safe work procedure and/or method statement, and a permit to work.
Frequent or routine lifting operations may only require a basic lifting plan supported by an on-site risk
assessment and briefing to related personnel.
High risk or complex lifts requires additional engineering design efforts to ensure that the lifting is conducted
safely. Refer Annex D: Sample of Basic Lifting Plan.
The lifting plan shall clearly address, but not be limited to, the following:
The type and number of personnel required, their specific roles and competencies, and the method of
briefing.
a. The nature and weight of the load and lifting points.
b. Pick up and set down points and constraints such as space and stacking.
c. Equipment required and certification checks.
d. Step-by-step instructions.
e. Communication methods to be used.
f. Emergency and rescue plans.
g. Restrictions on the lift based on weather conditions, lightning, location of work, etc.; however,
no person is authorized to change conditions which may impact the integrity/safety of
equipment or area. Example –
Cutting of railing
h. Access and egress for slinging and un-slinging the load.
i. Simultaneous, conflicting or nearby operations or work.
j. Whether permit to work procedures are applicable.
k. Load integrity check; and
l. Load charts for generic lifting plan and for heavy or complex lifts.
Document No: ABG/CB/SHE /2010.40
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Lifting plan shall be reviewed and approved by FLE / Initiator trained and aware of Material lifting operation
requirement as per standard Annexure D.

Additional requirement of lifting of Critical load:

Any load to be lifted shall be considered critical if any of the below conditions are met.
• Load having 5 MT or more.
• Loading of Crane above 75% of rated/certified SWL of equipment without outrigger. (This
shall be irrespective of Load to be lifted)
• Loading of Crane above 85% of rated/certified SWL of equipment with outrigger and EOT or
overhead travelling cranes. (This shall be irrespective of Load to be lifted)
• Two or more crane, one crane or hoist, or any such combination is used for lifting the load.
a. When two cranes are used for operation ensure 20% greater than the calculated
share of load
b. When three cranes are used for operation ensure 33% greater than the
calculated share of load Any other condition unit may specify

Requirements for critical Lift:

a. Approval of Annexure D – Basic Lift plan by member of Critical Lift Group (A group of experts
in the plant to support the Crane Champion for planning critical lift or when needed. To be
identified and approved by Unit Apex Safety committee based on Competency. Critical lift
group should include trained and expert riggers).
b. Preparation or Approval of Rigging Plan by Critical Lift group member
c. Proof load test: Before start of each critical lift LOAD FUNCTION TEST (Proof load test) should
be done.

Sample rigging plan:

Document No: ABG/CB/SHE /2010.40

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 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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5.8 Lifting Team

The Lifting Team refers to a group of personnel that are appointed to be directly involved in a lifting operation.
For simple routine lifts, it typically includes the site supervisor, lifting supervisor, crane operator, riggers and
signalmen. For more complex lifting operations, it shall include other personnel such as the Appointed Person
(refer Appendix 1: Definitions) who had planned for the lift, Banksmen who will serve to coordinate other
equipment or personnel movement near the zone of operation. Annex E: Responsibilities of Lifting Team.
Lifting supervisor is the person who is overall monitoring the lifting operations at the Site. Lifting supervisor
may be Contractual supervisor. In case of Lifting operation is executed directly by the FLE/Initiator he shall
ensure all the roles of lifting supervisor.

5.9 Criterion for authorizing crane operator who shall be authorized by FH (T)
1. Qualification & Experience: Should preferably be with middle level school education but must have
minimum 5 years of relevant experience as a crane operator with valid license and should be able to
read load chart. Crane operator appointed before 2011 having lower qualification shall be assessed
for capability of reading load chart and crane operation may be authorized if found adequate by FH T
or Equivalent.
2. S/He should have HMV license from state authority.
3. Knowledge: He should have basic knowledge of all safety precaution & safety gadgets used in plants.
He should be aware of risk analysis & risk involved in the job and should have sufficient knowledge for
reading load chart, rigging plans, multi crane lift, Do ‘s & Don ‘ts guidelines and signaling.
4. Skill: He should know the machine well. He must understand its functions and limitations as well as its
particular operating characteristics. The operator must understand the correct meaning of all notes
and warnings and be able to calculate or determine the crane's actual net capacity for possible
configuration of the machine.
5. Healthiness: Physical fitness to be checked specially for good eyesight.
6. Safety: Operator should be aware with general safety rule for the job to be done. He should be aware
of safe practices in crane operation & rigging activity. Mobile crane operators shall successfully
complete a test that meets mandatory site requirements. Normal and emergency operations,
load/capacity chart use, and crane signals shall be covered in the test. Mobile crane operators shall
pass a medical examination given by a health- care professional at least once every one year. Eye
examination should be once in 6 months. Site management may elect to specify a more frequent
medical examination.

5.10 Flagman requirements: -

While crane marching & placement flagman shall navigate the crane movements and provide the directions
to crane operator while marching on road.
1. Qualification & Experience of flagman: 3 years of relevant experience as a crane Flagman and basic
knowledge of crane marching and his role in lifting loading activity in safe manner.
2. Knowledge & Skill requirement: He must have basic knowledge of all safety precaution & safety
devices used with Cranes or HEM’s in plants. He should be aware of risk involved in the job and should
have sufficient knowledge of signaling guidelines. He should have knowledge of the path prescribed
to march the HEM or cranes In UTCL premises. The flagman must understand the correct meaning of
all warnings and be able to take decision for safety of plant structure and buildings. In any emergency,
he must be clear about the actions, rescue plans and Company helpline nos.
3. Physical fitness criterion: Physical fitness to be checked specially for good eyesight.

Document No: ABG/CB/SHE /2010.40

Prepared by: Standard, Rules and Procedure Subcommittee
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 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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4. Flagman should be aware with general safety rule for the job to be done. He should be aware of safe
practices in crane operation & rigging activity.
▪ Mobile crane flagman shall successfully complete a trade test that meets mandatory site
requirements.
▪ Normal and emergency operations, crane signals shall be covered in the test.
▪ Mobile crane flagman shall pass a medical examination given by a health-care professional
at least once every one year. Eye examination should be carried out in every 6 months
(reference various state factory rules requirement).
▪ While marching the crane, the Flagman must maintain a safe distance of 10 feet with cranes
and must be in continuing contact with crane operator.
▪ He must be visible to his crane operator as well as to passing by Vehicles.
▪ Not to use cell phone during crane operation.

Flagman not required for Hydras movement considering marching not allowed with load.

5.11 Labelling of Lifting Equipment

Every lifting equipment and its component parts shall be identified with a visible marking including the Safe
Working Load (SWL). The markings serve the following purpose:
a. Communicate clearly the maximum SWL of the equipment.
b. Clearly communicate the maximum number of persons it can carry if it is used for lifting
people.
c. Facilitate the identification of the equipment and its component including whether it is
genuine and compatible with the equipment.

5.12 Siting of Cranes

Every lifting appliance or machine shall be adequately and securely supported. During the planning operation,
the appointed person shall consider the siting of the crane. This shall consider of all the factors that may affect
its safe operation particularly the:
a. Crane standing and support conditions.
b. Presence of proximity and other hazards.
c. Effect of wind during in and out of service conditions.
d. Adequacy of access to allow for:

o Placing or erection of the crane in its working position; and o Dismantling and
removal of the crane following completion of lifting operations.

Document No: ABG/CB/SHE /2010.40

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e. Ensure Area/ground preparation is done wherever required in consultation with site civil engineer
if crane is required to be positioned on soft soil. It is to be done in consultation with Site - Civil
Engineer if crane is required to position on soft soil.
f. Distance from excavation pit shall be based on Load, type of soil and shall be established in
consultation with Site Civil Engineer. However, the minimum distance of siting of crane shall be
1.5 times depth of excavation.
g. Wherever needed soil compaction shall be undertaken and steel plates shall be used to provide a
firm base to lifting equipment/crane.

The minimum distance of lifting equipment, load line, or load (including rigging and lifting accessories) from
energized power line is shown in Table 4.1 below as recommended under Table A of OSHA CFR 1926.1408):

Table 5.1: Overhead Line Voltage and Minimal Clearance Distance

The authorized person shall ensure that the local offices of the concerned Electricity Department/ Authorities
are consulted if the crane is to be used within 15 m of overhead lines on steel towers, or 9 m of overhead lines
on wood, concrete or steel poles. This includes not only the crane but also the jib at its maximum length. All
distances shall be measured at ground level from a position estimated by eye to be vertically under the
outermost conductor at a tower or pole.

5.13 Capacity Loading* Limits

The margin of stability for determination of load ratings, with booms of stipulated lengths at stipulated
working radii for the various types of crane mountings, shall be established by taking a percentage of the loads
which will produce a condition of tipping or balance with the boom in the least stable direction, relative to the
mounting. The Capacity Loading shall not exceed the following percentages for cranes, with the indicated types
of mounting:
Type of crane mounting Maximum capacity loading
Crawler, without outriggers 75
Crawler, using outriggers fully extended 85
Truck and Wheel mounted without outriggers or 85
using outriggers fully extended

*Refer 4.16 for definition.

Document No: ABG/CB/SHE /2010.40
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 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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Any potential loading above 75% (without outrigger) shall be approved by Critical Lift group irrespective of
weigh of load. For Cranes with outriggers fully extended, EOTs, other electrical hoists the safe limit operation
will be 85% of SWL.
No capacity loading above 100% shall be allowed even under critical lift condition. Safe Load Indicator is
mandatory for all Mobile cranes including Hydras. In new installations of EOTs and Hoists above 10T, site
shall also ensure installation of SLI (Old installations before release of this standard will be allowed to have
EOTs without SLI).

As far as possible personnel lifting to be avoided. If unavoidable the capacity loading must be below 50% of
lifting capacity of the crane. Cage / Man basket used shall have specific identification no, SWL marked and
certified by competent person as per National/State regulation.

UTCL sites shall also refer the maximum permissible load ratings based on the manufacturer’s
recommendations.

5.14 Erection and Dismantling of Lifting Equipment

The lifting equipment shall be erected and dismantled in accordance with the manufacturer's specification as
laid out in the respective operational and maintenance manual.
Electrically operated cranes shall have an effective earth connection. In the case of cranes mounted on rails,
at least one rail track shall be electrically bonded at each rail joint and the track shall be effectively earthed.
Crane wheels shall not be used for earthing the crane.
Cables providing power to the crane shall be enclosed, positioned or constructed to protect them from
mechanical damage. This shall be achieved by following means:
a. Running in conduit or trays; or
b. Being clipped to a structure in a position where they are protected from mechanical damage, or c.
Being of armored construction.

5.15 Operation of Cranes

a. The load shall be lifted gently and operated smoothly to avoid load swinging. A swinging load will
increase the overturning moment of the cranes (see Figure 4.1 below). Always travel with the load
near to ground level so load swinging can be controlled. Travel with the load by hydra is prohibited
unless is designed and recommended by OEM.

Document No: ABG/CB/SHE /2010.40

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b. A crane shall not be operated if it does not have the facility of automatic braking (in case of power
failure).
c. Barricading/ warnings signs shall be provided to prevent moving below suspended load or the boom
areas of potential impact.
d. Cranes shall not be operated between sunset and sunrise without adequate lighting provision.
e. A standard code of hand signals shall be displayed in cabin and near the working area. Operator shall
respond to signals given by only authorized persons. The person directing crane movements (slingers
or signaller) shall be easily identifiable to the crane driver by wearing high visibility clothing or by other
means.
f. All personnel shall wear personal protective equipment including safety gloves, helmets, safety
spectacles, safety harness, high visibility vests, and safety shoes appropriate for the conditions of the
site.
g. Lifting person shall ensure that no person shall remain in line of fire or under lifted load anytime. Until
unless the slings are totally free (hanging on hook), the crane shall be considered under load.

Operation of Chain Pulley Block

a. Use only certified and tested Chain pulley blocks.
b. Never use block in excess of safe working load marked on block.
c. Before use, examine load chain to ensure that there is no twist (especially when the block is
reassembled at your end).
d. Observe that no foreign material, which may cause jamming, gets dragged with chain into the block
mechanism. Such jamming overloads block.
e. Keep load chain and Load chain wheel lubricated with medium viscosity lubricating oil along its whole
length and particularly at contact points between its links.
f. Chain Pulley Block is designed for lifting loads vertically and should not be used for pulling horizontally
or at an angle.
g. Do not leave or store pulley block lying on ground where they can collect dirt.
h. In the lower hook, there should not be any congestion of chains, ropes etc. Use of proper slings should
be resorted to for ensuring balanced lifting.
i. Chain block with multi fall should not be used with lesser fall or single fall.
j. No. of falls should be used strictly as per the manufacture’s recommendation.
k. No welding to be carried out on load chains.
l. While replacing spares the manufacturers material specification to be strictly followed. Better do
servicing with manufacturers authorized service centre.
m. Hooks are not to be crowded with multiple slings. ‘D’ shackle is to be used for use of multiple slings.
n. Chain blocks are designed for operation by a single person. If more than one person is called for it
means that the system is overloaded, or the appliance needs maintenance.

5. 16 Safe Working Load (SWL)

Safe working Load: It is maximum rated capacity of crane or equipment.

Lifting Capacity of Crane: It is the permissible rated capacity of crane at particular position as per load chart
for particular crane given by OEM.

Document No: ABG/CB/SHE /2010.40

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 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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Total weight: It is sum of the weight of the load and weight of hook block, sling and all other attachments.

Capacity loading: It will be calculated by dividing the “Total weight” with the “Lifting Capacity of Crane” in
percentage. Example-
SWL of Equipment – 10 T
Total weight (of Load to be lifted) – 6 T.
Lifting Capacity of crane (at X Meter boom & Y Meter radius) as per chart – 8 T
Capacity Loading = 75%

UTCL sites shall ensure that:

a. The SWL of every item of lifting equipment is known and clearly understood by lifting equipment
operators and signaller/ slingers. SWL shall be clearly marked on the lifting equipment
/accessories in a prominent position (as mentioned in the Test Certificate).
• Safe Working Load
• Date of Last Test
• Next due date
b. Any lifting accessory without its SWL clearly marked on it shall be removed from service.
c. Lifting accessory shall be removed from use until it has been thoroughly examined by an approved
third-party engineer.
d. Load Chart: A chart indicating SWL at various inclinations or radii of jib shall be displayed in the
driver’s cabin.
e. EOTs shall have SWL marking on both side of Beam clearly visible from Ground. Test dates shall
be marked on location below the EOT crane.

5.17 Load Radius Indicators

Sites shall ensure that all cranes with a variable radius are provided with a load radius indicator. The load
radius indicator shall be clearly visible to the crane operator and show the operating radius and the
corresponding safe working load.
5.18 Means of Communication.
a. UTCL sites shall ensure that there is an agreed and recognized means of communication between
the operator of the lifting equipment and the signaler/slingers. The agreed means of
communication shall be documented in the lifting plan (refer Section 5.7) and followed by all
those involved in lifting operations.
b. Where hand signals are used as the means of communication the signaler/ slingers shall be within
easy viewing distance of the crane operator. Where there is no clear line of site between the
signaller/ slingers and the crane operator, radio communication shall be used.
c. On tower cranes where the drivers cab is more than 35 meters from the ground level radio
communication shall be the mandatory means of communication between the crane operator
and the signaller/ slingers.
d. Sites shall provide clear instructions to all employees that only the appointed signaller/slingers
shall communicate with the crane operator. Crane operators shall also be instructed not to accept
signals from any person other than the appointed signaller/ slingers.

Document No: ABG/CB/SHE /2010.40

Prepared by: Standard, Rules and Procedure Subcommittee
Approved by: OH&S Board
(ABG Cement Business – Company Confidential Document)
 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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5.19 Wind Speed

b. Sites shall ensure that an anemometer is available on each worksite, where cranes are used, to
measure the wind speed. This shall be fitted to the highest point of the crane where reasonably
practicable.
c. Sites shall ensure that the manufacturer or supplier specifications are available for each crane and
that the wind-off speed of each crane is communicated to the crane operator and appointed
person.
d. Where wind speeds exceed the maximum figure stated by the crane manufacturer for a specific
mobile crane, crane operations shall cease, and the crane be placed out of service. Crane
operators shall recognize that dependent on the boom length, the wind speed may be greater at
the height of the load compared to the wind speed at the height of the crane’s cabin. A maximum
permissible wind speed of 10 m/second (36 km/hour) is specified for mobile crane operation and
15 m/second (54 km/hour) for tower crane operations by some crane manufacturers (Reference:
Tower and Mobile Crane Code of Practice 2006: Workplace Health and Safety Queensland). Sites
shall define the maximum permissible wind speed in consultation with the crane manufacturers.
e. For working at height wind speed shall be below 30 KMPH (Reference OSHA 1926.1431)

5.20 Pre-Use Checks and Periodic Inspections

Failure to carry out appropriate planned inspections, tests and preventative maintenance programs may lead
to decreased safety and efficiency in the operation of the lifting equipment. Inspection and appropriate testing
shall be carried out at sufficiently frequent intervals to ensure:
a. The parts of the crane subject to deterioration through corrosion, damage, wear and abrasion are
replaced before they become unserviceable; and
b. The crane is maintained in a safe and serviceable condition.
c. The inspection and testing regime for lifting equipment consists of the following:
• Pre-erection inspection and tests.
• Commissioning inspection and tests.
• Pre-operational inspection.
• Daily & Periodic (Routine) inspection and maintenance.
• Annual inspection; and
• Major inspection as per the manufacturers Operation and Maintenance (O&M)
manual.
Inspection: Routine (daily and Monthly) – Annexure G
▪ Each mobile crane operators shall inspect all controls and safety devices & fill daily checklist
before beginning of work.
▪ Crane operator’s inspection shall be documented, and records maintained.
▪ Crane champion shall inspect all mobile cranes at least once in a month following the same
inspection methodology used in the prior-to-use inspection.

Inspection: Annual
▪ Mobile crane equipment shall undergo periodic inspection by the competent person at least annually
( Annex – F ) .
▪ For company-owned mobile cranes, the annual inspection records shall be available on site.
▪ For equipment owned, leased, or rented by a contractor, the periodic inspection record shall be
reviewed prior to use.

Document No: ABG/CB/SHE /2010.40

Prepared by: Standard, Rules and Procedure Subcommittee
Approved by: OH&S Board
(ABG Cement Business – Company Confidential Document)
 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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▪ NDT (MPI) inspection of crane critical parts (hook, pin or others as necessary) shall be done once in
two years or earlier based on physical appearance.
Whenever lifting equipment has been subjected to high dynamic loading, e.g., jarring or working stuck pipe,
immediate inspection is required. This also applies to the derrick or mast after such operations.

See Annex F: Example of Crane Inspection Checklist (Annual).

Major inspection as per the manufacturers Operation and Maintenance (O&M) manual to be identified by unit
and mentioned in Site specific procedure.
Inspection of Wire Rope Slings, Hooks, Shackles and Winches

Slings
Slings should be tested and tagged in line with requirement of state factory rule or on yearly basis whichever
is earlier and marked with SWL and inspection date or color coded as per Unit color code for year. They shall
be visually inspected by a competent member of staff before all lifting operations.

Slings shall be rejected when there is:

❖ Severe deformation - where strands are severely kinked, or the core is protruding or formation of bird
caging.
❖ Severe wear - wear of high points of the sling caused by dragging the sling across decks contributes to
early broken wires. A sling which has wires worn to half normal diameter on high points should be
replaced.
❖ Termination damage
❖ Severe corrosion (be aware of the possibility of internal corrosion)
❖ Slings identified and rejected shall be destroyed beyond use. No slings or shackles shall be used by de-
rating on account of wear/tear or deformation.
❖ Manual spliced slings are prohibited.

Hooks and Shackles

❖ Use only hooks and shackles marked with the SWL and inspection Tag/color coded for current year.
❖ Check shackle and pin for excessive wear:
❖ Make sure that the pin is free, but not loose in the tapped hole. Secure pins with wire to prevent them
vibrating free.
❖ Threads of the pin should be undamaged and without appreciable wear.
❖ Never replace the pin of a shackle with a bolt. Bolts may not be to the same standard and could fail.
❖ Check shackle and pin for distortion, check alignment of the pin holes; the untapped hole should not
be too large.

Winches
❖ Check condition of wire - look for kinks, broken wires, flat spots, visible core, etc. Ensure that wire runs
freely in the mast.
❖ Check condition of eye - A thimble should be used. Check condition, spacing and correct installation of
bulldog clips.

Document No: ABG/CB/SHE /2010.40

Prepared by: Standard, Rules and Procedure Subcommittee
Approved by: OH&S Board
(ABG Cement Business – Company Confidential Document)
 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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❖ Check condition and operation of brake - brake rims and bands shall be in good condition and the
linkage operating freely. Avoid bands becoming contaminated with oil or mud or water.
❖ Check hook and safety latch are in good condition and the swivel is operating freely.
❖ Perform MPI Inspections on Winch pedestals and securing mechanisms (bolts or welds) once in year.
❖ Winches with a freewheeling device should not be used.
❖ The safe working load of the wire and the winch securing mechanism shall be greater than the
maximum winch.
pull (stall at overload).
Hook
❖ Prior to initial use, all new and repaired hooks shall be inspected by a qualified inspector to ensure their
compliance with the applicable provisions of ASME B30.10, Section 10-1.2. Dated and signed inspection
records shall be kept on file and shall be readily available.
❖ Inspection procedure and record keeping requirements for hooks in regular service shall be governed
by requirements for the kind of equipment in which they are used.
Daily Inspection
a. Operators or other designated personnel shall visually inspect hooks for deficiencies such as the
following each day or prior to use if the hook has not been in regular service (records are not
required):
1. Cracks, nicks, and gouges.
2. Deformation.
3. Damage from chemicals.
4. Latch engagement, damage to or malfunction of latch (if provided).
5. Evidence of heat damage.
b. A designated person shall examine deficiencies and determine whether they constitute a safety
hazard and
whether a more detailed inspection is required.

A. Periodic Inspection
A qualified inspector shall perform a complete inspection annually.
a. Hooks having any of the following conditions shall be removed from service until repaired or
replaced:
1. Deformation – Any visibly apparent bend or twist from the plane of the unbent hook.
2. Throat opening – Any distortion causing an increase in throat opening exceeding 5 percent,
not to exceed ¼ inch (or as recommended by the manufacturer).
Following is the standard chart indicating discarding criteria.

Document No: ABG/CB/SHE /2010.40

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3. Wear – Any wear exceeding 10 percent (or as recommended by the manufacturer) of the
original section dimension of the hook or its load pin.
4. Cracks.
5. If a latch is provided and it becomes inoperative because of wear or deformation or fails to
fully bridge the throat opening, the hook shall be removed from service until the device has
been repaired or replaced and the throat opening has been assessed as described above.
6. Any self-locking hook that does not lock.
b. If hooks are painted, a visual inspection should take the coating into consideration. Surface
variations can disclose evidence of heavy or severe service. The surface condition may call for
stripping the paint in such instances.
c. Hooks shall undergo NDT once in two years.
d. Dated and signed inspection records shall be kept on file and shall be readily available.

EOTs/ Electrical Hoist

❖ Follow monthly check by team of Electrical and Mechanical for EOTs. Unit may prepare check
points.
❖ Check condition of wire, hook, latch.
❖ Check condition of all Limit switches of Up/Down, Cross travel, Long Travel.
❖ Check hook and safety catch are in good condition and the swivel is operating freely.
❖ Provide access / rails / lifeline along rails, check its condition as per work at Height Standard
requirement ❖ Check rails alignment and wear tear.
❖ Check condition of panel, electrical equipment, Emergency stops ❖ Check earthing of all
electrical equipment, rails.
❖ Annual check to be carried out as per Annexure - H.

5.21 Test Certificates and Documentation

Appointed person shall ensure that the following documentation is always available at the place of use.
a. Safe Working Load Charts: Safe working load charts applicable to the various specified operating
conditions of the crane, with appropriate de-rating for special applications such as magnet or
grabbing duties, shall be prominently displayed to the driver. Operation of the crane outside
these parameters even in an unloaded situation may give rise to danger.
b. Instruction Manuals: Instruction manuals containing adequate information on the erection, use
and dismantling of the crane shall be kept readily available at the location of the crane.
c. Test Certificates: All current test certificates for cranes and lifting gear shall be kept readily
available. Lifting equipment and accessories shall not be used unless the appropriate current
test certificates are available.

5.22 Learning from Incidents (RCN/BCN Recommendations)

1. Basic lifting plan mandatory for all Lifts
2. Unsymmetrical object shall be considered as Critical lift and shall be reviewed and approved by
unit competent person.
3. Lifting supervisor must ensure that load end is completely free from slinging/sling entanglement
before signaling operator to take the boom up.
4. Ensure visibility of person engaged in rigging by operator.
5. Inspection of cleats/anchoring points of loads to be done before every use and recorded in SWP.
Document No: ABG/CB/SHE /2010.40
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Document. No. ABG/CB/SHE/2010.40 Page 29 of 61

6. Train and monitor to ensure no person are in line of fire.

7. While reviewing material lifting and lowering practices ensure the provision of locking
arrangement (Locking strips, bolting etc.) to avoid unintended movement during erection,
dismantling and maintenance.
8. Tandem lifting to be avoided and used only as exception.
9. Bypassing of SLI and other safety devices is prohibited.
10. Only trained and authorized operator to be deployed for cranes and Hydras. Recommended to
display picture and name of authorized operator(s) at door of crane.
11. Forklift driver shall be tested before deployment. (forklift recommendation added additionally
although not in scope of this or another standard)
12. Speed governor to be provided in all forklift to restrict speed.
13. Communication to be ensured among different teams during planning and execution of multiple
activities on specific risks arising from each other work including lowering lifting and work at
different levels of the same building. Ensure use of “Multi working Agency permit System”.
14. Competency of riggers and those authorized to issue permit should be assessed before
authorizing them.
15. Mechanical hold back arrangement required to prevent reversal of chain assembly (Bucket
elevator maintenance and handling activity)
16. Use of material cage for loose material, avoid bundling, direct lifting of refractory bags etc.
17. Ensure availability (healthy working conditions) of all Hoist, winches in plant to avoid using of
unsafe practices. Apart from annual check all equipment shall be checked before shutdowns)
18. Before start of each critical lift Load function test to be followed. Holding the load close to
ground for some time before lifting.

6.0 New Projects, Merger and Acquisition

New projects involving either brownfield or greenfield projects involve high risk due to erection, use,
maintenance and dismantling of numbers of lifting equipment within a construction site. All provisions as
mentioned above shall apply to new projects while carrying out any material lifting activity using hoists or
cranes.
Crane and hoisting contractors shall be selected based on the resource availability, competency and previous
experience in erection, use, and maintenance and dismantling of lifting equipment required at the project
sites. Safety in crane and hoisting operations may not be directly applicable during merger and acquisition.

7.0 Stakeholder Engagement

Stakeholder engagement shall be conducted for implementation of the Technical Standard.
This shall include the UTCL personnel, contractor’s employees and suppliers of lifting equipment and machines
who are involved in such activities. Engagement with such parties shall primarily include providing training on
lifting plans, risk assessment and safe work procedures.
.

8.0 Legal and Other Requirements

UTCL sites shall access, identify, evaluate and keep up to date the safety requirements for lifting as per
prevailing law in the area of operation. A register of such legal requirements shall be documented and updated
as appropriate. The legal requirements shall be incorporated into the lifting plan.

Document No: ABG/CB/SHE /2010.40

Prepared by: Standard, Rules and Procedure Subcommittee
Approved by: OH&S Board
(ABG Cement Business – Company Confidential Document)
 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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9.0 Emergency Preparedness and Response

Sites shall develop, implement and maintain a written Emergency Preparedness and Response Plan (EPRP)
which covers all aspects of the operations. The EPRP identifies the requirements and actions to be carried out
for any foreseeable emergency (with or without any casualty) in a clear and precise manner.
Sites shall, as a minimum, consider the following scenarios when planning emergency procedures:
• Recovery of a collapsed crane operator or erector from a tower crane.
• Employee becoming suspended by their safety harness following a fall during the erection or
maintenance of a tower crane.
• Overturning of a crane/ lifting equipment whilst lifting.
• Load being snagged during lifting operations.
• Security of the load being compromised during lifting operations; and
• Any other foreseeable emergency that may occur.
The EPRP shall include the emergency contact details of relevant persons and agencies. The contingency
procedure shall outline all possible emergency situations and identify the recovery actions to be taken if they
occur.
The documented procedures shall be tested by conducting EPRP drills involving all lifting operation personnel.
Such EPRP drills shall be documented and recorded as part of the safe system for work. The drills may be
conducted as a desk top review which includes all relevant personnel in the tabletop exercise. However, a
physical exercise and drill shall be carried out whenever possible.

10.0 Monitoring, Reporting and Verification

Each UTCL site shall monitor and verify the performance of the management program/ system on safe lifting
and hoisting operations including the compliance with applicable regulatory requirements. The requirements
but not limited to these, are presented in the sections below:
.

10.1 Monitoring
For each lifting operation various parameters shall be monitored. The following list provides generic
monitoring parameters.
1. A safe lifting and hoisting management program with adequate resources and management oversight
shall be developed and implemented to meet the objective/s of the monitoring program.
2. Certificates of lifting equipment and accessories (wire ropes/ chains, pulley blocks, etc.).
3. Lifting team competency checks and certifications\.
4. Lifting plan.
5. Inspection checklists specific to type of lifting and hoisting equipment; and
6. Incidents and accidents involving lifting equipment.

10.2 Reporting
UTCL sites shall maintained documented information for the following:
1. Records of risk assessment, lifting plan, technical specifications, operational manuals, record of
significant repairs, test and inspection records shall be maintained.
2. These records shall be maintained by the site for one year (unless otherwise required by the local
regulations).
3. Actions identified from inspection/ program audits shall be tracked and closed-out.
4. All incidents, accidents, near miss related material lift shall be reported and recorded in Enablon or
MySetu.

Document No: ABG/CB/SHE /2010.40

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5. Each UTCL site shall report the performance of their KPI’s in ENABLON (Sustainability Information
Management System) at appropriate frequency as defined by the ABG Sustainability Cell.

10.3 Verification
UTCL sites (Units Champion team) shall conduct annual internal assurance program to verify compliance and
performance of their safe lifting and hoisting management program. Refer Annex G: Self- Assessment
Checklist for Material Lifting Safety (Crane and Hoists). Sites shall also plan load tests, periodic examination/
testing of lifting equipment and accessories by competent agencies recognized by government agencies. The
frequency of these examination and lifting safety audit shall be dependent on the regulatory requirements or
once in a year, whichever is stringent.

11.0 Compliance and Performance

Each UTCL site shall monitor performance against the requirements of this standard periodically, document
in ENABLON. The assessment of performance shall include setting and reporting on key performance
indicators (KPIs).

11.1 Applicable KPI

Sites shall report the following KPI in mySetu/ ENABLON (as applicable).
HSI: High Severity Incidents which includes.
a. Material lifting activity without lifting plan as approved by appointed person (unless not exempted by
site requirements).
b. Use of lifting equipment without valid safety certification by competent person.
c. Lifting operations conducted by unauthorized operations/operators; and
d. Incidents related to lifting equipment erection, use, maintenance or dismantling.
Sites shall monitor the following KPIs and maintain record:
▪ Availability of up to date filled Inspection Check Lists,
▪ Availability of up to date filled Maintenance Check Lists,
▪ Field testing of Crane Safety devices
▪ Number of Lifting Plans prepared
▪ Related Tools & Tackles Inspection/certification records
▪ Availability of Qualified operator & Rigging crew Training programmed – scheduled Vs actual
conducted.

11.2 Change Management

UTCL sites shall ensure that there is a change management process in place in accordance with procedure on
Management of Change for any change in
Following are the changes, but not limited to, which can affect safe material lifting operations:
a. Lifting Equipment as supplied by OEM.
b. Change in Lifting Equipment.
c. Change in Lifting Supervisor/ Lifting Equipment Operator.
d. Any variation in lifting equipment erection or dismantling; and
e. Change in place or any change in proximate hazard.

Document No: ABG/CB/SHE /2010.40

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11.3 Monitoring by Senior Management

Senior management review shall enable decisions on issues that need senior management sign-off and have
material implications for business operations.

Site leadership to ensure following:

a. Self-assessment Questionnaire to be updated once in year as per Group Sustainability Guidance or
any other intervention recommended by Group Sustainability.
b. First Party Safety Audit shall be planned and conducted as per Audit Guidelines.
c. Second Party Safety Audit shall be planned by UTCL corporate and conducted as per UTCL Safety
Audit
Guidelines

12.0 Roles and Responsibilities

The overall responsibility to implement this Standard lies with the Business Head. Leaders and the Business
Review Council of UTCL shall ensure that roles and responsibilities for implementing and complying with this
Standard are allocated. Key responsibilities for each of the personnel shall be included in job descriptions,
procedures and/or other appropriate documentation.
Site should identify a mobile crane champion to assist the line management in implementing the mandatory
requirements. His responsibilities will include but not limited to:

o Check & confirm suitability of crane given in request as per load chart and allot in availability slot.
▪ Conduct periodical audit to verify compliance to daily checklist.
o To hold and/or check documents such as PUC/ RTO registration / Insurance certificate/certificate
from competent person/driving license of crane operator.
▪ Repair & maintenance of all cranes for smooth & safe operation and to ensure that record
is maintained.
▪ Predictive & proactive maintenance of all cranes for smooth & safe operation and to
ensure that record is maintained.
▪ Availability of cranes for allotment
▪ Assist for lift operations in plant.

Concerned Engineer
❖ Check suitability of crane referring to load chart & raise the request in Prescribed Format
including all details. Load chart will be provided by the crane supplier / contractor. For in-house
cranes load charts shall be maintained.
❖ Ensure Area/ground preparation is done wherever required in consultation with site civil
Engineer.
❖ Ensure completion of mandatory requirements such as vehicle entry permit, risk assessment,
equipment handling check list as per Annexure - D.
❖ Ensure use of tested lifting tool-tackles of appropriate capacity (sling / synthetic belt / D-
shackle etc.) ❖ Ensure toolbox talk before all movements & rigging operations.
❖ To discuss rigging plan with the foreman, signal man & crane operator for safe execution of
job.
❖ Ensure involvement of lifting supervisor in above process and risk assessment.

Document No: ABG/CB/SHE /2010.40

Prepared by: Standard, Rules and Procedure Subcommittee
Approved by: OH&S Board
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 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

Document. No. ABG/CB/SHE/2010.40 Page 33 of 61

Heavy Equipment Contractor

❖ Providing Lifting supervisor for monitoring operation safely.
❖ Ensuring that the deployed operator is well trained on safe handling of load, implementing
mandatory maintenance practices, licensed, experienced in crane operations, and competent
to operate the particular crane to which they are assigned on the particular job involved.
❖ Ensuring the crane is used in accordance with the manufacturers’ instructions and all
applicable regulations.
❖ Ensuring that the logbook/daily checklist is maintained and updated.
❖ Ensuring that all personnel involved in maintaining, repairing, transporting, and assembling the
equipment are well trained, experienced, and competent to handle their specific jobs in a safe
and efficient manner.
❖ Ensuring that a thorough crane maintenance and inspection program is established and
maintained.
Refer Annexure E - for responsibilities of Lifting supervisor, Equipment (Crane) operator, signalman and
Rigger.

13.0 RACI
The roles and responsibilities to implement this standard is outlined below:
Crane
Concerned Champion Critical Lift Unit Corporate Unit Head
Engineer (Qualified Person) Group Safety Safety

Identify Crane Champion & establish

Critical lift group for the unit I I I C C R, A
Determine the load to be
R, A C C
lifted
Crane suitability -
R A, C
noncritical lifting
Crane suitability - critical lifting R A C I
Tools /Tackles suitability
R A, C
& ensuring the certification
Safe access route & ground preparation R A C
Lift plan R A C I
Job execution (Critical & Non-Critical) R A C I C

Crane Inspection & Maintenance R, A C

Ensuring qualified crane operator R A C C C

R: Responsible
People who are expected to actively participate in the activity and contribute to the best of their
abilities.
A: Accountable
The person who is ultimately responsible for the results.
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C: Consulted
People who have a particular expertise and can contribute to specific decisions.
I: Informed
People who are affected by the activity/decision and therefore need to be kept informed, but do
not participate in the effort.

14.0 Training and Awareness.

Each site will have a process in place for the training of personnel who are involved in operation of lifting
equipment. Training shall ensure that personnel demonstrate competency in the relevant job
responsibilities. Information, instruction and training for lifting operations shall cover at least the
following:
• Understanding of lifting plan.
• Safe work method statements to be used in setting and safe operation of lifting equipment.
• Method for inspection and maintenance.
• Knowledge of the manufacturer’s operation and service manuals.
• The correct use, care and storage of personal protective equipment.
• The correct use, care and storage of tools and equipment to be used.
• Observance of electrical safety practice; and
• Procedures to be adopted in the event of accident or injury.
Training shall be provided through an e-learning platform, classroom training as well as on-the job
training. Site shall maintain accurate records of all personnel training.

15.0 Deviation Process

Each and every permanent deviation from this standard must have prior approval from concerned
Cluster/ Zonal Head followed by Corporate Safety and OH&S Board. Deviations must be documented,
and documentation must indicate causes of deviation with safety plan. Deviation authorization must be
renewed periodically and no less frequently than every three years. Temporary Deviation may be
authorized by Unit Head with mitigation method in consultation with unit competent person, temporary
deviation shall not exceed more than a month.

16.0 Review

This Standard shall be reviewed annually to determine its accuracy and relevance with regard to changes
in regulations, international standards and guidelines. Should such changes be identified, a brief
Addendum to the Standard shall be prepared outlining the change and its key requirements. The
Standard shall be revised once in every 5 years.

Document No: ABG/CB/SHE /2010.40

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 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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17.0 Annexures

Annex A: Example of Lift Categorization based on Routine and Non-routine lifts.

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Annex B: Common Types of Lifting Equipment

Mobile Cranes- These cranes consist of a jib mounted on’ a purpose designed chassis either road wheel
mounted, or crawler tracked. They may be permitted, when specified, to move on 'their wheels or tracks
when carrying loads or may require the use of stabilizers or outriggers to permit the lifting of their design
loads. Larger mobile cranes may consist -of separate units which when assembled for crane duties
operate on a fixed base. Enhanced duties may be obtained in special cases by the attachment of
additional structural members and counterweight or by mounting the mobile crane on a special base or
track, or by a combination of both. The common type of mobile crane include Tyre mounted mobile
crane (telescopic boom/ lattice boom); Crawler mounted crane; Rough Terrain Crane. Aerial man lifts
etc.

Lorry Loaders (Jib Type)-This type of lorry loader consists of a jib crane mounted on a load carrying
vehicle primarily intended for handling loads on or off the vehicle to which it is attached.

Tower Cranes-These cranes consist of a jib mounted at an elevated level on a vertical tower, the jib being
capable of slewing through 3600 or more. Tower cranes may be mounted on a fixed base, crawler tracks,
rails or wheels or may be mounted onto another structure.

Derrick Cranes- These cranes consist of a jib which is supported by ropes from a mast which in turn is
supported either by guy ropes, stays or other means.

Overhead Travelling Cranes (Electrical Overhead Travelling)- These cranes consist of a bridge girder or
girders mounted on end carriages housing the long travel wheels which travel along a gantry track. The
girders support a crab fitted with hoisting machinery having a hook, magnet or grab and traversing
machinery. The crab may support a fixed or slewing under hung jib or mast. The crane is normally
operated from a cabin either suspended from the main girders or attached to the crab.

Container Handling Cranes-These cranes are specifically designed for the purpose of handling containers
and incorporate a purpose-built spreader in their construction.

Hoist is a device used for lifting or lowering a load by means of a drum or lift-wheel around which rope
or chain wraps. The basic hoist has two important characteristics to define it:

Lifting medium and power type. The lifting medium is either wire rope, wrapped around a drum, or load-
chain, raised by a pulley with a special profile to engage the chain. Chain Pulley Block is designed for
lifting loads vertically and should not be used for pulling horizontally or at an angle.

The more commonly used hoist in today's worldwide market is an electrically powered hoist. These are
either the chain type or the wire rope type.
Winch: electric operated/ pneumatically operated.

Document No: ABG/CB/SHE /2010.40

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Document No: ABG/CB/SHE /2010.40

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Document No: ABG/CB/SHE /2010.40

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 Title: Material Handling and Lifting Operations Issue Date: April 07, 2021

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Document No: ABG/CB/SHE /2010.40

Prepared by: Standard, Rules and Procedure Subcommittee
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Annex C: Technical Standards on Lifting Equipment

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Annex D:Sample of Basic Lifting Plan

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Annex E: Responsibilities of Lifting Supervisor, Equipment Operator, Signalmen and

Riggers

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Annex F: Example of Crane Inspection Checklist

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Annex G: Self-Assessment Checklist for Material Lifting Safety

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Annex G-1: Operator’s daily checklist

Equipment Type: Tag No. Operator’s Name
Site Name:
S. No. Description
Date
Before Start:
1 Check Fuel Level; Engine Oil
Level; Hydraulic Oil Level
2 Check Radiator Water Level and
Break Oil Level
3 Check Belt Condition
4 Check Condition of Wire Rope,
Hook & Pulley, if applicable
5 Check any Leak – Diesel,
Radiator Water, Exhaust Gas
6 Check Condition of Hoses of Oil,
Diesel, Brake, Tyres
After Start:

7 Engine Oil Pressure,

8 Water temp.
9 Air Pressure Reading
10 Check for any Leak in
Pressurized Condition
11 Check for abnormal sound –
Gear Box, Engine and Rear Axle
12 Check Lights, Horn and
Indicators
13 Check all Operative Functions
14 Any abnormalities
observed/noticed
15 Check safety devices
Signature of Operator
Name & Signature of Lifting
Supervisor/Site Supervisor

Note: Same Checklist may be used for monthly checks

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Annex H: Annual Inspection Records

For EOT cranes / Gantry Cranes

Note: 1. Please specify ‘NA’ wherever not applicable

1. Proof Load applicable for New system and after major maintenance, repairs, annually if required as per
State Factory Rules

➢ GENERAL DETAILS OF E.O.T. CRANE -

Inspection Date – _________

01. Identification No. – 02. Mfg. Sr. No. –

03. Mfg. Year – 04. Make –
05. Span Length (Longitudinal) – _____Meter 06. Span Length (Transverse) – ____ Meter
07. SWL – ______Ton 08. Plant –
09. Lift – ______ Meter 10. No. of Falls – _____ Nos.

➢ SAFETY CHECKS –

HOOKS

DECRIPTION DETAILS
MAIN HOOK AUXILIARY HOOK
01. Identification Mark

02. Capacity of Hook (Marked)

03. Capacity of Hook (Standard)

04. Throat Opening (Measured)

05. Throat Opening (Standard)

06. Acceptance (Yes/No)

07. Condition of Hook

08. Condition of Swivel

09. Condition of Hook Block

10. Condition of Center Pin

11. Pulley Condition

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a) Nos. of Pulley

b) Play in Pulley

12. Safety Latches

HOIST
MAIN HOIST AUXILIARY HOIST
01. Wire Rope Diameter a). Nominal

b). Measured

02. Construction of Wire Rope

03. Original Test Certificate

04. No. of Falls

05. Condition of Wire Rope

06. Wire Rope Drum Condition

07. Wire Rope End Fitting

08. Hoist Brakes

09. Any Other Observation
LIMIT SWITCH / ALARM
01. Cross Travel Limit Switch
02. Long Travel Limit Switch
03. Up Limit Switch
04. Down Limit Switch
05. Gravity Limit Switch
06. Anti-Collision Limit Switch
07. Mechanical Stopper
08. Safe Load Indicator (for 10 T & above)
REMOTE CONTROL / PENDENT
01. Emergency Stop
02. Auto Off Released System
03. Key for on/Off and Mode Selection
04. Direction Marking of Motion
TROLLEY, RAIL AND BEAM
01. Beam Condition

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a) Structure
b) Weld Joints Beams/Angles
02. Rail Condition
a) Parallelism
b) Noise
03. Cross Trolley Platform and Trolley Wheel
Condition
04. Long Travel End Truck and Truck Wheel
Condition
05. Buffers of the End Truck
POWER TRANSMISSION
01. Gear Box Condition
02. Axle & Coupling
a). Alignment
b). Guarding
WALKWAY
01. Ladder to Walkway
02. Railing on Ladder
03. Walkway on The Crane
04. Railing on Walkway
05. Railing / Lifeline along Rails
ELECTRICALS
01. Motor Condition
02. Earthing to All Electrical Equipment’s
03. Main Switch Condition
04. Emergency Stop
05. Weather protection
06. All Controls and Panel Board
07. Siren, Fan, Lightings Etc.
08. Corner Switches
09. Rubber Mats Near Control panel
10. DSL Indicator Lamps.
OTHER GENERAL OBSERVATION
01.Operator’s cabin Condition
a) Sitting Arrangement
b) Lights, Fan, A/C
c) Control Levers & Panel Board
d) Glass & Beading

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e) Communicating Equipment’s
f) Fire Extinguisher
02. Electrical Cable Handling Trolley
03. Festoon Cable Handling Trolley
04. Guards to all moving equipment’s
05. Housekeeping nearby to crane .
PROOF LOAD TEST REPORT
➢ Tested Load (Proof Load):
➢ Thorough visual examination shall be done after load test.:
➢ Any defects observed after proof load test:
OPERATIONAL TEST REPORT
A). Long Travel
B). Cross Travel
C). Hoisting
D). Lowering
REMARKS: -

___________ _______________ ________________

Third Party (if applicable) Critical Group Engineer (Mech) Electrical Engineer

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Annex - I

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18.0 Appendices
Appendix 1: Definitions

UTCL UltraTech Cement Limited

Appointed Person The person appointed by the management or organization requiring the lifting
operation to be undertaken who will be responsible for all aspects of the lifting
operation.
Blind lift A lift where at any point in time during the lifting operation the crane operator
cannot directly see the load.
Capacity (dynamic and Structural capacity is the rated capacity based on strength of materials as well as
static) efficiency of hoisting devices, winches, cylinders, etc.

Static capacity is the rated capacity of the equipment based on the safety factors and
safe design of its components.

Dynamic capacity is the rated capacity of the equipment with deductions, depending
on the number of applied forces, from the structural capacity. It allows for dynamic
loading introduced into the machine or its components due to accelerating or
decelerating forces, the effects of vessel movements, etc. Thus, applies to all loads
lifted from or to a stationary vessel to a moving or floating vessel or from a floating
vessel to another floating vessel or structure.

Cranes mounted on fixed structures have a formula for deductions for all water lifts,
which shall be available to the operator and lift designer.

Certification Certification is an approved and legally compliant method of checking and providing
written evidence that a piece of equipment has been examined and meets required
standards.

Wire rope certifications prove that the materials are as stated and have been tested
to meet the standards indicated.
Competence In a broad sense, a competent person is an individual who, by way of training and/or
experience, is knowledgeable of applicable standards, is capable of identifying
workplace hazards relating to the specific operation, is designated by the employer,
and has authority to take appropriate actions
Crawler Crane A "crawler crane" consists of a rotating superstructure with power plant, operating
machinery, and boom, mounted on a base, equipped with crawler treads for travel.
Its function is to hoist and swing loads at various radii.
Counterweight The "counterweight" is a weight used to supplement the weight of the machine in
providing stability for lifting working loads.

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