J-0200000-06 PNSY Crane Regulations.pdf

J-0200000-X

CONTRACTOR CRANE, MULTI-PURPOSE MACHINE, FORKLIFT, CONSTRUCTION EQUIPMENT, AND

RIGGING GEAR REQUIREMENTS

The following requirements apply to any Contractor crane on Portsmouth Naval Shipyard.

1 CONTRACTOR CRANE, MULTI-PURPOSE MACHINE, FORKLIFT, CONSTRUCTION

EQUIPMENT, AND RIGGING GEAR REQUIREMENTS

1.1 The following is a list of requirements that contractors shall comply with for all contracts that may result in the use of a category 1 or 4 crane, multi-purpose machines, forklifts, construction equipment, and rigging gear when used on Navy property to lift suspended loads. Non-compliance with the requirements of this instruction may result in denial of access, stopping of operations, or removal from shipyard property.

1.2 References

1.2.1 NAVFAC P-307, Management of Weight Handling Equipment

1.2.2 American Society of Mechanical Engineers (ASME) B30.3 (tower cranes), B30.5

(mobile cranes), B30.8 (floating cranes), B30.9 (slings), B30.20 (below the hook lifting devices), B30.22

(articulating booms), B30.26 (rigging hardware); ANSI/ITSDF B56.6 (rough terrain forklifts); Safety

Standards for Cableways, Cranes, Derricks, Hoists, Hooks, Jacks, and Slings

1.2.3 CFR, Title 29, Chapter XVII, Part 1917, Marine Terminals.

1.2.4 CFR, Title 29, Chapter XVII, Part 1926, Safety and Health Regulations for Construction

1.2.5 CFR, Title 29, Chapter XVII, Part 1915, Occupational Safety and Health Standards for

Shipyard Employment

1.2.6 OPNAVINST 5100.23, Navy Safety and Occupational Health Program Manual

1.2.7 EM 385-1-1, Safety and Health Requirements Manual, U.S. Army Corps of Engineers

1.2.8 NAVFAC Guide Specification NFGS-01525D, Safety Requirements

1.3 These requirements are solely intended to provide for the protection of Government property and personnel and are not intended to, and do not, in any manner whatsoever, relieve the contractor of its responsibility, including, without limitation, its responsibility for the protection of its equipment and personnel.

1.4 Notification Requirement. Contractor shall notify the Contracting Officer 7 calendar days in advance of the intent of bringing a non-Navy owned crane onto Shipyard property (allows Contracting Officer to notify shipyard 3 days in advance of entry), or of any multi-purpose machines, material handling equipment, or construction equipment that may be used in a crane-like application to lift suspended loads. The contractor shall also specify when crane entry onto Shipyard property is scheduled during back shift, weekend, or holiday hours of operation. All entries shall be through a prearranged entry point. The following documentation shall be provided along with notification: a copy of the Certification of Compliance (reference 1.2.1) and objective evidence of operator qualifications for cranes with rated capacities of 2,000 lbs. or greater. Failure to schedule or provide necessary documentation may result in the crane being denied access to the facility.

1.5 The contractor shall comply with applicable reference 1.2.2 standards (e.g., B30.3 for construction tower cranes, B30.5 for mobile cranes, B30.8 for floating cranes, B30.9 for slings, B30.20 for below the hook lifting devices, and B30.22 for articulating boom cranes), B30.26 for rigging hardware, and ANSI/ITSDF B56.6 for rough terrain forklifts). For barge mounted mobile cranes, require a third party certification from an OSHA accredited organization (or from a state accredited organization for those states with OSHA approved state plans), a load indicating device, a wind-indicating device, and a marine type list and trim indicator readable in one-half degree increments. Third party certification is not required for barge-mounted mobile cranes at naval activities in foreign countries.

1.6 Certification of Compliance (reference 1.2.1). The contractor shall complete a certificate of compliance that the crane (or other machine if used to lift suspended loads) and rigging gear meet applicable OSHA and ANSI/ASME regulations (with the contractor citing which OSHA regulations are applicable, e.g., cranes/multi-purpose machines used in cargo transfer shall comply with reference 1.2.3; cranes/multi-purpose machines used in construction, demolition, or maintenance shall comply with reference 1.2.4; cranes/multi-purpose machines used in ship repair shall comply with reference 1.2.5; slings shall comply with ASME B30.9; rigging hardware shall comply with ASME B30.26). For cranes (or other machine if used to lift suspended loads) and rigging equipment at naval activities in foreign countries, the contractor shall certify that the crane and rigging gear conform to the appropriate host country safety standards. The contractor shall also certify that all of its crane (or other machine) operators working on the naval activity have been trained not to bypass safety devices (e.g., anti-two block devices) during lifting operations, and that its operators, riggers, and company officials are aware of the actions required in the event of an accident as specified in the contract. Require that the certifications be posted on the crane. When a crane on shipyard property is not authorized for use, the Certification of Compliance shall state, “Operation of this Crane is

NOT Authorized.”

1.7 The contractor shall certify (reference 1.2.1) that the crane or machine operator is qualified and trained for the operation of the crane to be used. For mobile and commercial truck mounted cranes with OEM rated capacities of greater than 2,000 pounds, the crane operator shall be designated as qualified by a source that qualifies crane operators (i.e., a union, a government agency, or an organization that tests and qualifies crane operators).

Proof of current qualification shall be provided.

1.8 For multi-purpose machines, material handling equipment, and construction equipment used to lift loads suspended by rigging equipment, the contractor shall have proof or authorization from the machine OEM that the machine is capable of making lifts of loads suspended by rigging equipment. The contractor shall demonstrate that the equipment is properly configured to make such lifts and is equipped with a load chart.

1.9 All hooks used on cranes, hoists, other machines, and rigging gear shall have self-closing latches or the throat opening shall be "moused" (secured with wire, rope, heavy tape, etc.) or otherwise secured to prevent the attached item from coming free of the hook under a slack condition. The following exceptions apply and shall be approved by the contractor’s technical organization: items where the hook throat is fully obstructed and not available for manual securing and lifts where securing the hook throat increases the danger to personnel such as forge shop, dip tank, or underwater work.

1.10 Loading Limitations

CAUTION: Piers and waterfront areas such as along dry docks and quay walls may have load restrictions.

1.10.1 The contractor shall notify the Contracting Officer prior to moving a crane on a pier, dry dock, or other waterfront area. Provide the Contracting Officer with the crane make, model, and configuration in which it is to be used.

1.10.2 The contractor shall comply with crane access routes and load limitations issued with the contract.

1.10.3 Allowable Surface Loads. Loads transferred to soils and pavements shall be minimized to a desired maximum of 3000 pounds per square foot, by placement of cribbing or steel pads under rubber-tired crane outriggers and trailer stanchions/sand shoes, or by placement of mats under treads of crawler cranes. Visually inspect areas adjacent to cribbing or plates and report any unusual bituminous pavement surface conditions, irregularities, or cracking to the Contracting Officer.

1.10.3.1 Outriggers of rubber-tired cranes shall be landed on two layers of timbers of appropriate thickness, oriented at right angles to each other, or landed on properly designed steel pads. Treads of crawler cranes shall run on appropriate mats. Use and design of cribbing, plates and mats shall be in a manner consistent with general construction industry standards.

1.10.3.2 Position loads that will remain on trailers detached from tractors to attain a distribution of 65 percent to rear axles and 35 percent to front support stanchions/sand shoes. For example, assuming an 83000 pound maximum gross weight and a soil bearing pressure of 3000 pounds per square foot, the required support under each sand shoe would be 2.5 feet x 2.5 feet. Accordingly, two tiers of timber cribbing at right angles, each 2.5 feet x 2.5 feet x 4 inches, or a properly designed 2.5 feet x 2.5 feet steel pad would be utilized under each trailer stanchion/ sand shoe.

1.11 Prior to making any critical lift, the contractor shall provide a critical lift plan for each of the following lifts: lifts over 75 percent of the capacity of the crane, hoist, or other machine (50 percent of the capacity of a barge mounted mobile crane’s hoists) at any radius of lift; lifts involving more than one crane, hoist, or other machine; lifts of personnel (lifts of personnel suspended by rigging equipment from multi-purpose machines, material handling equipment, or construction equipment shall not be permitted); lifts made in the vicinity of overhead power lines; erection of cranes; and lifts involving non-routine rigging or operation, sensitive equipment, or unusual safety risks. The plan shall include the following as applicable:

1.11.1 The size and weight of the load to be lifted, including crane (or other machine) and rigging equipment that add to the weight. The OEM's maximum load capacities for the entire range of the lift shall also be provided.

1.11.2 The lift geometry, including the crane (or other machine) position, boom length and angle, height of lift, and radius for the entire range of the lift. Applies to both single and tandem crane/machine lifts.

1.11.3 A rigging plan, showing the lift points, rigging equipment, and rigging procedures.

1.11.4 The environmental conditions under which lift operations are to be stopped.

1.11.5 For lifts of personnel, the plan shall demonstrate compliance with the requirements of reference

1.11.6 For barge mounted mobile cranes, barge stability calculations identifying crane placement/footprint; barge list and trim based on anticipated loading; and load charts based on calculated list and trim specific to the barge the crane is mounted on. The amount of list and trim shall be within the crane manufacturer’s requirements.

1.11.7 For lifts in the vicinity of overhead power lines (i.e., if any part of the crane or other machine, including the fully extended boom of a telescoping boom crane or machine, or the load could approach the distances noted in figure 10-3 of reference 1.2.1 during a proposed operation), the plan shall demonstrate compliance to 29 CFR 1926.550(a)(15).

1.12 The following additional documentation is required for contractor provided tower cranes (those cranes defined by ASME B30.3).

1.12.1 Foundation design and requirements

1.12.2 Installation instructions 1.12.4

1.12.3 Assembly and disassembly instructions including climbing/jumping instructions if applicable

1.12.4 Operating manual, limitations, and precautions

1.12.5 Periodic inspection and maintenance requirements

1.13 Crane and Rigging Gear Accident Reporting and Record Keeping. Contractors operating cranes on Shipyard property shall report all WHE accidents that occur incidental to an operation, project, or facility as prescribed by paragraphs (1.10.1) through (1.10.3) requirements below. Contractors shall report directly to their respective Contracting Officer. There are two general categories of accidents as defined below. Crane accidents are those that occur during operation of a crane. Rigging gear accidents are those that occur when gear is used by itself in weight handling operation i.e., without a crane.

1.13.1 Crane Accident: For the purpose of this definition, it is assumed there is an "operating envelope" around any crane, and inside the envelope are the following elements:

The crane

The operator

The rigger(s) and crane walker

Other personnel involved in the operation (supervisor, mechanic, tag line handler, engineer, etc.)

The rigging gear between the hook and the load

The load

The crane's supporting structure (ground, rail, etc.)

The lift procedure

1.13.1.1 Definition. A crane accident occurs when any one or more of the six elements in the operating envelope fails to perform correctly during operation, including operation during maintenance, or testing resulting in the following:

Personnel injury or death. Minor injuries that are inherent in any industrial operation, including strains and repetitive motion related injuries, shall be reported by the normal personnel injury reporting process in lieu of these requirements.

Material or equipment damage

Dropped load

Derailment

Two-blocking

Overload (This includes load tests when the test load tolerance is exceeded.)

Collision, including unplanned contact between the load, crane, and/or other objects.

A component failure (e.g., motor burnout, gear tooth failure, bearing failure) is not considered an accident solely due to material or equipment damage unless the component failure results in damage to other components (e.g., dropped boom, dropped load, roll over, etc.). [Bullets] 3, 4, 5, 6, and 7 are considered crane accidents even though no material damage or injury occurs.

Exception. If a crane is used as an anchor point for a portable hoist/rigging gear, rigging gear accident as defined in paragraph 1.10.2 below is not considered a crane accident if the crane is not being operated (no functions are in motion) at the time of the rigging gear accident, unless the accident results in an overload or damage to the crane, in which case it shall be reported as a crane accident.

1.13.2 Rigging Gear Accidents: For the purpose of this definition, it is assumed there is an

“operating envelope” around any weight handling operation, and inside the envelope are the following:

Rigging gear and miscellaneous equipment

The user of the gear or equipment

Other personnel involved in the operation (supervisor, mechanic, tag line handler, engineer, etc.)

The load

The gear or equipment’s supporting structure

The load’s rigging path

The rigging procedure

1.13.2.1 Definition. A rigging gear accident occurs when any one or more of the five elements in the operating envelope fails to perform correctly during weight handling operations resulting in the following:

Personnel injury or death. Minor injuries that are inherent in any industrial operation, including strains and repetitive motion related injuries, shall be reported by the normal personnel injury reporting process of the activity in lieu of these requirements.

Material or equipment damage that requires the damaged item to be repaired because it can no longer perform its intended function. This does not include superficial damage such as scratched paint, damaged lagging, or normal wear on rigging gear.

Dropped load.

Two-blocking of cranes and powered hoists.

Overload. (This includes load tests when the test load tolerance is exceeded.)

A component failure (e.g., motor burnout, gear tooth failure, bearing failure) is not considered an accident solely due to material or equipment damage unless the component failure results in damage to other components (e.g., dropped load, damaged load, etc.). [Bullets] 3, 4, and 5 are considered accidents even though no material damage or injury occurs.

1.13.3 The contractor shall notify the Contracting Officer as soon as practical, but not later than four hours, after any WHE accident. The contractor shall secure the accident site and protect evidence until released by the Contracting Officer. The contractor shall conduct an accident investigation to establish the root cause(s) of the accident. Crane operations shall not proceed until cause is determined and corrective actions have been implemented to the satisfaction of the Contracting Officer. The contractor shall provide the Contracting Officer within 30 days of any accident a Crane and Rigging Gear Accident Report using the form provided in reference1.2.1 consisting of a summary of circumstances, an explanation of causes(s), photographs if available, and corrective actions taken. These notifications and reporting requirements are in addition to those promulgated by reference 1.2.6 and related claimant instructions.

1.14 Each contractor shall perform the following actions prior to conducting crane operations on

Shipyard property:

1.14.1 Inspection Requirements. It shall be the sole responsibility of the contractor to assure the

Contracting Officer and/or designated Shipyard personnel that the crane and associated rigging gear are in good working order and safe for use.

1.14.1.1 Crane Inspection. Perform pre-operational inspection of the crane in the presence of a representative of the Contracting Office of the crane prior to starting work on

Shipyard property. Inspection shall meet all applicable reference 1.2.2, reference 1.2.7 (for

NAVFAC construction contracts), and OSHA requirements.

1.14.1.2 Wire Rope Inspection. Perform a Wire Rope Inspection in the presence of a representative of the contracting office to applicable reference 1.2.2, reference 1.2.7 (for

NAVFAC construction contracts), and OSHA requirements.

1.14.1.3 Rigging Gear Inspection. Perform a Rigging Gear Inspection in the presence of a representative of the contracting office to applicable reference 1.2.2, reference 1.2.7 (for

NAVFAC construction contracts), and OSHA requirements.

FIGURE P-1

APPENDIX P – CONTRACTOR CRANE (OR ALTERNATE MACHINE USED

TO LIFT SUSPENDED LOAD) AND RIGGING GEAR REQUIREMENTS

CERTIFICATE OF COMPLIANCE

This certificate shall be signed by an official of the company that provides cranes (or multi-purpose machines, material handling equipment, or construction equipment used to lift loads suspended by rigging gear) or rigging gear for any application under this contract. Post a completed certificate on each crane or alternate machine (or in the contractor’s on-site office for rigging operations) brought onto Navy property.

CONTRACTING OFFICER’S POINT OF CONTACT

(Government Representative)

PHONE

PRIME CONTRACTOR/PHONE CONTRACT NUMBER

CRANE OR ALTERNATE MACHINE SUPPLIER/PHONE

(if different from prime contractor)

CRANE OR ALTERNATE MACHINE

NUMBER (i.e., ID number)

CRANE OR ALTERNATE MACHINE MANUFACTURER/TYPE/CAPACITY

CRANE OR ALTERNATE MACHINE OPERATOR'S NAME(S)

I certify that

1. The above noted crane or alternate machine and all rigging gear conform to applicable OSHA regulations (host country regulations for naval activities in foreign countries) and applicable ASME B30 standards. The following

OSHA regulations and ASME standards apply:______________________________________________________

2. The operators noted above have been trained and are qualified for the operation of the above noted crane(s) or alternate machine(s).

3. The operators noted above have been trained not to bypass safety devices during lifting operations.

4. The operators, riggers and company officials are aware of the actions required in the event of an accident as specified in the contract.

COMPANY OFFICIAL SIGNATURE DATE

COMPANY OFFICIAL NAME/TITLE

POST ON CRANE (OR ALTERNATE MACHINE)

(IN CAB OR VEHICLE)

(or in the contractor’s on-site office for rigging operations)

J-0200000-XX

Crane Company: Date of Entry:

Crane Manufacturer/Crane Model/Crane Number: Time of Entry:

Date of Annual Inspection Expiration

Date of Quadrennial Inspection Expiration

4 Name & phone number of Contracting Official (or designated local representative)

Contracting Official

Phone Number

5 Does the package include a routine or critical lift plan?

Yes

No

Location of lift site?

7 Duration crane will be continuously on the job site (hrs, days, weeks…)

Does plan include certification from contractor that the crane complies with ASME B30 standard

[B30.5 (mobile cranes), B30.8 (floating cranes), B30.22 (articulating boom cranes), or B30.3

(construction tower cranes)] as applicable?

Does plan include a certificate of compliance?

Which OSHA regulations does the certificate of compliance indicate? (For cranes used in cargo transfer, 29 CFR 1917 applies; for cranes used in construction, demolition, or maintenance, 29 CFR 1926 applies; for cranes used in shipbuilding, ship repair, or ship breaking, 29 CFR 1915 applies).

Does plan include valid medical certificate and proof of operator qualification from a source that qualifies crane operators (union, governmental agency, or an organization that tests and qualifies crane operators)? Verify qualification for each back-up operator (if provided) on the certificate of compliance.

N/A

12 Does the plan designate a qualified Rigger-in-Charge

13 What is the weight of the heaviest load to be lifted? lbs.

14 What is the weight of the rigging gear? lbs.

What are the crane components (and their weights) that add to the weight of the load (hook, jib, etc.)?

Main Block lbs.

Aux. Block lbs.

Jib (Stowed) lbs.

Jib

(Erected) lbs.

Other lbs.

16 What is the maximum total crane lift (sum of 13, 14 & 15 above)? TOTAL lbs.

17 What is the capacity of the crane as configured lbs.

18 What percentage of crane capacity does this lift represent? %

What is the main boom length? If a jib will be utilized, indicate the length and offset.

MAIN JIB OFFSET

20 What are the minimum and maximum load radii? Min Max

21 Does the plan include the manufacturer’s load chart for entire range of lift(s)?

Does plan include ground loading and outrigger reaction data to determine cribbing requirements, or a Waterfront Operational Permit?

23 For crawler crane, does the plan indicate area restrictions for operation?

24 For floating crane, does plan include maximum allowable list?

For mobile crane mounted on barge, is crane equipped with load indicating device? wind indicating device? marine type list and trim indicator (readable in one-half degree increments)?

26 For mobile crane mounted on barge, does plan include revised load chart?

What are the environmental conditions under which crane operations are to be stopped?

Will the crane perform critical lifts? (If no, skip items 29 –49.)

What circumstances require this lift to be classified as a critical lift? (Blind lift, 75% of chart, non-routine rigging, etc.)

What are the exact dimensions of the load? (L x

W x H)

31 Does the plan indicate the crane position? (Overhead view)

32 What is the maximum lift height of the lift?

33 What is the minimum boom angle?

34 What is the maximum boom angle?

35 What is the name of the operator?

Indicate name(s) of backup operator (if required).

37 Does the plan show lift points?

38 Does the plan describe the rigging procedures?

39 Does the plan indicate rigging hardware requirements?

40 For personnel lifts, does the plan demonstrate compliance with 29 CFR 1926.550?

41 Does EM 385-1-1 govern this lift?

What are the coordination and communication requirements for the lift (e.g., radio and hand signals)?

For tandem or tailing crane lifts, does the plan indicate the make and model of the crane, the line, boom, and swing speeds, and the requirement for an equalizer beam?

44 For floating cranes, refer to questions 20-22?

45 What is the name of the lift supervisor?

56 Does the plan indicate the qualifications of the lift supervisor?

47 What are the names of the riggers?

48 Does the plan indicate the qualifications of the riggers?

49 Did all involved personnel (Operator, Riggers, Lift Supervisor, etc.) sign the critical lift plan?

Name Organization Signature Date Phone

Contracting Official:

wed By

CONTRACTOR CRANE, MULTI-PURPOSE MACHINE, FORKLIFT, CONSTRUCTION EQUIPMENT, AND RIGGING GEAR

REQUIREMENTS