Client: FALCON SAPS SECUNDA

Date: 31/07/2023

OCCUPATIONAL HEALTH AND SAFETY (ACT 85 OF 1993)

LIFTING MANAGEMENT PROCEDURES

LIFTING MANAGEMENT PROCEDURES

Purpose
This procedure defines Mokoena OTO’s minimum mandatory requirements for conducting
lifting operations safely in workplaces. It covers all lifting and hoisting operations using
cranes, hoists and winches, forklifts and other relevant mobile plant

Scope

This procedure applies throughout Mokoena OTO, all its sites and all activities under its
control. It applies to all Mokoena OTO employees and contractors, including visitors.

This Business Procedure does not apply to:

 Operational and maintenance requirements for plant

 Manual lifting,

This procedure applies to forklifts used for lifting operations that are outside of using just the
forklift tynes and that require rigging to be performed (i.e. using a jib attachment etc.).

Actions
The layout, constructability, operability, maintainability and accessibility of facilities shall be
optimised to eliminate or minimise the need for lifting operations. As a minimum the following
shall occur:

 Identification of foreseeable lifts during the design of facilities;

 Identification of opportunities for installing fixed lifting devices for routine lifts;

 Ensuring access for mobile lifting equipment;

 Planning lifting activities to minimise risks associated with lifting operations; and

 Planning of laydown areas to minimise the need for lifting over hazardous process plant /
equipment

Safe Systems of Work Requirements

Where practicable, the requirement to perform lifting operations shall be eliminated. Where
elimination is not possible the need to perform lifting operations shall be minimised as far as
practicable.

The following shall occur:

 Lifting operations are classified and planned;

 Lifting plant / equipment is certified fit for use;

 Lifting operations are performed only by trained and familiarised personnel who
hold a valid licence in accordance with the requirements of this procedure; and

 Lifting operations are assessed to identify potential hazards and make sure that
suitable risk control measures are put in place.

Lift Planning
Lifting operations shall be risk assessed and planned accordingly.

For repeated or routine operations, such planning is only necessary once, provided that
appropriate lift planning documentation is in place. Periodic revisions shall be carried out to
make sure that no factors have changed. The planning of all lifting operations shall as a
minimum ensure that:

 Lifts shall be evaluated, planned and appropriately approved in the planning

stage of the job or prior to execution of the lift;

 Regard to the hierarchy of controls has been provided for the lifting operation

 All personnel involved with lifting operations are trained and familiarised, and
their High Risk Work as required;

 The lift travel path is clarified, and any obstacles are removed before lifting commences;

 Barricading, signage and/or spotters are in place to prevent personnel from

walking or standing within the lift travel path or under the load;

 The lifting operation can be executed safely in relation to simultaneous

operations, e.g. different work fronts during an outage;

 Lifting equipment is suitable and will be used in accordance with the manufacturer’s
instructions;

 The lay down area is appropriately positioned and can accommodate the load in
terms of size and weight; and
Lift Travel Path / Hazardous Process Plant / Equipment
For all lifting operations (standard and complex), lift planning shall include consideration of the lift
travel path to be utilised, with specific regard to lifting over hazardous process plant / equipment

The hierarchy of controls shall be considered with regard to lifting over hazardous process plant /
equipment. Specifically, lift planning must apply the hierarchy of controls to select the control/s that
most effectively mitigate the risks of performing the lifting operation, so far as is reasonably practical.

Major Overhaul / Construction Work Projects – Project Lifting

Operations Register
For all major overhauls / designated construction work projects, a Project Lifting Operations Register
shall be documented and approved prior to the commencement of the major overhaul / designated
construction work project

The Project Lifting Operations Register shall document / list, as a minimum:

 Item to be lifted (not required to be a fully itemised list; appropriate grouping

acceptable [e.g. turbine valves]);

 Responsible party of the lift (organisation);

 Indication if lifting operation is classified as standard or complex;

 Indication if lifting operation includes lifting over hazardous process plant / equipment;

 If yes, a comment shall be recorded regarding why lifting over hazardous

process plant / equipment cannot be reasonably avoided; and

 Whether the lifting operation is ‘one-off’ or ‘repetitive’ (for repeated lifts of

same type, only one entry is required).

The completed Project Lifting Operations Register shall be reviewed and approved by the
relevant Site Manager or delegate. Approval can be recorded via e-mail appropriately saved
within the electronic document management system.

Work Environment Requirements

 Exclusion Zone
Control measures shall be implemented which restrict access to the lifting and potential fall
zone during a lifting operation; including consideration of potential deflection should an
incident occur. Control measures shall reflect restricted access and / or total exclusion zones.
Where personnel are required to enter an exclusion zone, authorisation / permission must be
provided by the person managing the lifting operation.
  Overhead Electrical Conductors
Workers shall observe safe approach distances and exclusion zones for overhead powerlines
and implement controls in accordance with Electrical Safety Standard ASM-STD-ENG-03.

An Electrical Safety Observer will be required when parts of the crane or load could
enter a designated electrical exclusion zone.

Note: The Dogger or Rigger cannot be used to perform the role of Electrical Safety
Observer when lifting equipment is operating close to overhead powerlines.

 Weather Conditions

Various weather conditions could affect the integrity of lifting equipment or expose
people to hazards which necessitate the cessation of a planned lifting operation
(e.g. excessive wind speeds affecting a load which features a large surface area,
poor visibility due to mist or fog, lightning, heavy rain).
Lift planning for all lifting operations must include the consideration of forecast and current
weather conditions

 Plant and Equipment Requirements

All lifting equipment shall be used, maintained, stored and inspected in accordance with the
manufacturer’s instructions and the relevant regulations

 Register
Each site shall appoint a person / role responsible for maintaining a lifting equipment
register. As a minimum the register shall record certification and inspection details for
each piece of equipment.

Identification and Compliance

Lifting equipment shall be marked with:

 A unique identifier that can be used to track the testing and inspection history of the item;

 An identifier with the correct inspection date; and

 The working load limit (WLL).

Certification

Lifting equipment shall be certified as fit for use by a competent person:

 Before initial use; and

 Following major repairs or overhaul of load-bearing components.

Lifting equipment shall meet all applicable legislative and requirements
  Inspection and Maintenance
Lifting equipment used shall be regularly maintained and subjected to routine, documented
inspections by a competent person. All lifting equipment, accessories and equipment shall be
inspected, tested and certified by a competent person in accordance with the manufacturer’s
instructions and the relevant standards

The owner or supplier shall supply inspection and test sheets for all items of lifting
equipment before they are used on site.

Additional inspection must take place if the equipment has been:

 Involved in an incident; or

 Modified or repaired.

Records of lifting equipment inspections shall be maintained in accordance with

Business Standards: Document Control and Records Management.
Lifting equipment shall be stored in dedicated storage areas

 Removal from Service

Lifting equipment shall be removed from service if it is not safe for use, including the following:

 Damaged;

 Incorrectly tagged or coded; or

 Outside the defined inspection date.

Safe Work Practice Requirements

The following shall be ensured:

 All lifting operations that include lifting over hazardous process plant / equipment
shall be planned in advance of the lift;

 Lift planning documentation shall be appropriately approved (i.e. in line with the
level of control required by the type of lift and the risk assesment in the planning
stage of the job or prior to execution of the lift.

 A pre-lift briefing shall be undertaken for all lifts. The pre-lift briefing should
include all work party members and review the relevant risk assessment, and
the lift plan where applicable. For routine repetitive lifts, there may be a single
briefing at the start of shift.

 All lifting operations are undertaken by a competent person;

 Operators of lifting plant conduct pre-start checks of all plant and equipment to be used;

 Persons actively in control of a lift are not to use distracting devices i.e. mobile phones;
  All personnel shall comply with designated exclusion zone requirements (no
person enters the zone where a suspended load may fall);

 Tag lines are used to control the movement of the load, unless their attachment
presents additional risk;

 Loads are carried as near to the support surface as practicable;

 Loads do not exceed the defined working load limits of plant and equipment;

 Lifting operations are stopped if operations become unsafe; and

 A reliable and tested communication method is in place between all personnel

involved in lifting operations (Operators, Doggers etc.).
A crane or hoist shall not to be left unattended unless the following controls are in place:
 All loads (not including rigging equipment [e.g. slings]) have been removed from the hook;
and

 the hook has been raised to a position where it is safely clear of other
operations, hooked back or otherwise appropriately secured.
or

 All powered motions have been disabled; and

 access to the cabin / controls has been securely restricted

Positioning
Lifting plant and attachments shall be correctly positioned and installed in a clearly defined
and protected operational area. Lifting plant shall be positioned to:

 Minimise the risk of the equipment or load striking a person;

 Minimise the risk of losing control of the load;

 Minimise the risk of adversely impacting other plant, structures or underground services;
and

 Ensure all personnel have an unrestricted escape route throughout the entire lifting
operation.

Using other Mobile Plant for Lifting Operations

Other mobile plant shall be used for lifting operations only if:

 The equipment has been designed and certified for use in lifting operations;

 Mobile plant with a lifting capacity exceeding one tonne is fitted with burst protection valves;
and

 Locking pins are used on quick-hitches.

Use of Temporary Lifting Points
Temporary lifting points or devices (chain block, come along, air winch etc.) shall be
assessed and approved prior to activities using the following criteria:

 For loads under one tonne, the point or device shall be assessed by a
competent person to validate safe lifting practices and the integrity of the point or
device.

 For loads of one tonne or greater, the lifting point or device shall be load rated
(i.e. a certified lifting point or rated via engaging engineering advice).

All lifting points used as part of a scaffold structure shall be load rated. Note: Configurations
such as scaffold tube on a grid mesh floor, which is used as an anchor for a sling, is not
considered to be part of a scaffold structure.

Definitions
Term Meaning
Competent person A person who has, through a combination of training, education and
experience, acquired knowledge and skills enabling that person to perform
correctly the specified task.
Crane An appliance intended for raising or lowering a load and moving it
horizontally, but does not include an industrial lift truck, earthmoving
machinery, or an amusement structure, a tractor, an industrial robot, a
conveyor, a suspended scaffold or a goods or passenger lift.
Dogging Work  The application of slinging techniques, including the selection and
inspection of lifting gear, to safely sling a load; or
 The directing of a plant operator in the movement of a load when the
load is out of the operator’s view.
Hazardous process plant Is process equipment (including exposed live pipework) that if damaged
/ equipment has the potential to release hazardous materials or energy that can cause
toxic effects, fire, pressure release or explosion and could ultimately result
in serious injuries, fatalities, property damage, lost production, or
environmental impact.
Hoist An appliance intended for raising or lowering a load or people, vertically,
which includes a mast climbing work platform, personnel and materials
hoist, scaffolding hoist and serial hoist, but does not include a lift or
building maintenance equipment.
Lifting Equipment Any equipment / device that is used or designed to be used directly or
indirectly to connect a load to a crane and which does not form part of the
load, e.g. wire rope slings, chain swings, man-made fibre slings, hooks
and fittings, swivels, shackles, eye bolts, rigging screws, wedge sockets,
plate
clamps and lifting beams.
Luffing Angular movement, of a crane boom or jib, in a vertical plane.
Meter tonne Meter tonnage lifting capacity in relation to Vehicle Loading Cranes is a
figure that is derived by multiplying the lifting capacity by the working
radius of the boom or jib for that lifting capacity.
 Rigging Work  The use of mechanical load shifting equipment and associated gear to
move, place or secure a load using plant, equipment or members of a
structure to ensure the stability of those members; or
 The setting up or dismantling of cranes or hoists.
Spotter - Trained Is a person who has undergone specific training and is competent to
Electrical Safety perform the role in observing, warning and communicating effectively with
Observer the operator of the plant if is likely that the operating plant will come within
an exclusion zone for the operating plant for an overhead electric line.
Working near overhead and underground electric lines.

Spotter A competent person who watches for obstructions that are out of sight of

Lift Classification

Type Description Minimum Controls

Standard 1 Risk Assessment

All lifting operations that are not classified as complex (includes the
basic use of chain blocks, winches, come-a-longs etc.).

And

2 Pre-lift briefing

Complex A lifting operation which meets one or more of the following criteria: Lift Planning, including:
 Lifting of persons in workbox.
 There is a risk that any part of the crane or the crane’s load could 1 Safe Work
enter the exclusion zone of an overhead powerline Authorisation (SWA)
 Lifting large pressure vessels or tanks.
 Heavy lifts where the load is 50 tonnes or more. and
 A lift over hazardous process plant / equipment outside of a
major overhaul / construction work project (or within one, but not 2 Complex Lift Plan
originally planned). (documented via Complex
Lift Plan or an external
 Tilt-up panel lifting tasks.
contractor equivalent
 Multiple crane lift. document that is reviewed
 A lift >80% of the crane’s rated capacity (if using a mobile and deemed appropriate
crane). 3 by Mokoena OTO person
 The load will be lowered into, or lifted from, or over an occupied in control of lifting
confined space or building. operation [e.g. Safe Work
Coordinator])

and

3 Pre-lift briefing