13.2 Safety and Design Aspects. High quality off-the-shelf OEM type equipment is acceptable if it is designed, maintained, and operated according to this standard. 109 13.2.1 Design criteria/general design requirements for jacks are contained in ASME B30.1. It is the responsibility of the applicable engineering, operations/maintenance, and safety organizations to ensure the design, testing, maintenance, inspection, and operation of this equipment complies with this standard, the manufacturersí recommendations, and ASME B30.1
a. Control parts shall be designed to provide a means of operation and adjustment, which will minimize exposure of the operator to injury. b. Jack construction shall incorporate a positive stop or method to prevent over travel. The over travel prevention (or stop) shall not alter the operating characteristics of the jack. 13.2.2 Labeling/Tagging of Jacks
a. The rated load/applicable capacity ratings shall be clearly and permanently marked on the jack
b. Mechanical jacks with two ratings (sustaining and lifting) shall be so marked. c. Hydraulic pressure or lever arm length and force shall be legibly marked on the jack. d. Marking shall indicate the recommended hydraulic fluid to be used. e. Double acting hydraulic jacks shall be marked to indicate the need for a relief valve. f. A standard system of labeling shall be established and used throughout the installation
g. A standard lockout/tagout system shall be established and used throughout the installation to indicate equipment that is not to be used due to inspection discrepancies, ongoing maintenance, or other reasons
h. Certification/recertification are required as described in paragraph 13.3.4
13.2.3 Safety Analysis and Documentation of Jacks. A recognized safety hazard analysis such as fault tree analysis, FMEA, O&SHA shall be performed on all jacks used for lifts where failure/loss of control could result in loss of or damage to flight hardware. The analysis shall, as a minimum, determine potential sources of danger, identify failure modes, and recommend resolutions and a system of risk acceptance for those conditions found in the hardware-facility-environment-human relationship that could cause loss of life, personal injury, and loss of or damage to the jack, facility, or load. The analysis shall be done as part of the initial activation process, included in the equipment documentation, and updated as required to reflect any changes in operation and/or configuration. 13.3 Testing. Testing of jacks shall be performed according to this section, the manufacturersí recommendations, and ASME B30.1. Three types of tests are required for jacks: proof load tests, periodic load tests, and operational tests. Proof load tests and110 operational tests shall be performed prior to first use for new or extensively repaired or altered components directly in the jack load path. Repairs or alterations to nonlifting or nonholding components do not require a load test, although a functional check should be performed to determine if the repairs or alterations are acceptable. The periodic load and operational tests shall be performed annually. The acceptable tolerance for load test accuracy is +5/-0 percent unless otherwise specified. All load and operational tests shall be performed by qualified personnel according to written (specific or general) technical operating procedures. An inspection of the jack and its components shall be performed after each load test and prior to the jack being released for service to ensure there is no damage. The periodic load test requirement may be fulfilled by a concurrently performed proof load test. 13.3.1 Proof Load Test. Before first use, all new, extensively repaired, or altered jacks shall undergo a proof load test at 120% of the rated load and operated to its full length of travel in accordance with the manufacturersí instructions and ASME B30.1. A proof load test may also be performed when there is a question in design, previous testing or to ensure system integrity. The load shall be lifted slowly in an area where minimal damage will occur if the jack fails. For new jacks, manufacturer documentation of performed proof load tests will be acceptable as meeting this requirement. 13.3.2 Periodic Load Test. For jacks used where failure/loss of control could result in loss of or damage to flight hardware, a periodic load and operational test shall be performed at least once every year with a load equal to the rated load. 13.3.3 Operational Test. Together with proof load and periodic load tests, the following shall be performed with a dummy rated load unless otherwise specified: a. Hydraulic jacks shall be operated to full length of travel. Hold the load for a minimum of 5 minutes and verify drift does not exceed that specified by the responsible engineering organization. b. Mechanical jacks shall be operated to full length of travel. Hold the load for a minimum of 5 minutes and verify no drift. c. The operational test for a modified jack can be tailored to test only those portions of the equipment that were modified/repaired, only if the rated and operational test interval has not expired. 13.3.4 Test Reports and Periodic Recertification Tags. After each test, designated personnel shall prepare written, dated, and signed test reports. Inadequacies shall be documented and, if determined to be a hazard, corrected prior to further use. These reports shall be kept on file for a minimum of two test cycles and shall be made readily available. Following the periodic load test, jacks shall be given a permanently affixed tag identifying the equipment and stating the next required periodic load test date or load test expiration date
13.4 Inspection. 13.4.1 Safety inspections shall be performed on all jacks. Inspections shall be performed according to this section, the manufacturersí recommendations, and ASME B30.1. Inadequacies discovered during an inspection shall be documented and, if determined to be a hazard, tagged out and corrected prior to further use. Inspections shall be performed by qualified personnel according to approved technical operating procedures. 111 13.4.2 All new, extensively repaired, or modified jacks shall be inspected to the requirements of both daily and periodic inspections prior to first use. For component repair on jacks, only the inspections that apply to the repaired portion need to be performed prior to first use unless a periodic inspection interval expires during the downtime (see paragraph 13.4.5)
13.4.3 Jacks in regular service (used at least once a month) shall be inspected as required in paragraphs 13.4.4 and 13.4.5. Idle and standby jacks shall be inspected according to paragraph 13.4.6
13.4.4 Daily Inspections. These inspections shall be performed each day the jack is used. Inspect for (without disassembly): a. Operating lever and load-bearing surfaces free of slippery material or fluids. b. Improper engagement or extreme wear of pawl and rack. c. Chipped, cracked, or worn rack teeth. d. Defects such as cracked welds, damaged housing. e. Damaged, bent, or worn threads. f. Hydraulic systems for observable deterioration or leakage and check hydraulic system for proper oil level if suspect. g. Scored or damaged plunger. h. Improper function operation. i. Free movement of swivel, heads, and caps. j. Loose bolts or rivets. k Damaged or improperly assembled accessory equipment. l. Rack wear or bending. m. Other items specified in manufacturersí recommendations. If external conditions indicate possible internal difficulty, notify the supervisor. Repairs and adjustments shall be made before operations begin 13.4.5 Periodic Inspections. Periodic inspections are the same as paragraph 13.4.4. Periodic inspections shall be performed at least once per year or more frequently if required by the manufacturer or ASME B30.1. Periodic inspections consist of visual inspection by an appointed person and require dated documented records. If external conditions indicate possible internal difficulty, notify the supervisor. Repairs and adjustments shall be made before operations begin. 112 13.4.6 Idle and Standby Jacks. Idle and standby jacks shall be inspected prior to first use according to the requirements of paragraphs 13.4.4 and 13.4.5 unless these daily and periodic inspections were performed at required intervals and recorded during the idle/standby period
13.5 Maintenance. A maintenance program based on manufacturersí recommendations, integrating proactive, reactive, preventive, and predictive maintenance shall be established to increase the probability the jack will function in the required manner over its design life cycle with a minimum of maintenance. The program shall include procedures and a scheduling system for normal periodic maintenance items, adjustments, replacements, and repairs. The program also shall ensure that records are kept and unsafe test and inspection discrepancies are documented and corrected. Any jack found in an unsafe operating condition shall be removed from service, tagged out, and not used until repaired. All repairs shall be made by qualified personnel in accordance with the manufacturersí instructions. 13.5.1 Only hydraulic jack fluid which is compatible with the jack manufacturerís specifications shall be used. 13.5.2 Clean and lubricate moving parts requiring lubrication, exposed screw threads, and check for proper delivery of lubricant per manufacturer recommendations. 13.5.3 Jacks exposed to rain, sand, or grit-laden air should be cleaned prior to use. 13.5.4 Jacks should be stored where protected from the elements, abrasive dust, and damage and should be stored in the vertical position. 13.5.5 Replacement parts should be purchased from the original manufacturer or verified as meeting the original manufacturer requirements. A qualified person shall verify replacement parts meet manufacturer requirements and instructions. 13.5.6 Hydraulic jacks exposed to freezing temperatures shall be supplied with an adequate anti-freeze liquid. 13.6 Personnel Certification. Only qualified and designated personnel shall be authorized to perform inspection and/or maintenance operations on jacks. Operators shall be instructed in the proper use of jacks. 13.7 Operations. Jacks shall be operated according to this section, the manufacturersí recommendations, and ASME B30.1. The following practices shall be followed for jack operations: a. Before the jack is used each day (shift), the operator shall have read and understood the manufacturerís operating instructions and safety rules, and have read and understood all decals and warnings on the equipment. b. Before the jack is used each day (shift), the operator shall perform a pre- operational check to demonstrate operational readiness, including all limit switches. If controls do not operate properly, the operator is responsible for notifying the supervisor. Repairs and adjustments shall be made before operations begin. 113 c. Before operating the jack, the operator shall survey the area for applicable hazards such as obstructions, debris, bumps, drop-offs and holes, obstructed path of travel, unstable footing, and other possible hazardous conditions. The operator shall establish appropriate safety zones, if required, before initiating operations
d. The equipment shall not be loaded beyond its rated load (capacity) except for required testing. e. The operator shall ensure the equipment is within inspection and testing intervals by examination of the periodic load test tags and/or documentation. The operator shall adhere to all tags on the controls
f. Verify that there is sufficient swing area for the operating lever. g. The jack shall be firmly supported at the base under load. h. The operating lever is the recommended lever and that it is properly seated in its socket. i. Operators shall not straddle the operating lever of a mechanical jack. j. Operating levers shall be removed when not in use to avoid accidental dislodging of the jack and reduce the tripping hazard. k. Measures shall be taken to prevent personnel from working or passing under the load until the load is secured by cribbing, blocking, or other means. l. Precautions shall be taken to ensure all personnel are clear of the load before lowering. m. Personnel shall be instructed in the signals and procedures for multiple jack use or special jack lift operations. n. Off-center loading of jacks shall be avoided
o. Extenders shall not be used unless authorized by a qualified person. p. If there is a possibility of slippage of the cap, a block shall be placed in between the cap and the load.
APPENDIX A NATIONAL AERONAUTICS AND SPACE ADMINISTRATION ALTERNATE STANDARD FOR SUSPENDED LOAD OPERATIONS 115 OSHA Alternate Standard on Suspended Loads Revalidation Letter 116 OSHA Alternate Standard on Suspended Loads Revalidation Letter117 OSHA Alternate Standard on Suspended Loads Validation Letter118 A.1 This standard applies to specifically identified operations controlled by the National Aeronautics and Space Administration (NASA) involving both civil service and contractor employees. The standard is an alternate to Code of Federal Regulations 29 CFR 1910.179(n)(3)(vi), 29 CFR 1910.180(h)(3)(vi), and 29 CFR 1910.180(h)(4)(ii). NASA Safety is responsible for its implementation and enforcement
A.2 As an alternative standard developed pursuant to Section 1-201(d) of Executive Order 12196 and 29 CFR 1960.17, it applies only to NASA employees. The Occupational Safety and Health Administration (OSHA) will inspect the working conditions of NASA employees performing these specified operations for compliance with these alternate standard requirements. Although OSHA cannot inspect private sector employees working in the same operation with NASA employees for compliance with the alternate standard, it will fully consider the equivalent safeguards specified in this standard for both NASA and contractor employees as the basis for a de minimis violation which is recorded, but not issued
A.3 Suspended Load Operation Definition. An operation is considered a suspended load operation and subject to the requirements of this standard if it meets all three of the following criteria: A.3.1 The operation involves the use of a crane or hoist that supports the weight of a suspended load. (This excludes operations where the load is secured in a holding fixture or on substantial blocks supporting the entire load even though the crane/hoist hook may still be attached.) No distinction is made between a static load and a dynamic load. Rigging, i.e., slings, Hydra-sets, lifting fixtures, shackles, straps, when attached to the hook, is considered part of the load
A.3.2 Personnel involved in the operation have any part of the body directly beneath the suspended load. (This excludes operations where employees have their hands on the sides of a load, i.e., to guide the load.) A.3.3 In the event of a crane/hoist failure, as the load drops it could contact personnel working directly beneath it, with injury or death as a possible result. (This excludes operations where employees have their hands only partially under a load such that a crane or hoist device failure would push their hands out of the way not resulting in injury. This also excludes situations where the falling load would come to rest on hardware that is not suspended before an employee could be injured.) A.4 Requirements. It is recognized that cranes and hoists do not generally meet the support requirements of a system that would allow personnel to work beneath a suspended load. NASAís first hazard avoidance protocol is to design hazards out of the system or operation. Accordingly, it is NASAís intent and goal that all future systems, hardware, and equipment be engineered, designed, installed, and operated to prevent exposing employees to working under loads suspended from cranes and hoists. Due to the uniqueness of NASA activities and the limitations imposed when using present systems, hardware, equipment, and facilities, suspended load operations may be permitted only under specifically approved and controlled conditions. No suspended load operation shall be performed unless all (15) of the following special requirements are met: A.4.1 All suspended load operations will be approved by the Center/facility NASA Director of Safety based upon a detailed engineering hazards analysis of the operation. The hazards analysis will be prepared by the responsible safety organization and coordinated119 through appropriate engineering and design offices. The analysis documentation will include the following: a. A justification why the operation cannot be conducted without personnel beneath the load. Feasible procedure/design options will be investigated to determine if the work can be accomplished without personnel working under a load suspended from a crane/hoist
b. Details of the precautions taken to protect personnel should the load drop. Secondary support systems, i.e., equipment designed to assume support of (catch) the load preventing injury to personnel should the crane/hoist fail, shall be evaluated and used whenever feasible. Secondary support systems will be constructed with a minimum safety factor of 2 to yield
c. The maximum number of exposed personnel allowed. Steps shall be taken to limit the number of personnel working under a load suspended from a crane/hoist. Only those essential personnel absolutely necessary to perform the operation will be allowed to work in the safety controlled area
d. The time of exposure. Steps shall be taken to ensure that personnel do not remain under the load any longer than necessary to complete the work
A.4.2 Each operation will be reviewed on a case-by-case basis
A.4.3 Only those suspended load operations approved by the Center/facility NASA Director of Safety will be permitted, subject to this standard. A list of approved suspended load operations will be maintained by NASA Safety and made available to OSHA personnel upon request
A.4.4 The operational procedures document (e.g., Operations and Maintenance Instruction, Technical Operating Procedure, Work Authorization Document) will be revised to specify the necessary additional requirements identified by the hazard analysis discussed in paragraph A.4.1. The procedures will be available on site for inspection during the operation. A.4.5 During a suspended load operation, if a new procedure not covered by the original analysis is deemed necessary due to unusual or unforeseen circumstances, the NASA Center/facility Safety Office will be consulted and must approve and document the procedure before operations continue. Safety will coordinate with Operations, Engineering, and other organizations as appropriate. If the new procedure is to be performed on a regular basis, a detailed hazards analysis and approval as outlined in paragraph A.4.1 are required. A.4.6 The crane/hoist shall be designed, tested, inspected, maintained, and operated in accordance with the NASA Standard for Lifting Devices and Equipment (NASA-STD-8719.9). Test, inspection, and maintenance procedures will be developed and approved by qualified, responsible NASA engineers. Qualified specialists will perform the procedures and resolve noted discrepancies. NASA Quality Assurance will perform an independent annual inspection of all cranes/hoists involved in suspended load operations. The results of the annual inspections will be maintained and made available to OSHA personnel upon request
A.4.7 Each crane/hoist involved in suspended load operations shall undergo a Failure Modes and Effects Analysis (FMEA) that shall be approved by the Center/facility NASA Director120 of Safety. The FMEA will determine Single Failure Points (SFP), assessing all critical mechanical functional components and support systems in the drive trains and critical electrical components
a. For those cranes/hoists identified as having no SFP whose failure would result in dropping the load, the total weight of the suspended load shall not exceed the deviceís rated load. b. For those cranes/hoists identified as having a SFP whose failure would result in dropping the load, use of that device for suspended load operations must be approved by NASA Headquarters. Complete documentation on the suspended load operation, including the hazards analysis outlined in paragraph A.4.1 and the FMEA described above, will be forwarded to NASA Headquarters for evaluation. Approval will be given based upon detailed analysis of the potential hazards and rationale for acceptance. Such cases will never exceed the deviceís rated load. OSHA shall be notified when NASA Headquarters approves using any crane/hoist identified as having a SFP whose failure would result in dropping the load
A.4.8 Before lifting the load involved in a suspended load operation, the crane/hoist will undergo a visual inspection (without major disassembly) of components instrumental in assuring that the load will not be dropped (e.g., primary and secondary brake systems, hydraulics, mechanical linkages, and wire rope per NASA-STD-8719.9). Noted discrepancies will be resolved before the operation continues. This pre-lift inspection will be in addition to the inspections required in 1910.179(j) and 180(d)
A.4.9 A trained and licensed operator (certified per NASA-STD-8719.9) shall remain at the crane/hoist controls while personnel are under the load. A.4.10 Safety controlled areas shall be established with appropriate barriers (rope, cones, etc.). All nonessential personnel shall be required to remain behind the barriers
A.4.11 Prior to the suspended load operation, a meeting with the crane/hoist operator(s), signal person(s), person(s) who will work under the load, and the person responsible for the task shall be held to plan and review the approved operational procedures that will be followed, including procedures for entering and leaving the safety controlled area
A.4.12 Communications (voice, radio, hard wired, or visual) between the operator(s), signal person(s), and the person(s) working under the load shall be maintained. Upon communication loss, operations shall stop immediately, personnel shall clear the hazardous area, and the load shall be safed. Operations shall not continue until communications are restored
A.4.13 Personnel working beneath the load shall remain in continuous sight of the operator(s) and/or the signal person(s). A.4.14 NASA shall conduct periodic reviews to ensure the continued safety of the procedures. As a minimum, NASA will annually evaluate the implementation of this procedure at each Center with operations on the suspended load list. 121 A.4.15 A list of approved suspended load operations, list of cranes/hoists used for suspended load operations, and copies of the associated hazards analyses will be provided to the OSHA Office of Federal Agency Programs via NASA Headquarters for distribution to the appropriate regional and area OSHA offices. (NASA Headquarters, in conjunction with OSHA, will develop a format for transmittal of this information.) Quarterly updates to the documentation will be provided as needed.
APPENDIX B HAND SIGNALS Overhead Cranes HOIST. With forearm vertical, forefinger pointing up, move hand in small horizontal circle
LOWER. With arm extended downward, forefinger pointing down, move hand in small horizontal circle
BRIDGE TRAVEL. Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel. TROLLEY TRAVEL. Palm up, fingers closed, thumb pointing in direction of motion, jerk hand horizontally. STOP. Arm extended, palm down, move arm back and forth
EMERGENCY STOP. Both arms extended, palms down, move arms back and forth
MULTIPLE TROLLEYS. Hold up one finger for block marked ì1î and two fingers for block marked ì2î. Regular signals follow
MOVE SLOWLY. Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. (Hoist slowly shown as example.) 123 Mobile Cranes HOIST. With forearm vertical, forefinger pointing up, move hand in small horizontal circle. LOWER. With arm extended downward, forefinger pointing down, move hand in small horizontal circle
USE MAIN HOIST. Tap fist on head then use regular signals. USE WHIP LINE. (Auxiliary Hoist) Tap elbow with one hand, then use regular signals. RAISE BOOM. Arm extended, fingers closed, thumb pointing upward
LOWER BOOM. Arm extended, fingers closed, thumb pointing downward. MOVE SLOWLY. Use one hand to give any motion signal and place other hand motionless in front of hand giving the motion signal. (Hoist slowly shown as example.) RAISE THE BOOM AND LOWER THE LOAD. With arm Extended, thumb pointing up. Flex fingers in and out as long as load movement is desired
LOWER THE BOOM AND RAISE THE LOAD. With arm extended, thumb pointing down, flex fingers in and out as long as load movement is desired. SWING. Arm extended, point with finger in direction of swing of boom
STOP. Arm extended, palm down, move arm back and forth horizontally
EMERGENCY STOP. Both arms extended, palms down, move arms back and forth horizontally
124 Mobile Cranes (Continued) TRAVEL. Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel. DOG EVERYTHING. Clasp hands in front of body
TRAVEL. (Both Tracks) Use both fists in front of body, making a circular motion, about each other, indicating direction of travel; forward or backward. (For land cranes only.) TRAVEL. (One Track) Lock the track on side indicated by raised fist. Travel opposite track in direction indicated by circular motion of either fist, rotated vertically in front of body. (For land cranes only.) EXTEND BOOM. (Telescoping Booms) Both fists in front of body with thumbs pointing outward
RETRACT BOOM. (Telescoping Booms) Both fists in front of body with thumbs pointing toward each other
EXTEND BOOM. (Telescoping Booms) One Hand Signal. One fist in front of chest with thumb tapping chest
RETRACT BOOM. (Telescoping Booms) One Hand Signal. One fist in front of chest, thumb pointing outward and heel of fist tapping chest
APPENDIX D CRANE/HOIST REQUIREMENTS TO LOAD TEST OTHER LIFTING EQUIPMENT Overhead cranes and hoists should not exceed 50% of their rated capacity and mobile cranes/derricks should not exceed 75% of their rated capacity when used to load test other lifting equipment, unless specifically designed for and dedicated for such use. The following requirements shall be followed when a crane/hoist is used to load test other lifting equipment: a. Crane/hoist hook and load line(s) shall only be loaded vertically
b. A certification of the initial proof load test or the current periodic load test shall be supplied with the lifting equipment prior to performing the load test
c. Items to be tested by an overhead crane shall be freely suspended from the crane hook with the height of the test not to exceed 6 inches above the floor/working surface
d. Items to be tested by a mobile crane shall be suspended from the crane hook and the height of the test shall not exceed 6 inches, or the lowest reasonable height based on dimension and test article configuration
e. No overhead crane shall be used to load test items attached to an immovable object
f. When a mobile crane is used to load test items attached to an immovable object, the boom angle shall be minimized as much as safely possible to prevent the boom from contacting the boom stops when load testing
g. For lattice boom mobile cranes, the boom shall be adequately restrained to prevent damage to the crane due to sudden unloading should the test article fail
h. A load-sensing device shall be installed in the lifting assembly.
