NASA’s goal for achieving “best class” status as an organization poised for preventing mishaps requires perfecting our processes in four areas of excellence. These areas are: management commitment and employee involvement; system and worksite hazard analysis; hazard prevention and control; and safety and health training. This standard was developed to address hazard prevention and control as well as safety and health training and expands on NPG 8715.3, “NASA Safety Manual,” policy and guidelines for safety assurance. It is a compilation of pertinent requirements from the Occupational Safety and Health Administration (OSHA), American Society of Mechanical Engineers (ASME), American National Standards Institute (ANSI), Crane Manufacturers Association of America (CMAA), and unique NASA requirements. The standard combines the knowledge of all NASA Installations and contractors including NASA operations in host countries, standardizes definitions, clarifies/documents OSHA interpretations, addresses the subject of criticality, and conveys standardized requirements. With the exception of Alternative Standard for Suspended Load Operations contained in Appendix A, this standard is not a substitute for OSHA or local government (including such host country requirements as those in Australia or Spain) requirements which apply to NASA operations in full
Significant changes in this revision of the standard include the coverage for Mobile Aerial Platforms, Powered Industrial Trucks, and Jacks. Appendices C and D have been added concerning lifting personnel with a crane and using a crane to load test other lifting equipment, respectively. The designation of an installation Lifting Devices and Equipment Manager (LDEM) is also required with this revision
Compliance with this standard is mandatory for all NASA-owned and NASA contractor-supplied equipment used in support of NASA operations at NASA installations. The individual installation safety organizations are responsible for assuring implementation. This document establishes minimum safety requirements; NASA installations are encouraged to assess their individual programs and develop additional requirements as needed
Requests for information, corrections, or additions to this standard should be directed to the National Aeronautics and Space Administration Headquarters, Director, Safety and Risk Management Division, Code QS, Washington, DC 20546. Requests for general information concerning NASA Technical Standards should be sent to NASA Technical Standards Program Office, ED41, MSFC, AL, 35812. This and other NASA Standards may be viewed and downloaded free-of-charge from our NASA Standards Homepage: http//standards.nasa.gov. This NASA Technical Standard cancels NSS/GO-1740.9, dated November 1991 as updated March 1993
-Michael A. Greenfield, Ph.D. Acting Associate Administrator for Safety and Mission
REVISION LOG
Significant Changes. Converts document to NASA-STD format. Adds sections on mobile aerial platforms, powered industrial trucks, and jacks. Adds appendices on lifting personnel with a crane and using a crane to load test other lifting equipment. Designation of an installation Lifting Devices and Equipment Manager (LDEM) is also required. A note concerning the history of this document: The original NASA Safety Standard for Lifting Devices and Equipment was issued as NSS/GO-1740.9 in July 1982. In July 1988 it was revised and Revision A was issued reflecting significant changes related to mobile cranes, hoist supported personnel platforms, personnel lifting buckets, and guidance concerning super critical lifts. In November 1991 it was revised again and Revision B was issued which deleted the guidance on super critical lifts and added the NASA Alternate Standard for Suspended Load Operations. Additional revisions were issued as change pages in March 1993 to expand operational test requirements for special hoist supported personnel lifting devices. When it came time to update the standard again, in addition to the technical changes to the document (synopsized in the Revision Log above) the format and numbering were changed to reflect current practices and conventions for NASA Standards
STANDARD FOR LIFTING DEVICES AND EQUIPMENT 1. SCOPE 1.1 Scope. This standard applies to overhead and gantry cranes (including top running monorail, underhung, and jib cranes) mobile cranes, derricks, hoists, winches, special hoist supported personnel lifting devices, hydra-sets, load measuring devices, hooks, slings and rigging, mobile aerial platforms, powered industrial trucks, and jacks. This document does not include coverage for front-end loaders and elevators
1.2 Purpose. This standard establishes NASA’s minimum requirements for the design, testing, inspection, maintenance, personnel certification, and operation of lifting devices and equipment (LDE) described in paragraph 1.1. 1.3 Applicability. Compliance with this standard is mandatory for all NASA-owned and NASA contractor-supplied equipment used in support of NASA operations at NASA installations and NASA operations in host countries. The individual installation Lifting Devices and Equipment Manager (LDEM) and safety organizations are responsible for implementation and enforcement. This document establishes minimum requirements; NASA installations should assess their individual programs and develop additional requirements as needed. The need for compliance with this standard at contractor installations performing NASA work should be evaluated and made a contractual requirement where deemed necessary by the contracting officer and the responsible NASA installation/program safety office. Rented or leased LDE is exempt from this standard only by the decision of the contracting officer, the responsible NASA installation/program safety office, and the LDEM. If determined that rented or leased LDE will be used for a critical lift, this standard applies. 1.3.1 The testing, inspection, maintenance, operational, and operator and rigger certification/recertification/licensing requirements apply to new and existing lifting devices and equipment
1.3.2 The design/hardware requirements contained in this document are applicable to new lifting devices/equipment purchased after 6 months from the issue date of this document. Existing equipment and that purchased during the first 6 months from issue of this document shall be reviewed for compliance with all design/hardware aspects of this standard within 12 months of its issue and the need to update such equipment shall be evaluated
1.3.3 Deviations/waivers from the requirements of this document (including design/hardware requirements for both new and existing equipment) shall be approved as outlined in paragraph 1.7. The deviation/waiver documentation shall include any alternate or special criteria or procedures that will be imposed to ensure safe design and operations for those devices that do not meet the applicable requirements
1.3.4 Portions of this standard refer to various national consensus codes/standards for equipment design/hardware requirements (e.g., ASME, CMAA, etc.). Lifting devices and equipment purchased after the initial review required in paragraph 1.3.2 shall comply with the specified codes/standards in effect at the time of manufacture. Each installation shall periodically review subsequent codes/standards and evaluate the need to update existing equipment. Based on an evaluation of NASA’s overall safe lifting program and any significant changes in the consensus codes/standards, the NASA Safety and Risk Management with concurrence from the field installations shall decide when the next complete review (as described in paragraph 1.3.2) is warranted
1.4 Relation to Occupational and Safety Health Administration (OSHA) Requirements. This document is not a substitute for OSHA requirements. OSHA requirements apply to all NASA operations. This document meets or exceeds Federal OSHA requirements. Some States have their own OSHA programs that must comply with Federal OSHA and may be stricter. All NASA installations are responsible for keeping up to date with the Federal and State OSHA requirements that apply to their operations. This standard contains some OSHA requirements where deemed necessary to stress the importance of the requirement, clarify the requirement, document interpretation of the requirement, and/or define NASA’s program for meeting the requirement. The NASA Safety and Risk Management Division, with assistance from the field installations, shall monitor subsequent OSHA requirements for any impact on NASA’s safe lifting program
1.5 Critical and Noncritical Lifting Operations. There are two categories of lifting operations for the purposes of this standard, critical and noncritical
1.5.1 Critical lifts are lifts where failure/loss of control could result in loss of life, loss of or damage to flight hardware, or a lift involving special high dollar items, such as spacecraft, one-of-a-kind articles, or major facility components, whose loss would have serious programmatic or institutional impact. Critical lifts also include the lifting of personnel with a crane, lifts where personnel are required to work under a suspended load, and operations with special personnel and equipment safety concerns beyond normal lifting hazards. Personnel shall not be located under suspended or moving loads unless the operation adheres to the OSHA-approved NASA Alternate Standard for Suspended Load Operations (see Appendix A). Lifting of personnel with a crane shall be in accordance with 29 CFR 1926.550 (see Appendix C)
a. Each installation or program shall develop a process to identify critical lifting operations and lifting devices/equipment that must meet critical lift requirements. Input shall be gathered from facility, program, user, and assurance personnel. The results of the process shall be documented and approved, as a minimum, by the installation LDEM
b. It is NASA policy that the comprehensive safeguards outlined in this standard be provided for critical lifting operations. This includes special design features, maintenance, inspection, and test intervals for the lifting devices/equipment used to make critical lifts
c. Specific written procedures shall be prepared and followed for all critical lifts
d. During critical lifts there shall be one person present (NASA or contractor) that is designated as responsible for the safety of the operations. That person may be a safety professional, a supervisor, an engineer, or a task leader
1.5.2 Noncritical lifts typically involve routine lifting operations and are governed by standard industry rules and practices except as supplemented with unique NASA testing, operations, maintenance, inspection, and personnel licensing requirements contained in this standard
1.5.3 The requirements for critical and noncritical lifts outlined in this standard shall be followed unless a specific deviation/waiver is approved as outlined in paragraph 1.7. Different levels of risks associated shall be evaluated using the risk determination criteria in NPG 8715.3
1.6 Recordkeeping and Trend Analysis. A data collection system shall be established at each installation or location to support NASA-wide lifting device trend and data analysis. Data entered locally would typically be associated with type and manufacturer of the equipment, age, maintenance history, operational problems and their corrective actions, lifting mishaps, safety notices, inspection discrepancies, waivers, and proof and load test results. 1.7 Safety Variances
1.7.1 If a mandatory requirement cannot be met, a safety variance shall be prepared in accordance with NPG 8715.3. 1.7.2 The NASA variance process does not apply to Federal and applicable State/local regulations (e.g., OSHA, Cal OSHA). Any variance of a Federal or State/local regulation must be approved by the appropriate Federal/State/local agency (e.g., NASA Alternate Safety Standard for Suspended Load Operations approved by OSHA). The NASA Safety and Risk Management Division shall review all proposed safety variances of Federal regulations before submittal for approval
1.7.3 Example: A variance request to a requirement in this standard that uses the word shall would be routed through the Center Safety Director for concurrence and approved or denied by the Center Director. A copy would then be sent to the NASA Safety and Risk Management Division within 14 days along with detailed rationale for its approval and other documentation
1.8 Lifting Devices and Equipment Committee
1.8.1 NASA LDE Committee. Each installation Director shall designate in writing at least one person and an alternate, with appropriate background in lifting devices, lifting operations, lifting equipment industry standards and an understanding of lifting safety, as the installation LDEM, to participate as a member of the NASA LDE Committee. The committee is chaired by the Director, Safety and Risk Management Division, or designee, and is responsible for reviewing proposed changes to this standard and addressing general LDE safety issues. The LDEM is responsible for overall management of the installation LDE program, coordinating with appropriate personnel at their installation on lifting issues and providing the NASA LDE Committee with their installation’s position on LDE issues
1.8.2 Installation LDE Committee. Each installation shall establish a LDE Committee, to ensure this standard is understood and applied across other organizations at the installation and to resolve any issues and provide a forum to exchange information. The Installation LDE Committee shall be chaired by the LDEM, with representation from all organizations at the installation that are responsible for and/or involved with LDE
1.9 Personnel Performing Nondestructive Testing. Personnel performing lifting devices and equipment nondestructive testing (NDT), including visual inspections, shall be qualified and certified in accordance with written practices meeting the requirements contained in American Society for Nondestructive Testing (ASNT) Recommended Practice No. SNT-TC- 1A, Personnel Qualification and Certification in Nondestructive Testing. 2. APPLICABLE DOCUMENTS 2.1 General. The applicable documents cited in this standard are listed in this section for reference only. The specified technical requirements listed in the body of this document must be met whether or not the source document is listed in this section
2.2 Government Documents
2.2.1 Specifications, Standards, and Handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issuances in effect on date of invitation for bids or request for proposal shall apply
DEPARTMENT OF LABOR, OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION OCCUPATIONAL SAFETY AND HEALTH STANDARD, 29 CFR 1910, Subpart I, Personal Protective Equipment
OCCUPATIONAL SAFETY AND HEALTH STANDARD, 29 CFR 1910.29, Manually Propelled Mobile Ladder Stands and Scaffolds (Towers)
OCCUPATIONAL SAFETY AND HEALTH STANDARD, 29 CFR 1910.67, Vehicle-Mounted Elevating and Rotating Work Platforms
OCCUPATIONAL SAFETY AND HEALTH STANDARD, 29 CFR 1910.178, Powered Industrial Trucks
OCCUPATIONAL SAFETY AND HEALTH STANDARD, 29 CFR 1910.179, Overhead and Gantry Cranes
OCCUPATIONAL SAFETY AND HEALTH STANDARD, 29 CFR 1910.180, Crawler, Locomotive, and Truck Cranes
OCCUPATIONAL SAFETY AND HEALTH STANDARD, 29 CFR 1910.181, Derricks
OCCUPATIONAL SAFETY AND HEALTH STANDARD, 29 CFR 1910.184, Slings
OCCUPATIONAL SAFETY AND HEALTH STANDARD, 29 CFR 1926.550, Cranes and Derricks
NATIONAL AERONAUTICS AND SPACE ADMINISTRATION NASA Specifications Kept Intact (SPECSINTACT), Standard Construction Specification System
NASA SPECSINTACT, Section 14370, Monorails and Hoists
NASA SPECSINTACT, Section 14380, Electric Overhead Cranes
(Copies of OSHA standards are available at: http://www.osha.gov/comp-links.html, copies of NASA Standards are available at http://standards.nasa.gov.) 2.2.2 Other Government Documents, Drawings, and Publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issuances in effect on date of invitation for bids or request for proposal shall apply
NATIONAL AERONAUTICS AND SPACE ADMINISTRATION NASA Procedures and Guidelines 8715.3, NASA Safety Manual
NASA Procedures and Guidelines 8820.2C, Facility Project Implementation Handbook
(Copies of NASA directives are available at http://nodis.hq.nasa.gov/Welcome.html.) 2.3 Non-Government Publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issuances in effect on date of invitation for bids or request for proposals shall apply
AMERICAN INSTITUTE OF STEEL CONSTRUCTION, INC
“Manual of Steel Construction,” 400 North Michigan Avenue, Chicago, Illinois 60611
AMERICAN SOCIETY FOR NONDESTRUCTIVE TESTING SNC-TC-1A, Personnel Qualification and Certification in Nondestructive Testing
AMERICAN SOCIETY OF MECHANICAL ENGINEERS (ASME), AMERICAN NATIONAL STANDARDS INSTITUTE (ANSI) ANSI A10.22, Safety Requirements for Rope Guided and Nonguided Worker’s Hoists
ANSI/SIA A92.2, Vehicle Mounted Elevating and Rotating Aerial Devices
ANSI/SIA A92.3, Manually Propelled Elevating Aerial Platforms
ANSI/SIA A92.5, Boom Supported Elevating Work Platforms
ANSI/SIA A92.6, Self Propelled Elevating Work Platforms
ANSI/ISA S84.01, Electrical, Electronic, Programmable Electronic Systems in Safety Applications
ASME B30.1, Jacks. ASME B30.2, Overhead and Gantry Cranes
ASME B30.3, Construction Tower Cranes
ASME B30.4, Portal, Tower, and Pedestal Cranes
ASME B30.5, Mobile and Locomotive Cranes
ASME B30.6, Derricks
ASME B30.7, Base Mounted Drum Hoists
ASME B30.8, Floating Cranes and Floating Derricks
ASME B30.9, Slings
ASME B30.10, Hooks
ASME B30.11, Monorails and Underhung Cranes
ASME B30.12, Handlings Loads Suspended from Rotorcraft
ASME B30.14, Side Boom Tractors
ASME B30.16, Overhead Hoists
ASME B30.17, Overhead and Gantry Cranes
ASME B30.19, Cableways
ASME B30.20, Below-the-Hook Lifting Devices
ASME B30.21, Manually Lever Operated Hoists
ASME B30.22, Articulating Boom Cranes
ASME B30.23, Personnel Lifting Systems
ASME B56.1, Safety Standard for Low Lift and High Lift Trucks
ASME HST-1, Performance Standard for Electric Chain Hoists
ASME HST-2, Performance Standard for Hand Chain Manually Operated Chain Hoists
ASME HST-3, Performance Standard for Manually Lever Operated Chain Hoists
ASME HST-4, Performance Standard for Overhead Electric Wire Rope Hoists
ASME HST-5, Performance Standard for Air Chain Hoists.12 ASME HST-6, Performance Standard for Air Wire Rope Hoists
AMERICAN WELDING SOCIETY D1.1, Structural Welding and Cutting Code
D1.2, Structural Welding Code – Aluminum
D14.1, Specifications for Welding Industrial and Mill Cranes
CRANE MANUFACTURERS ASSOCIATION OF AMERICA (CMAA) CMAA Specification No. 70, Specifications for Electric Overhead Traveling Cranes
CMAA Specification No. 74, Specification for Top Running and Under Running Single Girder Electric Overhead Traveling Cranes
NATIONAL FIRE PROTECTION ASSOCIATION (NFPA) NFPA No. 70, National Electric Code
POWER CRANE AND SHOVEL ASSOCIATION (PCSA) PCSA, Standards No. 4 and No. 5
SOCIETY OF AUTOMOTIVE ENGINEERS (SAE) SAE J765, Crane Load Stability Test Code
WIRE ROPE TECHNICAL BOARD Wire Rope Users Manual Wire Rope Sling Users Manual 2.4 Order of Precedence. Where this document is adopted or imposed by contract on a program or project, the technical guidelines of this document take precedence, in the case of conflict, over the technical guidelines cited in other referenced documents
3. DEFINITIONS AND ACRONYMS 3.1 Definitions Used in this Standard 3.1.1 Brake: A device used for retarding or stopping motion. 3.1.2 Certification: That situation when the lifting device or equipment maintenance, test, or other operational checks have been performed and are current. 13 3.1.3 Control Braking Means: A method of controlling speed by removing energy from the moving body or by imparting energy in the opposite direction
3.1.4 Crane: A machine for lifting and lowering a load and moving it horizontally, with the hoisting mechanism an integral part of the machine
3.1.5 Critical Lift: A lift where failure/loss of control could result in loss of life, loss of or damage to flight hardware, or a lift involving special, high dollar items, such as spacecraft, one- of-a-kind articles, or major facility components, whose loss would have serious programmatic or institutional impact. Critical lifts also include the lifting of personnel with a crane, lifts where personnel are required to work under a suspended load, and operations with special personnel and equipment safety concerns beyond normal lifting hazards. 3.1.6 Critical Weld: A weld where the single failure of which could result in injury to personnel or damage to property or flight hardware by dropping or losing control of the load
3.1.7 Derrick: An apparatus with a mast or member held at the head by guys or braces, with or without a boom and that uses a hoisting mechanism and operating ropes for lifting or lowering a load
3.1.8 Designated Person: Any person who has been selected or assigned (in writing) by the responsible NASA organizational element or the using contractor as being qualified to perform specific duties. A licensed operator may serve as a designated person for the equipment he/she is licensed to operate
3.1.9 Design Load: The value used by the manufacturer as the maximum load around which the device or equipment is designed and built based on specified design factors and limits. This is also the load referred to as the “Manufacturer’s Rated Load.” 3.1.10 Design Factor: A numeric term that is broadly used. It is usually expressed as a ratio of the ultimate stress, or yield stress, to the capacity of a component, or to the service load, or its rated capacity. It is also used or includes factors in calculations to quantify variations found in the properties of materials, manufacturing tolerances, operating conditions, and design assumptions
3.1.11 Design Safety Factor: See Design Factor
3.1.12 Deviation: A variance that authorizes departure from a particular safety requirement that does not strictly apply or where the intent of the requirement is being met through alternate means that provide an equivalent level of safety with no additional risk
3.1.13 Dummy Load: A test load, to simulate the real load; typically a test weight
3.1.14 Eddy Current Brake (control braking means): A method of controlling or reducing speed by means of an electrical induction load brake
3.1.15 Emergency Stop (E-Stop): A manually operated switch or valve to cut off electric power or control fluid power independently of the regular operating controls
14 3.1.16 Failure Modes and Effects Analysis (FMEA): A systematic, methodical analysis performed to identify and document all identifiable failure modes at a prescribed level and to specify the resultant effect of the modes of failure
3.1.17 Frequently: For the purpose of this document, the term “frequently” is used to mean once or more per year
3.1.18 Hazard: Any real or potential condition that can cause injury or death to personnel, or damage to or loss of equipment or property
3.1.19 Hoist: A machinery unit device used for lifting and lowering a load
3.1.20 Hoist Supported Personnel Lifting Device: Lifting equipment such as a platform, bucket, or cage supported by hoist(s) that is designed, built, tested, maintained, inspected, and certified as having sufficient reliability for safely lifting and lowering personnel
3.1.21 Holding Brake: A brake that automatically prevents motion when power is off
3.1.22 Hydra-set: Trade name for a closed circuit hydraulically operated instrument installed between hook and payload that allows precise control of lifting operations and provides an indication of the applied load. It will be used in the general sense in this standard as a means of identifying precision load positioning devices
3.1.23 Idle Lifting Device: Lifting device that has no projected use for the next 12 months. 3.1.24 Infrequently: For the purpose of this document, the term “infrequently” is used to mean less than once per year
3.1.25 Jack: A mechanism with a base and load point designed for controlled linear movement
3.1.26 Licensed Operator: Any person who has successfully completed the examination for crane, hoist, or heavy equipment operator and has been authorized to operate such equipment. (NOTE: This term includes certified and/or authorized operator.) 3.1.27 Lifting Devices and Equipment: Devices such as overhead and gantry cranes (including top running monorail, underhung, and jib cranes), mobile cranes, derricks, hoists, winches, special hoist supported personnel lifting devices, hydra-sets, load measuring devices, hooks, slings and rigging, mobile aerial platforms, powered industrial trucks, and jacks used for lifting and lowering
3.1.28 Lifting Devices and Equipment Manager (LDEM): Person responsible for overall management of the installation lifting devices and equipment program, coordinating with appropriate personnel at their installation on lifting issues and providing their installation’s position on lifting devices and equipment safety issues. 3.1.29 Linear Fiber Sling: A sling where load bearing fibers are bundled in a linear fashion
3.1.30 Load: The total load, including the sling or structural sling, below the hoisting device hook, being raised or moved
3.1.31 Load Measuring Device: A measuring device below the hook that is part of the load path for lifting operations
3.1.32 Mobile Aerial Platform: A mobile device that has an adjustable position platform, supported from ground level by a structure
3.1.33 NASA Operation: Any activity or process that is under NASA direct control or includes major NASA involvement
3.1.34 Noncritical Lift: A lift involving routine lifting operations governed by standard industry rules and practices except as supplemented with unique NASA testing, operations, maintenance, inspection, and personnel licensing requirements contained in this standard
3.1.35 Nondestructive Testing (NDT): The development and application of technical methods to examine materials or components in ways that do not impair future usefulness and serviceability in order to detect, locate, measure, and evaluate flaws; to assess integrity, properties, and composition; and to measure geometrical characteristics
3.1.36 Operational or Working Load: A value representing the weight of the load actually being handled plus the weight of the attaching equipment (slings, Hydra-set, spreader bars, etc.)
3.1.37 Operational Test: A test to determine if the equipment (limit switches, emergency stop controls, brakes, etc.) is functioning properly
3.1.38 Payload: The actual object, below the sling or structural sling, being raised or moved
3.1.39 Periodic Load Test: A load test performed at predetermined intervals with load greater than or equal to the rated load, but less than the proof load
3.1.40 Personnel Certification: A means to assure an individual is qualified to perform a designated task
3.1.41 Personnel Lift: For the purposes of this document, a working platform that will lift, lower, sustain, and transport people
3.1.42 Platform Hoist: A dedicated hoist whose only purpose is to raise and lower a platform not carrying personnel
3.1.43 Proof Load: The specific load or weight applied in performance of a proof load test and is greater than the rated load
3.1.44 Proof Load Test: A load test performed prior to first use, after major modification of the load path or at other prescribed times. This test verifies material strength, construction, and workmanship and uses a load greater than the rated load. Proof load test, as used in this standard, is equivalent to the OSHA rated load test
16 3.1.45 Rated Load or Safe Working Load or Rated Capacity: An assigned weight that is the maximum load the device or equipment shall operationally handle and maintain. This value is marked on the device indicating maximum working capacity. This is also the load referred to as “safe working load” or “working load limit.” If the device has never been downrated or uprated, this also is the “manufacturer’s rated load.” 3.1.46 Regular Service Lifting Device: Lifting device that is being used one or more times per month
3.1.47 Remote Emergency Stop (Remote E-Stop): An emergency stop remotely located from the regular operator controls
3.1.48 Side Pull: That portion of the hoist pull acting horizontally when the hoist lines are not operating vertically
3.1.49 Side Load: A load applied at an angle to the vertical plane of the hoist line
3.1.50 Single Failure Point: A single item or component whose failure would cause an undesired event such as dropping a load or loss of control
3.1.51 Shall: The word “shall” indicates that the rule is mandatory and must be followed
3.1.52 Should: The word “should” indicates that the rule is a recommendation, the advisability of which depends on the facts in each situation
3.1.53 Sling: A lifting assembly and associated hardware used between the actual object being lifted and hoisting device hook
3.1.54 Special Hoist Supported Personnel Lifting Device: Device specifically designed to lift and lower persons via a hoist. These devices include hoist supported platforms where personnel occupy the platform during movement. These devices do not including elevators, lifting personnel with a crane, mobile aerial platforms, or platforms or others items hoisted unoccupied to a position and anchored or restrained to a stationary structure before personnel occupy the platform
3.1.55 Standby Lifting Device: Lifting device that is not in regular service but used occasionally or intermittently as required. Intermittent use is defined as a lifting device which has not been used for a period of one month or more, but less than 6 months
3.1.56 Structural Sling: A rigid or semi-rigid fixture that is used between the actual object being lifted and hoisting device hook. Examples are spreader bars, equalizer bars, and lifting beams
3.1.57 Surface Nondestructive Testing: Test and inspection methods used to examine the surface of equipment/materials; e.g., magnetic particle and liquid penetrant
3.1.58 Tagline: A line used to restrain or control undesirable motion of a suspended load
3.1.59 Valley Break: A broken wire in a wire rope in which the outside wire of a strand breaks in the immediate vicinity of the point where it contacts a wire or wires of an adjacent17 strand, generally at a point not visible when the wire rope is examined externally. One end of the broken wire is long enough to reach from one valley to the next one and the other end of the broken wire generally cannot be seen
3.1.60 Variance: Documented and approved permission to perform some act contrary to established requirements
3.1.61 Volumetric Nondestructive Testing: Test and inspection methods used to examine the interior of equipment/materials; e.g., ultrasonic and radiographic
3.1.62 Waiver: A variance that authorizes departure from a specific safety requirement, where a special level of risk has been documented and accepted
3.1.63 Winch: A stationary motor-driven or hand-powered hoisting machine having a drum around which is wound a rope, chain, or web used for lifting and lowering a load (does not apply to winches used for horizontal pulls)
3.1.64 Wire Rope Slings: Wire ropes made into forms, with or without fittings, for handling loads and so made as to permit the attachment of an operating rope
3.1.65 Working Load: If the device has never been downrated or uprated, this also is the “manufacturer’s rated load.” 3.2 Abbreviations and Acronyms Used in this Standard 3.2.1 AC Alternating Current 3.2.2 AGMA American Gear Manufacturers Association 3.2.3 ANSI American National Standards Institute 3.2.4 ASME American Society of Mechanical Engineers 3.2.5 cm centimeter 3.2.6 CMAA Crane Manufacturers Association of America, Inc
3.2.7 DC Direct Current 3.2.8 FMEA Failure Modes and Effects Analysis 3.2.9 km/hr kilometer/hour 3.2.10 LDEM Lifting Device and Equipment Manager 3.2.11 m meter 3.2.12 mm millimeter 3.2.13 mph mile/hour 18 3.2.14 NEMA National Electrical Manufacturers Association 3.2.15 NFPA National Fire Protection Association 3.2.16 NPG NASA Procedures and Guidelines 3.2.17 OEM Original Equipment Manufacturer 3.2.18 OSHA Occupational Safety and Health Administration 3.2.19 O&SHA Operating and Support Hazard Analysis 3.2.20 PCSA Power Crane and Shovel Association 3.2.21 RCM Reliability Centered Maintenance 3.2.22 SPECSINTACT Specifications Kept Intact 4. OVERHEAD CRANES 4.1 General. This section establishes minimum standards for the design, testing, inspection, maintenance, personnel certification, and operation for overhead and gantry cranes, including underhung, monorail, and jib cranes
4.2 Safety and Design Aspects. Generally, high quality off-the-shelf, OEM type equipment is acceptable for critical and noncritical lifts if it is designed, maintained, and operated according to this standard
4.2.1 Design criteria that should be emphasized during overhead crane design are contained in the documents listed in Section 2
4.2.2 Labeling/Tagging of Cranes
a. The rated load of all cranes shall be plainly marked on each side of the crane. If the crane has more than one hoisting unit, each hoist load block shall be marked with its rated load. This marking shall be clearly legible from the ground floor (OSHA requirement for all overhead cranes)
b. Cranes that have the specified design features, maintenance/inspection, and test intervals to lift critical loads shall be marked conspicuously so that the operator and assurance personnel can distinguish that the crane is qualified for critical lifts
c. A standard system of labeling shall be established and used throughout the installation
d. 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 operations, or other reasons
19 e. Certification/recertification tags are required as described in paragraph 4.3.4
f. Each overhead crane shall have the directions of its bridge and trolley movements displayed on the underside of the crane. These directions shall correspond to the directions on the operator station. These markings shall be visible from the floor but are not required if the crane is at such a height the markings would be legible without unaided vision
4.2.3 Safety Analysis and Documentation of Cranes Used for Critical Lifts. A recognized safety hazard analysis, such as fault tree analysis, FMEA, Operating and Support Hazard Analysis (O&SHA), shall be performed on all cranes used for critical lifts. 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 crane, facility, or load. The analysis shall be done as part of the initial evaluation process for critical lift compliance and prior to use in a critical lift, included in the crane documentation, and updated as required to reflect any changes in operation and/or configuration. 4.2.4 Performance. Crane service classification, load capability, and the desired control characteristics with which the crane handles the load shall be addressed for all designs. Crane service classification requirements shall be based on the worst expected duty the unit will encounter. Operational requirements shall be considered in the design phase to ensure load and function are adequately defined and critical crane design features are incorporated on the delivered units
4.2.5 Structural. Structural design shall be in accordance with industry standards for material selection, welding, allowable stresses, design limitations, framing, rails, wheels, and other structural elements. Refer to ASME and CMAA standards for specific design details
4.2.6 Mechanical
a. The use of high quality, off-the-shelf, OEM type equipment is acceptable for critical and noncritical lift applications if it meets all user requirements and the requirements of this document. This high quality commercial equipment employs a modular type construction of the hoist unit with standard frame sizes and interchangeable gear boxes, drums, motors, brakes, and controls to achieve a wide range of capacities, lifts, operating speeds, reeving arrangements, and controls. These interchangeable parts are standardized for each manufacturer’s product line and the hoists are built to order
b. The mechanical design requirements for crane components are as follows: (1) They shall meet all applicable requirements of OSHA, ASME, and CMAA
(2) For critical lift application, speed reduction from the motor to the drum on the hoist should be achieved by enclosure in a gear case. If20 open gears are required, they shall be guarded with a provision for lubrication and inspection
(3) Gearing shall be designed and manufactured to comply with the latest AGMA gear standards
(4) Each hoisting unit shall be provided with at least two means of braking: a holding brake and a control brake. The torque ratings, physical characteristics, and capabilities of the brakes shall be in accordance with CMAA specifications
(5) For cranes used for critical lifts, two holding brakes shall be provided, each capable of bringing a rated load to zero speed and holding it. Holding brakes shall be applied automatically when power to the brake is removed. If the control brake and holding brake are designed to operate as a system and cannot independently stop and hold a rated load, then another means of braking is required for cranes used for critical lifts (e.g., emergency brake). The brakes shall be designed so that they can be tested as required in paragraph 4.3.3.d. The brake design shall provide for emergency load lowering
(6) Worm gears shall not be used as a braking means unless the lead angle is sufficient to prevent back driving. The braking properties of a worm gear tend to degrade with use; the design engineer shall consider this when purchasing new equipment or in existing installations where the hoist is subject to heavy use
(7) In the procurement of new lifting equipment, the use of cast iron components in the hoist load path shall be approved, as a minimum, by the LDEM and the responsible design engineering organization. The material properties of cast iron allow catastrophic failure and should not be considered as reliable as steel or cast steel. The engineer shall consider this when selecting equipment and avoid the use of load bearing cast iron materials where possible
(8) Safe and adequate access to crane components to inspect, service, repair, or replace equipment shall be provided for during design. The design shall provide for visual and physical accessibility
(9) Pneumatic cranes shall have the capability to lock out the supply air pressure to prevent unauthorized use
(10) Based on the sensitivity of the loads to be lifted, cranes shall have appropriate speed modes that provide for safe, smooth starting and stopping to preclude excessive “G” forces from being applied to the load
(11) All wire rope hoists shall have not less than two wraps of hoisting rope on the drum when the hook is in its extreme low position. Drum grooves, when provided, shall be as recommended by CMAA. The rope ends shall be anchored securely by a clamp or a swaged terminal in a keyhole slot, provided a keeper is used to prohibit the swage from moving21 out of the narrow slot. Other methods recommended by the hoist or wire rope manufacturer are acceptable if the rope termination anchor together with two wraps of rope on the drum will give an anchor system equal to or greater than the breaking strength of the wire rope
(12) Malleable iron clips for wire rope termination shall not be used. Forged steel wire rope clips are acceptable
(13) Manually operated (nonpowered) hoist cranes that are off-the- shelf OEM type are acceptable for critical and noncritical lift applications. They shall comply with applicable ASME requirements. These hoists shall be equipped with at least one self-setting brake, referred to as a holding brake, applied directly to the motor shaft or some part of the gear train. No limit switches are required if proper over-travel restraint is provided
(14) Air operated chain hoists can be equipped with over-travel protection devices instead of the hoist travel limit switches
(15) Initial and final upper limit switches (limit control valves) shall be provided and tested for critical air operated hoists as described in paragraph 4.2.7.k. The final upper limit switch (limit control valve) shall exhaust air from the crane hoist, set the brakes, and require reset at the upper limit switch (limit control valve) level
(16) A minimum clearance of 3 inches (7.6 cm) overhead and 2 inches (5.1 cm) laterally shall be provided and maintained between the crane and all obstructions
c. When the use of high quality, off-the-shelf, OEM type equipment is not possible due to unique design and operation requirements, then built-up type equipment must be used. These built-up cranes generally use many commercially available or made-to-order motors, brakes, couplings, gear reducers, etc. These components are then custom engineered together as an assembly mounted on custom designed and built equipment frames. In many cases, gear reducers, drums, and drive shafts are custom designed and built. Structural and mechanical parts, such as sheave pins, hook-block components, bridge girders, and bridge and trolley drives are also custom designed and built as components or assemblies. The built-up type crane should only be used where commercial equipment is not available to meet the user/operational requirements described in this paragraph. Due to the nature of its one of a kind design and construction, this type of equipment is generally more prone to break down and should be considered as less reliable than commercial equipment. These units shall meet the mechanical design requirements provided in paragraph 4.2.6.b and the following additional minimum requirements: (1) Drum supporting structures should be designed so that bearings are mounted under compression to (1) minimize wearing of the bearings and (2) increase the probability of maintaining the mesh between the drum gear and the drive gear in the case of bearing failure. The structure shall be designed to preclude failure of the bearings and drum supports.22 Pillow block bearings shall have steel, or cast steel housings (the use of cast iron is not permitted)
(2) In descending order of preference, the drum gear when used shall be integrally attached, splined, bolted with close fitting body-bound bolts to a flange on the drum, or pressed on and keyed to either the periphery of the hub or shell of the drum, or attached by other means of equal safety
(3) Couplings shall be located immediately next to bearings. Couplings between closely spaced bearings shall be of a full flexible type with integral gear form or grids, having metal to metal contact, and shall run in oil or be lubricated as recommended by the manufacturer. All couplings for hoists shall be pressed fit with keys
(4) Each load-bearing component shall be specified or detailed to lift the maximum imposed loads resulting from zero to rated hook load with appropriate design factors. 4.2.7 Electrical. Electrical design requirements are as follows: a. The use of high quality, off-the-shelf, OEM type equipment is acceptable for critical and noncritical lift applications if it meets all user requirements and the requirements of this document
b. When the use of high quality, off-the-shelf, OEM type equipment is not possible due to unique design and operation requirements, then built-up type equipment must be used. This built-up equipment generally uses many commercially available or made-to-order components which are then custom engineered together as an assembly. Built-up equipment should only be used where commercial equipment is not available to meet the user/operational requirements. Due to the nature of its one of a kind design and construction, this type of equipment is generally more prone to break down and should be considered less reliable than commercial equipment
c. Wiring and safety devices shall be in accordance with NFPA National Electrical Code. Conduit and wiring shall be such that on-site work is minimized. Hard wire conductors such as festooned cables or articulated cable carriers, instead of power or feed rails, shall be considered to provide power and control to overhead cranes handling explosives or solid propellants, or to cranes with solid state controls
d. Electrical enclosures shall provide protection for the contained equipment against environmental conditions according to the class rating established by NEMA
e. In addition to overload protection required by the National Electrical Code, under-voltage and phase reversal should be considered
f. Control stations shall operate on 150 volts DC, 120 volts AC, or less. Positive detent pushbuttons or a control lever shall be used for speed control.23 Controls shall return to the off position when the operator relieves pressure. A red, emergency stop pushbutton shall be provided to operate the mainline contactor and/or the main circuit breaker (main breaker preferred). A positive lockout to the controls shall be provided to ensure the safety of maintenance personnel
g. All cab-operated cranes with step type control shall be equipped with lever controls. The levers shall be of the continuous effect type and provided with a deadman feature that will not unduly tire the operator during lengthy operations
h. The electrical system shall be designed fail-safe to ensure that a failure of any component will not cause the crane to operate in a speed range faster than commanded. A failure that causes a speed different from that selected is acceptable provided no hazards are introduced. Failure modes that cause the bridge, trolley, or hoist to slow down or come to a safe stop are acceptable; those that could cause unplanned directional shifts, and/or loss of control are unacceptable
i. Provisions for grounding the hook are required for handling explosives, solid propellants, flammables, or any other load that requires a nonelectrical or static-free environment. See paragraph 4.8 for handling explosives or Electro- Explosive Devices (EED’s)
j. For cranes used for critical lifts, an assessment shall be performed to determine the operational needs for remote emergency stops independent from the operator controlled emergency stop. Not all cranes used for critical lifts require a remote emergency stop. Remote emergency stops are required for cranes used for critical lifts where the crane operator’s view is restricted/obstructed. When provided, this independent remote emergency stop should be located such that the independent remote emergency stop operator(s) can clearly see the critical lift area(s). The remote emergency stop circuit shall be separate from and take precedence over the operator control circuit. The control, when activated, shall cause all drives to stop and the brakes to set. Hand-held remote emergency stop pendants should be standardized and should include power and circuit continuity indication. For those cranes required to make critical lifts that have not been modified to provide a remote emergency stop, handling procedures shall be developed and implemented to minimize the risk
k. For cranes used for critical lifts, dual upper limit switches are required. For electric cranes, the limit switches shall meet the following requirements: (1) Initial upper limit switch electrical contacts shall be a set of normally closed contacts in the “raise” contactor circuit such that movement in the raise direction shall be precluded after the limit switch is encountered. Movement in the “lower” direction will not be inhibited
(2) Final upper limit switch electrical contacts shall be a set of normally closed electrical contacts wired into the mainline circuit, hoist power circuit, main contactor control circuit, or hoist power contactor24 control circuit such that all crane motion or all hoist motion shall be precluded after the limit switch is encountered. These normally closed contacts may be located in the low voltage control circuitry
(3) After a final upper limit switch has been activated, movement of the load will require action (resetting) at the final upper limit switch level. An inspection shall be made to determine the cause of failure of the initial upper limit switch. Stopping crane motion by the above design configuration may result in a hazardous suspended load condition. The crane design should include a means of detecting limit switch failure and allow for safe inspection and repair. For example, a system may be equipped with two different colored annunciator lights, one for each limit switch. A reset button may be included so that when a final upper limit switch is tripped, the load can be lowered immediately. The reset button should be secured to prevent unauthorized use
(4) The initial upper limit switch shall be adjusted sufficiently low to preclude inadvertent actuation of the final upper limit switch if the hoist actuates the initial upper limit switch at full speed with no load. Similarly, the final upper limit switch shall be adjusted sufficiently low to ensure that the hoist will not two-block (or otherwise damage wire rope) if the hoist actuates the final upper limit switch at full speed with no load. Both limits shall be tested from slow speed to full speed to verify correct operation. It should be noted that this requirement effectively lowers the usable hook height of the hoist. The limit switch arrangement shall be considered during new equipment design
l. For cranes used for critical lifts, lower limit switches to prevent reverse winding of the wire rope shall be provided
m. Electrical cranes shall have the capability to be locked out at the main breaker to prevent unauthorized use
n. Cranes shall be designed fail-safe in the event of a power outage
4.3 Testing. Three types of tests are required for cranes: proof load tests, periodic load tests, and operational tests. The proof load tests and operational tests shall be performed prior to first use for new cranes, or for existing cranes that have had modifications or alterations performed to components in the load path. This applies only to those components directly involved with the lifting or holding capability of a crane that has been repaired or altered. Repairs or alterations to nonlifting, secondary lifting, or holding components such as suspension assemblies, electrical system, crane cab, etc., do not require a load test, although a functional check should be performed to determine if the repairs or alternations are acceptable. The periodic load and operational tests shall be performed at least every 4 years. Cranes used frequently for critical lifts shall be load tested annually. Cranes used infrequently for critical lifts shall be load tested before the critical lift if it has been more than a year since the last test. If a crane is upgraded (increased lifting capacity), a proof load test and an operational test shall be performed based on the upgraded rating. All load and operational tests shall be performed by qualified personnel according to written (specific or general) technical operating procedures. An inspection of the crane and lifting components shall be performed after each load test and prior to the crane being released for service to ensure there is no damage. Surface or volumetric25 NDT of critical components shall be used to validate the existence or absence of cracks or other load test effects indicated by this inspection. The periodic load test requirement may be fulfilled by a concurrently performed proof load test
4.3.1 Proof Load Test. Before first use and after installation, all new, extensively repaired, extensively modified, or altered cranes shall undergo a proof load test with a dummy load as close as possible to, but not exceeding 1.25 times the rated capacity of the crane. A proof load test also should be performed when there is a question in design or previous testing. The load shall be lifted slowly and in an area where minimal damage will occur if the crane fails. The acceptable tolerance for proof load test accuracy is -5/+0 percent. 4.3.2 Periodic Load Test. Each crane shall be tested at least once every 4 years with a dummy load equal to the crane’s rated capacity. Cranes used for critical lifts shall be load tested at least once per year. Cranes used infrequently for critical lifts shall be load tested before the critical lift if it has been more than a year since the last test. The acceptable tolerance for periodic load test accuracy is +5/-0 percent
4.3.3 Operational Test. Together with proof load and periodic load tests, the following shall be performed with a dummy rated load unless otherwise specified: a. Load hoisting, lowering at various speeds (maximum safe movement up and down as determined by the LDEM and the responsible safety, engineering, operations, and maintenance organizations), and braking/holding mechanisms. Holding brakes shall be tested to verify stopping capabilities and demonstrate the ability to hold a rated load (see paragraph 4.3.3.d). The load should be held long enough to allow any dynamics to dampen out
b. Trolley and bridge travel (maximum safe movement in all directions with varying speeds as determined by the LDEM and the responsible safety, engineering, operations, and maintenance organizations)
c. All limit switches, locking devices, emergency stop switches, and other safety devices, excluding thermal overload and circuit breakers. The limit switch, emergency stop, and locking device tests except for the final upper limit switch shall be performed with no load on the hook at full speed. The final upper limit switch can be tested by manually tripping the switch and verifying that all hoist motion is precluded (see paragraph 4.5.2.c)
d. Cranes used for critical lifts are required to be equipped with two holding brakes (hoist), each capable of bringing a rated load to zero speed and holding it (see paragraph 4.2.6.b(5)). If a worm gear is used as a holding brake, it shall be tested to ensure it is able to hold a static load and stop a dynamic load. The operational test must demonstrate each brake’s ability to stop and hold a rated load. This can be done in one of the following ways: (1) Each brake’s ability to hold shall be statically tested (under no load) with 150 percent of the rated load hoisting torque at the point of brake application
(2) Alternately, each brake shall be tested for its ability to stop and hold a rated load in both the raising and lowering modes. (CAUTION: It26 must be possible to quickly reenergize the out-of-circuit brake or provide other safety measures to perform this test safely.) (3) Other methods as approved by the LDEM with concurrence from the responsible safety, engineering, operations, and maintenance organizations
e. The operational test for a modified crane can be tailored to test those portions of the equipment that were modified only if the normal periodic load and operational test interval has not expired. 4.3.4 Test Reports and Periodic Recertification Tags. After each test, designated personnel shall prepare written, dated, and signed test reports including procedure reference. Inadequacies shall be documented and, if determined to be a hazard, corrected prior to further use. These reports shall be kept on file by the owner organization for a minimum of two test cycles and shall be made readily available. Following the periodic load test, cranes shall be given a permanently affixed tag, posted on the crane or an appropriate location, identifying the equipment and stating the next required periodic load test date or load test expiration date
Related Files
NASA crane spec 8719.9
