DOE-STD-1090-2004, Hoisting and Rigging (Formerly Hoisting and Rigging Manual)
Functional areas: Hoisting and Rigging
The U.S. Department of Energy (DOE) Hoisting and Rigging Standard is intended as a reference document to be used by supervisors, line managers, safety personnel, equipment operators, and any other personnel responsible for safety of hoisting and rigging operations at DOE sites. The standard quotes verbatim or paraphrases (with minor editorial changes for consistency) the requirements of the U.S. Occupational Safety and Health Administration (OSHA) and the
American National Standards Institute (ANSI). It also encompasses, under one cover, hoisting and rigging requirements, codes, standards, and regulations, eliminating the need to maintain extensive (and often incomplete) libraries of hoisting and rigging standards throughout DOE.
Unknown Block text
Superseded By:
DOE-STD-1090-2007 Chg Notice 1, Hoisting and Rigging on Aug 29, 2007
Version history and related documents
Superseded by
A newer version replaces this document.
- DOE-STD-1090-2007 Chg Notice 1Hoisting and Rigging (Aug 29, 2007)
Document text
Text extracted from the attached file. Refer to the original document for the authoritative version.
Section 1
DOE-STD-1090-2004
June 2004
Superseding
DOE-STD-1090-01
April 2001
DOE STANDARD
HOISTING AND RIGGING
(Formerly Hoisting and Rigging Manual)
U.S. Department of Energy AREA SAFT
Washington, D.C. 20585
DISTRIBUTION STATEMENT A. Approved for public release; distribution is
unlimited.
INCH-POUND
CONTENTS
HISTORY AND BACKGROUND
ACKNOWLEDGMENT
INTRODUCTION
CHAPTER 1 TERMINOLOGY AND DEFINITIONS ................................................. 1-1
CHAPTER 2 CRITICAL LIFTS................................................................................. 2-1
2.1 CRITICAL-LIFT DETERMINATION........................................................ 2-1
2.2 CRITIAL-LIFT REQUIREMENTS ............................................................. 2-2
CHAPTER 3 PREENGINEERED PRODUCTION LIFTS................................3-1
3.1 GENERAL....................................................................................................... 3-1
3.2 OPERATION EVALUATION ...................................................................... 3-2
3.2.1 Load Identification................................................................................ 3-2
3.2.2 Task Determination............................................................................... 3-2
3.2.3 Hazards Evaluation ............................................................................... 3-2
3.2.4 Equipment/Rigging Selection ............................................................... 3-2
3.3 LIFTING FIXTURES .................................................................................... 3-3
3.3.1 Design ................................................................................................... 3-3
3.3.2 Fabrication ............................................................................................ 3-3
3.3.3 Inspection and Testing .......................................................................... 3-3
3.3.4 Storage, Maintenance, and Control....................................................... 3-3
3.3.5 Modification and Repair ....................................................................... 3-4
3.4 PROCEDURES ............................................................................................... 3-5
3.4.1 Content.................................................................................................. 3-5
3.4.2 Development ......................................................................................... 3-5
3.4.3 Preparation and Revision ...................................................................... 3-5
3.4.4 Approval ............................................................................................... 3-6
3.4.5 Review .................................................................................................. 3-6
3.4.6 Use ........................................................................................................ 3-7
3.5 DESIGNATED LEADER .............................................................................. 3-7
3.6 TRAINING ...................................................................................................... 3-8
3.6.1 Equipment Operation............................................................................ 3-8
3.6.2 Procedure .............................................................................................. 3-8
CHAPTER 4 LIFTING PERSONNEL..............................................................4-1
Section 2
4.1 GENERAL....................................................................................................... 4-1
4.1.1 Personnel Lifting Evaluation ................................................................ 4-1
4.1.2 Designated Leader ................................................................................ 4-1
4.1.3 Trial Lift................................................................................................ 4-2
4.1.4 Lifting Operations................................................................................. 4-2
4.2 MOBILE CRANES......................................................................................... 4-5
4.3 OVERHEAD CRANES .................................................................................. 4-6
4.4 PERSONNEL LIFT PLATFORM ................................................................ 4-7
4.4.1 Platform Design and Construction........................................................ 4-7
4.4.2 Platform Suspension System................................................................. 4-7
4.5 INSPECTIONS ............................................................................................... 4-9
4.5.1 Frequent Inspection............................................................................... 4-9
4.5.2 Periodic Inspection................................................................................ 4-9
4.6 TESTING....................................................................................................... 4-10
4.6.1 Platform Manufacturer Test................................................................ 4-10
4.6.2 Rated Load Test .................................................................................. 4-10
4.6.3 Hoisting Equipment ............................................................................ 4-10
4.7 LIFTING PERSONNEL NEAR ELECTRICAL POWER LINES ......... 4-11
4.7.1 General................................................................................................ 4-11
4.7.2 Condition A......................................................................................... 4-11
4.7.3 Condition B......................................................................................... 4-11
4.7.4 Condition C......................................................................................... 4-12
Exhibit I Personnel Lift Platform Pre-Lift Inspection ....................................... 4-15
Exhibit II Personnel Lifting Planning and Authorization Form.......................... 4-16
CHAPTER 5 HOSTILE ENVIRONMENTS
5.1 GENERAL....................................................................................................... 5-1
5.2 HOSTILE ENVIRONMENT PLAN............................................................. 5-2
5.2.1 Marking and Posting............................................................................. 5-2
5.2.2 Inspection and Testing .......................................................................... 5-2
Exhibit I Hostile Environment Plan ..................................................................... 5-3
CHAPTER 6 PERSONNEL QUALIFICATION AND TRAINING
6.1 GENERAL....................................................................................................... 6-1
Section 3
6.2 QUALIFICATIONS ....................................................................................... 6-2
6.2.1 General.................................................................................................. 6-2
6.2.2 Operators of Cab-Operated and Pulpit-Operated.................................. 6-2
6.2.3 Operators of Mobile Cranes.................................................................. 6-2
6.2.4 Operators of Truck Mounted Cranes – Capacity 1 Ton or Less ........... 6-4
6.2.5 Operators of Floor-Operated Cranes..................................................... 6-4
6.2.6 Operators of Forklift Trucks ................................................................. 6-4
6.2.7 Operators of Remote Operated Cranes ................................................. 6-4
6.2.8 Riggers .................................................................................................. 6-4
6.2.9 Person-In-Charge (PIC) ........................................................................ 6-4
6.2.10 Designated Leader ................................................................................ 6-5
6.2.11 Inspectors .............................................................................................. 6-5
6.2.12 Instructors ............................................................................................. 6-5
6.2.13 First-Line Supervisors........................................................................... 6-5
6.2.14 Maintenance Personnel ......................................................................... 6-5
6.3 TRAINING ...................................................................................................... 6-7
6.3.1 General.................................................................................................. 6-7
6.3.2 Cab-Operated, Pulpit-Operated, and Floor-Operated Cranes ............... 6-7
6.3.3 Mobile Crane Operators........................................................................ 6-8
6.3.4 Operators of Truck Mounted Cranes – Capacity 1 Ton or Less ........... 6-8
6.3.5 Forklift Truck Operators ....................................................................... 6-8
6.3.6 Riggers ................................................................................................ 6-10
6.3.7 Inspectors ............................................................................................ 6-10
6.3.8 Instructors ........................................................................................... 6-11
6.3.9 Maintenance Personnel ....................................................................... 6-11
6.4 REQUALIFICATION .................................................................................. 6-12
6.5 RECORDS ..................................................................................................... 6-13
CHAPTER 7 OVERHEAD AND GANTRY CRANES......................................7-1
7.1 GENERAL....................................................................................................... 7-1
7.1.1 Operator Training/Qualification ........................................................... 7-1
7.1.2 Rated-Load marking ............................................................................. 7-1
7.1.3 Modification.......................................................................................... 7-1
7.1.4 Egress.................................................................................................... 7-1
7.1.5 Hoist Brakes.......................................................................................... 7-1
7.1.6 Power Shutoff ....................................................................................... 7-1
7.1.7 Hoist-Limit Switch................................................................................ 7-5
7.1.8 Load Limits........................................................................................... 7-5
Section 4
7.1.9 Maintenance History............................................................................. 7-5
7.2 INSPECTIONS ............................................................................................... 7-6
7.2.1 General.................................................................................................. 7-6
7.2.2 Crane Service ........................................................................................ 7-6
7.2.3 Initial Inspection ................................................................................... 7-6
7.2.4 Daily Preoperational Check .................................................................. 7-6
7.2.5 Monthly Rope, Chain and Hook Inspection ......................................... 7-6
7.2.6 Frequent Inspection............................................................................... 7-7
7.2.7 Periodic Inspection................................................................................ 7-7
7.2.7.1 Cranes ....................................................................................... 7-7
7.2.7.2 Wire Rope ................................................................................. 7-8
7.2.7.3 Chain (Welded Link) ................................................................ 7-8
7.2.7.4 Chain (Roller) ........................................................................... 7-9
7.2.8 Cranes Not in Regular Service............................................................ 7-11
7.3 TESTING....................................................................................................... 7-12
7.3.1 Operational Tests ................................................................................ 7-12
7.3.2 Rated Load Test .................................................................................. 7-12
7.4 MAINTENANCE .......................................................................................... 7-14
7.4.1 Operating Equipment .......................................................................... 7-14
7.4.2 Wire-Rope Maintenance ..................................................................... 7-14
7.5 OPERATION ................................................................................................ 7-15
7.5.1 Conduct of Operator ........................................................................... 7-15
7.5.2 Hoist-Limit Switch/Device ................................................................. 7-15
7.5.3 Standard Hand Signals........................................................................ 7-16
7.5.4 Identification of Signalers................................................................... 7-16
7.5.5 Size of Load ........................................................................................ 7-16
7.5.6 Attaching the Load.............................................................................. 7-16
7.5.7 Moving the Load................................................................................. 7-16
7.5.8 Ordinary Lifts...................................................................................... 7-18
7.5.9 Critical Lifts ........................................................................................ 7-18
Exhibit I Bridge, Wall, Gantry Crane Load Test ............................................... 7-21
Exhibit II Overhead Crane Pre-Operational Checklist........................................ 7-25
Exhibit III Overhead Crane Periodic Inspection Report (Mechanical) ................ 7-27
Exhibit IV Overhead Crane Periodic Inspection Report (Electrical).................... 7-29
Section 5
CHAPTER 8 HOISTS .....................................................................................8-1
8.1 GENERAL....................................................................................................... 8-1
8.1.1 Operator Training/Qualification ........................................................... 8-4
8.1.2 Marking................................................................................................. 8-4
8.1.3 Warning Labels..................................................................................... 8-4
8.1.3.1 Electric- or Air-Powered Hoists................................................ 8-4
8.1.3.2 Hand-Chain-Operated or Manual-Lever-Operated Hoists........ 8-4
8.1.4 Design Standards .................................................................................. 8-5
8.1.5 Design Factors ...................................................................................... 8-5
8.1.6 Load-Braking/Load-Controlling Mechanisms...................................... 8-5
8.1.6.1 Electric-Powered Hoists............................................................ 8-5
8.1.6.2 Air-Powered Hoists................................................................... 8-5
8.1.6.3 Hand-Chain-Operated Hoists.................................................... 8-6
8.1.6.4 Manual-Lever-Operated Hoists ................................................ 8-6
8.1.7 Wire Rope ............................................................................................. 8-6
8.1.8 Load Chain............................................................................................ 8-6
8.1.8.1 Electric-Powered, Air-Powered, and Manual-Lever-Operated
Hoists ................................................................................................... 8-6
8.1.8.2 Hand-Chain-Operated Hoists.................................................... 8-6
8.1.9 Web Strap.............................................................................................. 8-7
8.1.10 Overtravel Protection ............................................................................ 8-7
8.1.10.1 Travel Warning Devices ......................................................... 8-7
8.1.10.2 Lower-Limit Switches/Devices .............................................. 8-7
8.1.11 Travel Warning Devices ....................................................................... 8-7
8.1.12 Support.................................................................................................. 8-7
8.1.13 Location ................................................................................................ 8-7
8.1.14 Load Rating........................................................................................... 8-7
8.2 INSPECTIONS ............................................................................................... 8-8
8.2.1 Hoist Service......................................................................................... 8-8
8.2.2 Initial Inspection ................................................................................... 8-8
8.2.3 Daily Inspection .................................................................................... 8-8
8.2.4 Frequent Inspection............................................................................... 8-8
8.2.5 Periodic Inspection................................................................................ 8-8
8.2.5.1 Hoists ........................................................................................ 8-9
8.2.5.2 Wire Rope ................................................................................. 8-9
8.2.5.3 Welded-Link Chain................................................................. 8-10
8.2.5.4 Roller Chain ............................................................................ 8-11
8.2.5.5 Synthetic-Web Strap ............................................................... 8-12
8.2.6 Hoists Not in Regular Service............................................................. 8-12
Section 6
8.3 TESTING....................................................................................................... 8-13
8.3.1 Operational Tests ................................................................................ 8-13
8.3.1.1 Electric- or Air-Powered Hoists.............................................. 8-13
8.3.1.2 Hand-Chain-Operated Hoists.................................................. 8-13
8.3.1.3 Manual-Lever-Operated Hoists .............................................. 8-13
8.3.2 Proof-Load Test .................................................................................. 8-13
8.3.2.1 Electric- or Air-Powered Hoists.............................................. 8-13
8.3.2.2 Hand-Chain-Operated or Manual-Lever-Operated Hoists...... 8-13
8.4 MAINTENANCE .......................................................................................... 8-16
8.5 OPERATION ................................................................................................ 8-17
8.5.1 Conduct of Operator ........................................................................... 8-17
8.5.2 Size of Load ........................................................................................ 8-17
8.5.3 Attaching the Load.............................................................................. 8-17
8.5.4 Moving the Load................................................................................. 8-17
8.5.5 Hoist-Limit Switch.............................................................................. 8-18
8.5.6 Ordinary Lifts...................................................................................... 8-18
8.5.7 Critical Lifts ........................................................................................ 8-19
Exhibit I Hoist Load Test and Inspection .......................................................... 8-23
Exhibit II Underhung Hoist Periodic Inspection Report ..................................... 8-25
CHAPTER 9 MOBILE CRANES.....................................................................9-1
9.1 GENERAL....................................................................................................... 9-1
9.1.1 Operator Training/Qualification ........................................................... 9-1
9.1.2 Load Limits........................................................................................... 9-1
9.1.3 Load Rating Chart................................................................................. 9-1
9.1.4 Load Hoist Brakes................................................................................. 9-6
9.1.5 Power-Controlled Lowering ................................................................. 9-6
9.1.6 Booms ................................................................................................... 9-6
9.1.7 Counterweight....................................................................................... 9-6
9.1.8 Rerating................................................................................................. 9-6
9.1.9 Maintenance History............................................................................. 9-6
9.1.10 Design Standards .................................................................................. 9-6
Section 7
9.2 INSPECTIONS ............................................................................................... 9-7
9.2.1 General.................................................................................................. 9-7
9.2.2 Initial Inspection ................................................................................... 9-7
9.2.3 Preoperational Check ............................................................................ 9-7
9.2.4 Monthly Inspection ............................................................................... 9-7
9.2.5 Frequent Inspection............................................................................... 9-7
9.2.6 Periodic Inspection................................................................................ 9-8
9.2.6.1 Cranes ....................................................................................... 9-8
9.2.6.2 Hydraulic and Pneumatic Hose, Fittings, and Tubing .............. 9-9
9.2.6.3 Hydraulic and Pneumatic Pumps and Motors........................... 9-9
9.2.6.4 Hydraulic and Pneumatic Valves.............................................. 9-9
9.2.6.5 Hydraulic and Pneumatic Cylinders ......................................... 9-9
9.2.6.6 Hydraulic Filters ....................................................................... 9-9
9.2.6.7 Wire Rope ................................................................................. 9-9
9.2.7 Load Hoods/Load Blocks ................................................................... 9-11
9.2.8 Cranes Not in Regular Use ................................................................. 9-11
9.3 TESTING....................................................................................................... 9-12
9.3.1 Operational Tests ................................................................................ 9-12
9.3.2 Rated Load Test .................................................................................. 9-12
9.4 MAINTENANCE .......................................................................................... 9-13
9.4.1 Preventive Maintenance...................................................................... 9-13
9.4.2 Maintenance Procedures ..................................................................... 9-13
9.4.3 Wire-Rope Maintenance ..................................................................... 9-13
Section 8
9.5 OPERATION ................................................................................................ 9-15
9.5.1 Conduct of Operator ........................................................................... 9-15
9.5.1.1 Traveling the Machine ............................................................ 9-16
9.5.1.2 Making Adjustments or Repairs ............................................. 9-16
9.5.1.3 Ensuring Stability.................................................................... 9-17
9.5.1.4 Observing Boom-Length Precautions..................................... 9-18
9.5.2 Operating Near Power Lines and Transmitter Towers ....................... 9-18
9.5.2.1 Crane Operations De-energized and Grounded Electrical Power
Lines........................................................................................ 9-19
9.5.2.2 Power Lines Energized, Crane Operating Less Than
Erected/Fully Extended Boom Length Away From
Prohibited Zone....................................................................... 9-19
9.5.2.3 Crane Operations are Within the Prohibited Zone and the
Power Lines are Energized ..................................................... 9-22
9.5.2.4 Crane in Transit with no Load and Boom Lowered ............... 9-22
9.5.2.5 Crane Operations Near Transmitter Towers ........................... 9-22
9.5.3 Hoist-Limit Switch.............................................................................. 9-22
9.5.4 Standard Hand Signals........................................................................ 9-25
9.5.5 Identification of Signalers................................................................... 9-25
9.5.6 Size of Load ........................................................................................ 9-25
9.5.7 Attaching the Load.............................................................................. 9-25
9.5.8 Moving the Load................................................................................. 9-25
9.5.9 Ordinary Lifts...................................................................................... 9-29
9.5.10 Critical Lifts ........................................................................................ 9-30
Exhibit I Mobile Crane Load Test ..................................................................... 9-33
Exhibit II Mobile Crane Daily Pre-Operational Check....................................... 9-37
Exhibit III Mobile Crane Frequent Inspection Report.......................................... 9-41
Exhibit IV Mobile Crane Periodic Inspection Report........................................... 9-43
CHAPTER 10 FORKLIFT TRUCKS ................................................................... 10-1
10.1 GENERAL..................................................................................................... 10-1
10.1.1 Operator Training/Qualification ......................................................... 10-1
10.1.2 Rated Capacity .................................................................................... 10-1
10.1.3 Nameplate(s) and Markings................................................................ 10-1
10.1.3.1 Fork Arm Data ..................................................................... 10-1
10.1.4 Attachments ........................................................................................ 10-1
Section 9
10.1.5 Modifications ...................................................................................... 10-2
10.1.6 Warning Devices................................................................................. 10-2
10.1.7 Overhead Guards ................................................................................ 10-2
10.1.8 Fire Hazard Areas ............................................................................... 10-2
10.1.9 Work Atmosphere............................................................................... 10-2
10.2 TYPE DESIGNATIONS AND AREAS OF USE..................................... 10-10
10.2.1 Type Designation.............................................................................. 10-10
10.2.1.1 Nonhazardous Locations.................................................... 10-10
10.2.1.2 Hazardous Locations.......................................................... 10-10
10.2.2 Specific Areas of Use........................................................................ 10-11
10.3 INSPECTIONS ........................................................................................... 10-14
10.3.1 Daily Preoperational Check .............................................................. 10-14
10.3.2 Initial Inspection of New and Rented Equipment............................. 10-14
10.3.3 Inspection and Maintenance ............................................................. 10-14
10.3.4 Forks ................................................................................................. 10-15
10.3.4.1 Fork Load Rating ................................................................ 10-15
10.3.4.2 Fork Inspections.................................................................. 10-15
10.3.4.3 Fork Repair ......................................................................... 10-16
10.3.5 Battery Maintenance ......................................................................... 10-16
10.3.6 History File ....................................................................................... 10-17
10.4 TESTING..................................................................................................... 10-18
10.4.1 Forklift Truck Load Test................................................................... 10-18
10.4.2 Fork Load Test.................................................................................. 10-18
10.4.3 Attachments Load Test ..................................................................... 10-18
10.5 OPERATION .............................................................................................. 10-19
10.5.1 Conduct of Operator ......................................................................... 10-19
10.5.1.1 General............................................................................... 10-19
10.5.1.2 Traveling ............................................................................ 10-20
10.5.1.3 Loading ...............................................................................10.21
10.5.2 Lifting of Personnel .......................................................................... 10-22
10.5.3 Standard Hand Signals...................................................................... 10-24
10.5.4 Ordinary Lifts.................................................................................... 10-24
10.5.5 Critical Lifts ...................................................................................... 10-24
10.5.6 Equipment Qualifications ..................................................................10.24
Section 10
Exhibit I Operations Pre-Shift Inspection Form .............................................. 10-29
Exhibit II Forklift Load Test and Inspection Form ........................................... 10-31
CHAPTER 11 WIRE ROPE AND SLINGS........................................11-1
11.1 GENERAL..................................................................................................... 11-1
11.2 WIRE ROPE ................................................................................................. 11-4
11.2.1 Wire-Rope Lays .................................................................................. 11-4
11.2.2 Wire-Rope Cores ................................................................................ 11-4
11.2.3 Wire Rope for General Purposes ........................................................ 11-4
11.2.3.1 6 x 19 Classification............................................................. 11-4
11.2.3.2 6 x 37 Classification............................................................. 11-5
11.2.4 Wire-Rope Inspections........................................................................ 11-5
11.2.5 Wire-Rope Maintenance ..................................................................... 11-5
11.3 SLINGS .......................................................................................................... 11-8
11.3.1 General................................................................................................ 11-8
11.3.1.1 Load Angle Factor ............................................................... 11-8
11.3.1.2 Safe Load ............................................................................. 11-8
11.3.1.3 Design Factor ..................................................................... 11-10
11.3.1.4 Sling Care........................................................................... 11-10
11.3.1.5 Sling Storage...................................................................... 11-10
11.3.2 Wire-Rope Slings.............................................................................. 11-10
11.3.2.1 Inspections ......................................................................... 11-19
11.3.2.2 Proof-Testing ..................................................................... 11-19
11.3.2.3 Operation............................................................................ 11-20
11.3.2.4 Critical Lifts ....................................................................... 11-23
11.3.3 Alloy Steel-Chain Slings................................................................... 11-24
11.3.3.1 Pre-Use Inspections ........................................................... 11-25
11.3.3.2 Annual Inspections............................................................. 11-25
11.3.3.3 Proof-Testing ..................................................................... 11-26
11.3.3.4 Operation............................................................................ 11-28
11.3.3.5 Critical Lifts ....................................................................... 11-29
11.3.4 Metal-Mesh Slings ............................................................................ 11-29
11.3.4.1 Inspections ......................................................................... 11-32
11.3.4.2 Proof-Testing ..................................................................... 11-32
11.3.4.3 Operation............................................................................ 11-32
11.3.4.4 Critical Lifts ....................................................................... 11-33
11.3.5 Synthetic-Web Slings........................................................................ 11-33
11.3.5.1 Inspections ........................................................................ 11-36
11.3.5.2 Proof-Testing .................................................................... 11-36
11.3.5.3 Operation........................................................................... 11-40
11.3.5.4 Critical Lifts ...................................................................... 11-40
11.3.6 Synthetic Roundslings ...................................................................... 11-41
11.3.6.1 Inspections ......................................................................... 11-41
11.3.6.2 Proof-Testing ..................................................................... 11-42
11.3.6.3 Operation............................................................................ 11-42
11.3.6.4 Critical Lifts ....................................................................... 11-43
Section 11
Exhibit I Rigging Tackle Periodic Inspection (Wire-Rope Slings) ................. 11-47
Exhibit II Wire Rope Periodic Inspection ......................................................... 11-48
Exhibit III Wire Rope Periodic Inspection (Historical Record) ......................... 11-51
Exhibit IV Rigging Tackle Periodic Inspection (Chair) ........................................ 11-53
Exhibit V Rigging Tackle Periodic Inspection (Synthetic-Web & Round Slings) 11-55
CHAPTER 12 RIGGING ACCESSORIES .........................................12-1
12.1 GENERAL..................................................................................................... 12-1
12.1.1 Inspections .......................................................................................... 12-1
12.1.2 Testing................................................................................................. 12-3
12.1.3 Good and Bad Rigging Practices ........................................................ 12-3
12.2 RIGGING HOOKS....................................................................................... 12-6
12.2.1 Design ................................................................................................. 12-6
12.2.2 Marking............................................................................................... 12-6
12.2.3 Construction........................................................................................ 12-6
12.2.4 Load Limits......................................................................................... 12-6
12.2.5 Inspections .......................................................................................... 12-6
12.2.5.1 Initial Inspection .................................................................. 12-6
12.2.5.2 Daily Inspection ................................................................... 12-6
12.2.5.3 Frequent Inspection.............................................................. 12-6
12.2.5.4 Periodic Inspection............................................................... 12-8
12.2.6 Testing................................................................................................. 12-8
12.2.7 Maintenance........................................................................................ 12-8
12.2.8 Operation............................................................................................. 12-8
12.3 SHACKLES................................................................................................. 12-10
12.3.1 General.............................................................................................. 12-10
12.3.2 Critical Lifts ...................................................................................... 12-10
12.4 EYEBOLTS ................................................................................................. 12-12
12.4.1 General.............................................................................................. 12-12
12.4.2 Critical Lifts ...................................................................................... 12-13
12.5 TURNBUCKLES ........................................................................................ 12-16
12.5.1 General.............................................................................................. 12-16
12.5.2 Critical Lifts ...................................................................................... 12-16
Section 12
12.6 LINKS AND RINGS................................................................................... 12-18
12.6.1 General.............................................................................................. 12-18
12.6.2 Critical Lifts ...................................................................................... 12-18
12.7 SWIVEL HOIST RINGS ........................................................................... 12-21
12.7.1 General.............................................................................................. 12-21
12.7.2 Critical Lifts ...................................................................................... 12-21
12.8 LOAD-INDICATING DEVICES .............................................................. 12-23
12.9 PRECISION LOAD POSITIONERS ........................................................12.24
12.9.1 General.............................................................................................. 12-24
12.9.2 Critical Lifts ...................................................................................... 12-24
Exhibit I Rigging Accessories Load Test and Inspection (Hooks, Shackles,
Rings, etc.) ........................................................................................ 12-27
CHAPTER 13 LOAD HOOKS......................................................................13-1
13.1 GENERAL..................................................................................................... 13-1
13.1.1 Marking............................................................................................... 13-1
13.1.2 Attachments ........................................................................................ 13-1
13.1.3 Load Limits......................................................................................... 13-1
13.1.4 Hook Standards................................................................................... 13-1
13.2 INSPECTIONS ............................................................................................. 13-2
13.2.1 Hook Service....................................................................................... 13-2
13.2.2 Initial Inspection ................................................................................. 13-2
13.2.3 Daily Inspection .................................................................................. 13-2
13.2.4 Frequent Inspection............................................................................. 13-2
13.2.5 Periodic Inspection.............................................................................. 13-2
13.3 TESTING....................................................................................................... 13-4
13.4 NONDESTRUCTIVE TESTING (NDT) .................................................... 13-6
13.4.1 NDT Requirements ............................................................................. 13-6
13.4.2 NDT Records ...................................................................................... 13-6
13.4.3 NDT Methods ..................................................................................... 13-6
13.4.4 Acceptance Criteria............................................................................. 13-6
13.4.5 Discontinuity Removal ....................................................................... 13-6
13.5 MAINTENANCE .......................................................................................... 13-8
Section 13
13.6 OPERATION ................................................................................................ 13-9
Exhibit I Exhibit Hood Periodic Inspection Report ......................................... 13-11
CHAPTER 14 BELOW-THE-HOOK LIFTING DEVICES............................14-1
14.1 GENERAL..................................................................................................... 14-1
14.2 STRUCTURAL AND MECHANICAL LIFTING DEVICES ................. 14-2
14.2.1 Design/Fabrication.............................................................................. 14-2
14.2.2 Marking............................................................................................... 14-2
14.2.3 Modification/Rerating......................................................................... 14-2
14.2.4 Guarding ............................................................................................. 14-2
14.2.5 Inspections .......................................................................................... 14-2
14.2.5.1 Initial Inspection .................................................................. 14-2
14.2.5.2 Frequent Inspection.............................................................. 14-2
14.2.5.3 Periodic Inspection............................................................... 14-3
14.2.6 Testing................................................................................................. 14-3
14.2.6.1 Operational Test................................................................... 14-3
14.2.6.2 Rated Load Test ................................................................... 14-7
14.2.7 Maintenance........................................................................................ 14-7
14.2.8 Training/Qualification......................................................................... 14-7
14.2.9 Operation............................................................................................. 14-7
14.2.10 Critical Lifts ...................................................................................... 14-8
14.3 VACUUM LIFTING DEVICES.................................................................. 14-9
14.3.1 Design/Fabrication.............................................................................. 14-9
14.3.2 Marking............................................................................................... 14-9
14.3.3 Installation......................................................................................... 14-11
14.3.4 Inspections ........................................................................................ 14-11
14.3.4.1 Initial Inspection ................................................................ 14-11
14.3.4.2 Frequent Inspection............................................................ 14-11
14.3.4.3 Periodic Inspection............................................................. 14-11
14.3.5 Testing............................................................................................... 14-12
14.3.5.1 Operational Test................................................................. 14-12
14.3.5.2 Rated Load Test ................................................................. 14-12
14.3.6 Maintenance...................................................................................... 14-12
14.3.7 Training/Qualification....................................................................... 14-12
14.3.8 Operation........................................................................................... 14-13
14.3.9 Critical Lifts ...................................................................................... 14-14
Section 14
14.4 MAGNETS, CLOSE-PROXIMITY-OPERATED .................................. 14-15
14.4.1 Design/Fabrication............................................................................ 14-15
14.4.2 Marking............................................................................................. 14-15
14.4.2.1 Rated Load (Capacity) ....................................................... 14-17
14.4.2.2 Controls.............................................................................. 14-17
14.4.3 Installation......................................................................................... 14-17
14.4.4 Inspections ........................................................................................ 14-17
14.4.4.1 Initial Inspection ................................................................ 14-17
14.4.4.2 Frequent Inspection............................................................ 14-17
14.4.4.3 Periodic Inspection............................................................. 14-17
14.4.5 Testing ............................................................................................ 14-18
14.4.5.1 Operational Test................................................................. 14-18
14.4.5.2 Rated Load Test ................................................................. 14-18
14.4.6 Maintenance...................................................................................... 14-18
14.4.7 Training/Qualification....................................................................... 14-19
14.4.8 Operation........................................................................................... 14-19
14.4.8.1 External-Powered Electromagnets..................................... 14-20
14.4.8.2 Battery-Operated Electromagnets...................................... 14-20
14.4.8.3 Electrically Controlled Permanent Magnets ...................... 14-20
14.4.8.4 Manually Controlled Permanent Magnets ......................... 14-20
14.4.9 Critical Lifts ...................................................................................... 14-20
14.5 MAGNETS, REMOTE-OPERATED ....................................................... 14-21
14.5.1 Design/Fabrication............................................................................ 14-21
14.5.2 Marking ............................................................................................ 14-21
14.5.3 Installation......................................................................................... 14-21
14.5.4 Inspections ........................................................................................ 14-21
14.5.4.1 Initial Inspection ................................................................ 14-21
14.5.4.2 Frequent Inspection............................................................ 14-21
14.5.4.3 Periodic Inspection............................................................. 14-21
14.5.5 Testing ............................................................................................ 14-23
14.5.5.1 Operational Test................................................................. 14-23
14.5.6 Maintenance...................................................................................... 14-23
14.5.7 Training/Qualification....................................................................... 14-23
14.5.8 Operation........................................................................................... 14-24
14.5.9 Critical Lifts ...................................................................................... 14-24
Section 15
Exhibit I Lifting Bars and Spreaders Load Test and Inspection ...................... 14-27
CHAPTER 15 CONSTRUCTION HOISTING AND RIGGING
EQUIPMENT REQUIREMENTS ................................15-1
15.1 GENERAL .............................................................................................. 15-1
15.2 PERSONNEL QUALIFICATIONS............................................................ 15-2
15.2.1 Qualified Operators of Mobile Cranes................................................ 15-2
15.2.2 Qualified Operators of Forklift Trucks ............................................... 15-3
15.2.3 Qualified Riggers ................................................................................ 15-4
15.2.4 Person-in-Charge (PIC) ...................................................................... 15-4
15.2.5 Designated Leader .............................................................................. 15-5
15.2.6 Inspector .............................................................................................. 15-5
15.2.7 Maintenance........................................................................................ 15-5
15.3 INSPECTION AND TESTING ................................................................... 15-6
15.4 OPERATION .............................................................................................. 15-7
15.4.1 General .............................................................................................. 15-7
15.4.2 Wire Rope Slings ................................................................................ 15-7
15.5 STEEL ERECTION ..................................................................................... 15-8
15.5.1 General .............................................................................................. 15-8
15.5.2 Definitions........................................................................................... 15-8
15.5.3 Pre-Shift Inspection of Cranes ............................................................ 15-8
15.5.4 Qualified Rigger.................................................................................. 15-9
15.5.5 Lifting Personnel................................................................................. 15-9
15.5.6 Safety Latches..................................................................................... 15-9
15.5.7 Working Under Loads......................................................................... 15-9
15.5.8 Multiple Load Lifts ............................................................................. 15-9
CHAPTER 16 MISCELLANEOUS LIFTING DEVICES.....................16-1
16.1 GENERAL...................................................................................................... 16-1
16.1.1 Operator Training/Qualifications........................................................ 16-1
16.1.2 Rated-Load Markings, Safety Markings and Operating Instructions . 16-1
16.1.3 Modifications ...................................................................................... 16-1
16.1.4 Load Limits......................................................................................... 16-2
16.1.5 Operating Controls.............................................................................. 16-2
16.1.6 Load Hook .......................................................................................... 16-2
16.1.7 Wire Rope ........................................................................................... 16-2
16.1.7 Assembly............................................................................................. 16-2
Section 16
16.2 INSPECTIONS ............................................................................................. 16-5
16.2.1 General................................................................................................ 16-5
16.2.2 Initial Inspection ................................................................................. 16-5
16.2.3 Daily Preoperational Inspection.......................................................... 16-5
16.2.4 Periodic Inspection.............................................................................. 16-5
16.3 TESTING....................................................................................................... 16-7
16.3.1 Operational Test.................................................................................. 16-7
16.3.2 Rated Load Test .................................................................................. 16-7
16.4 MAINTENANCE .......................................................................................... 16-8
16.5 OPERATION ................................................................................................ 16-9
16.5.1 Conduct of Operator ........................................................................... 16-9
CHAPTER 17.............................................................................. REFERENCES
APPENDIX A .................................................... PROCUREMENT GUIDELINES
History and Background
In 1975, cognizant safety and health personnel at the U.S. Department of Energy (DOE) Headquarters
(HQ) met to discuss the need for a DOE hoisting and rigging manual. At that meeting, existing,
applicable hoisting and rigging codes, standards, and regulations, such as the Occupational Safety and
Health Administration (OSHA) 29 CFR 1910, the American National Standards Institute (ANSI) B-
30 series, and others, were reviewed in detail. Subsequently, it was determined that these documents,
while adequate as minimum general industry standards, did not contain the detail necessary to adequately
accomplish the extremely complex, critical, and hazardous hoisting and rigging operations being
performed at DOE sites, in all probability, at other government agency and private sectors throughout the
country. Because of the high potential for accidents that could result in significant property loss or
serious personnel injury or death, it was decided that a DOE hoisting and rigging manual was not only
desirable but absolutely necessary.
Preliminary work on the manual was initiated in 1976. The manual that was developed at that time
incorporated the minimum requirements of OSHA, ANSI, and similar documents and also included
additional more stringent requirements deemed necessary to adequately control hoisting and rigging work
processes throughout DOE. Each phase of the manual was then critically reviewed by DOE and
contractor personnel. A final draft was completed in 1978 and implemented on a trial basis.
Section 17
In June 1980, a decision was made to formally issue and distribute the manual under controlled
distribution, an arrangement where the manual must be specifically requested from the originating source;
however, once requested, updates are automatically received through an actively maintained distribution
list. In 1982, the manual was included as a reference standard in DOE 5480.4, “Environmental
Protection, Safety, and Health Protection Standards.” Updates and improvements have been made over
the years on an approximately annual basis. Revisions have occurred in 1984, 1985, 1986, 1988, 1989,
1993, 1995, 1996, 1999, 2001 and 2004 to clarify intent, comply with OSHA and ANSI B-30 changes,
improve format, strengthen wording, delete needless redundancy, eliminate obsolescence, and the like.
Prior to inclusion in the manual, all changes must be approved by the DOE Hoisting and Rigging
Committee, which meets annually, and by the Headquarters Office of Nuclear and Facilities Safety
Policy, which has safety responsibility for DOE hoisting and rigging. The Committee is also a major
source for input into the manual, particularly concerning those areas that are not defined or are only
generally defined by Federal and national standards, such as training and qualification, and those
concerning the DOE's unique operational environment, such as hoisting and rigging over nuclear reactors
and other locations containing critical equipment. In the years that minor revisions occur, only the
changed pages, usually 8 to 10, are sent to individuals on the distribution list. After two to three such
supplements, the manual is reissued in its entirety, which incorporates the previous supplements plus the
most recent unpublished changes approved by the committee. An example is the complete revision issued
in 1993 followed by another complete revision in 1996, 1999, 2001and 2004 without any intervening
supplements. In this case, the supplements were omitted because of the numerous improvements
incorporated within the very short time period.
The reissued June 1995 edition marked a change in classification. The DOE Office of Scientific and
Technical Information (OSTI) reclassified the manual as a handbook and it was issued as DOE Hoisting
and Rigging Handbook (DOE-HDBK-1090-95). After further review, OSTI has reclassified the
handbook as a DOE Technical Standard and the September 1996 edition was issued as DOE
STANDARD HOISTING AND RIGGING (Formerly Hoisting and Rigging Manual) DOE-STD-1090-96
(Rev-1). Additional revisions issued are DOE-STD-1090-99, DOE-STD-1090-2001 and DOE-STD-
1090-2004.
While The Hoisting and Rigging Standard is in itself a best practice document, much of its content, such
as the OSHA, ANSI/ASME, and Crane Manufacturers Association of America standards, is mandatory
within DOE. In addition, many DOE organizations have, on their own initiative, adopted the standard as
mandatory to ensure safe and proper hoisting and rigging operations at their facilities. Whether
mandatory or not, the standard is and will continue to be the standard by which the excellence of DOE
hoisting and rigging programs are judged.
Acknowledgment
The Department of Energy (DOE) acknowledges the many organizations whose documents provided
important source material for the standard. They include:
American Society of Mechanical Engineers
ASME B30.2, “Overhead and Gantry Cranes (Top Running Bridge, Multiple Girder)”
ASME B30.5, “Crawler, Locomotive, and Truck Cranes”
Section 18
ASME B30.9, “Slings”
ASME B30.10, “Hooks”
ASME B30.16, “Overhead Hoists (Underhung)”
ASME B30.17, “Overhead and Gantry Cranes (Top Running Bridge, Single Girder Underhung
Hoist)
ASME B30.20, “Below-the-Hook Lifting Devices”
ASME B30.21, “Manually Lever Operated Hoist”
ASME B30.22, “Articulating Boom Cranes”
ASME B30.23, “Personnel Lifting Systems”
ASME B56.1, “Low Lift and High Lift Trucks”
ASME B56.6, “Rough Terrain Forklift Trucks”
ASME PALD, “Portable Automotive Lifting Devices”
ASME MH11.4, “Forks and Fork Carriers for Powered Industrial Fork Lift Trucks”
Construction Safety Association (CSA) of Ontario
"The Rigging Handbook"
Society of Automotive Engineers, Inc. (SAE)
SAE J1028, "Mobile Crane Working Area Definitions”
Permission to reprint specific figures and illustrations was obtained from CSA and SAE.
Applicable sections of 29 CFR 1910, "Occupational Safety and Health Standards for General Industry,"
and 29 CFR 1926, "Occupational Safety and Health Regulations for Construction," have been
paraphrased or reproduced verbatim throughout. The contributions of DOE's Hoisting and Rigging
Committee, which has met annually since 1980, is also recognized. Representing many DOE sites, this
group has provided advice and clarification of the codes and standards that form the underlying basis for
this document. Without their time and talent, which has been provided gratuitously, there would be no
standard.
Other significant contributors include the two editors, Ingeborg Westfall and Marshall Henrie, whose
considerable efforts resulted in several of the substantive improvements described in the History and
Background section, and whose changes regarding text, format, and spelling have improved the standard
to what we believe is the equivalent of desktop-publishing quality and in doing so increased its usefulness
to the hoisting and rigging community. The Department is also greatly indebted to Mr. Kay Johnson,
now retired, who, during his 10-year tenure as program coordinator, perhaps more than any other person,
was responsible for developing the standard into the truly invaluable document that it is today.
The standard is a safety, not a design, document intended for use by safety professionals and managers.
In keeping with this philosophy, only those portions of standards and regulations dealing with safety,
particularly those deemed most relevant to DOE operations, have been included. In that the target
audience for this document is safety professionals and managers and not hoisting and rigging equipment
designers, the design references cited within Chapter 17 of this Standard (References) should be consulted
for specific design, fabrication, and other performance criteria. While it is convenient to have focused, in-
depth hoisting and rigging safety information concentrated into one document, the significance of the
above source material is acknowledged, and readers are strongly encouraged to review each of them so as
to have a full description of the subject area covered.
DOE-STD-1090-2004
i
Introduction
The U.S. Department of Energy (DOE) Hoisting and Rigging Standard is intended as a reference
document to be used by supervisors, line managers, safety personnel, equipment operators, and
any other personnel responsible for safety of hoisting and rigging operations at DOE sites. The
standard quotes verbatim or paraphrases (with minor editorial changes for consistency) the
requirements of the U.S. Occupational Safety and Health Administration (OSHA) and the
American National Standards Institute (ANSI). It also encompasses, under one cover, hoisting
and rigging requirements, codes, standards, and regulations, eliminating the need to maintain
extensive (and often incomplete) libraries of hoisting and rigging standards throughout DOE.
Section 19
As indicated in the History and Background section, the use of the imperative voice (as in “Never
use discarded load chain for slings”) or the word “shall” denotes a mandatory action, whereas use
of the word “should” denotes a recommended action in keeping with best management practices.
From chapter to chapter, the reader may notice what appears to be excessive repetition. Such
repetition, however, is by design, enabling the use of each chapter, if needed or convenient, as a
stand-alone document.
The standard occasionally goes beyond the minimum general industry standards established by
OSHA and ANSI; and also delineates the more stringent requirements necessary to accomplish
the extremely complex, diversified, critical, and oftentimes hazardous hoisting and rigging work
found within the DOE complex. In doing so, it addresses the following items that are not covered
in detail in the general industry standards:
1. Management responsibility and accountability
2. Operator/inspector training and qualification requirements
3. Definition of critical lifts and the additional requirements for making them
4. The need and responsibilities of a person-in-charge for critical lifts
5. The need and responsibilities of a designated leader for ordinary lifts
6. The definition and special requirements for preengineered production lifts
7. Special requirements for the testing, inspection, and maintenance of hoisting
equipment in hostile environments
8. Nondestructive testing/nondestructive examination requirements for such items as
hooks, welds, and spreader bars
9. Special requirements for inspection and load-testing of hoisting and rigging
equipment/accessories
10. Hook latch requirements for cranes, slings, and rigging accessories
11. Design standards for such equipment as cranes, forklifts, and hooks
DOE-STD-1090-2004
ii
12. Operating practices for hoisting and rigging operations
13. Rigging information and load tables
14. Good and bad rigging practices.
Because the possibility of serious accidents resulting in personnel injury or death or significant
property damage exists whenever hoisting and rigging take place, the requirements for these
operations must be clearly defined and precautions ensured, including proper preplanning,
extreme care, attention to detail, teamwork on the part of trained operators/riggers, and the use of
equipment that is reliable, properly designed, inspected, and maintained. Although not
mandatory at all DOE sites and locations, this standard has been used for many years by DOE and
its contractors as a valuable resource for conducting hoisting and rigging safely and efficiently
and as the standard against which to judge all hoisting and rigging programs. The full
implementation of the requirements and recommendations of this standard will dramatically
strengthen hoisting and rigging programs throughout the DOE complex and will significantly
decrease the probability of serious accidents resulting in personnel injury or death or severe
property damage.
It should be noted that not all hoisting and rigging equipment or operational methods could be
covered comprehensively by this standard. Hoisting and rigging equipment fabricated onsite or
operated in manner not envisioned by this Standard shall be designed, constructed, operated,
inspected and tested in accordance with the design engineer of record and applicable design
standards. This Standard does not address elevators, drilling rigs, or the lifting loads with
construction equipment not normally intended for lifting purposes (e.g., excavators, payloaders).
Section 20
Also, this Standard does not repeat other DOE nuclear regulatory orders or standards (e.g., 10
CFR 830, "Nuclear Safety Management") with respect to safety analysis, technical safety
requirements, or safety classifications of hoisting equipment. The applicable regulatory
documents should be consulted to ensure conformance with these requirements which go beyond
national consensus safety standards normally associated with hoisting and rigging equipment and
activities.
To propose improvements to this standard, please provide suggested text changes as well as
supporting technical documentation to:
Mr. Patrick F. Finn, PE
U.S. Department of Energy
EH-2.2, 270 Corporate Square Building
1000 Independence Avenue, SW
Washington, DC 20585-0270
DOE-STD-1090-2004
CHAPTER 1
TERMINOLOGY AND DEFINITIONS
1-1 Chapter 1
Terminology and Definitions
The following are specialized terms commonly
used when discussing hoisting and rigging
operations. Many may not be used in this
standard, but are included for general
information. The terms are arranged in
alphabetical order. Illustrations are included for
clarity.
ABRASION: Surface wear.
ACCELERATION STRESS: Additional
stress imposed due to increasing load velocity.
ALTERNATE LAY: Lay of wire rope in which
the strands are alternately regular and lang lay.
ANSI: American National Standards Institute.
APPOINTED: Assigned specific
responsibilities by the employer or the
employer’s representative.
AREA, METALLIC: Sum of the cross-
sectional areas of individual wires in a wire rope
or strand.
ATTACHMENT: A device other than
conventional forks or load backrest extension,
mounted permanently or removably on the
elevating mechanism of a truck for handling the
load. Popular types are fork extension clamps,
rotating devices, side shifters, load stabilizers,
rams and booms.
AUTHORIZED: Assigned by a duly
constituted administrative or regulatory
authority.
AUXILLARY HOIST: Supplemental hoisting
unit of lighter capacity and usually higher speed
than the main hoist.
BACK STAY: Guy used to support a boom or
mast or that section of a main cable, as on a
suspension bridge, or cableway, and the like,
leading from the tower to the anchorage.
BAIL: A U-shaped member of a bucket, socket,
or other fitting.
BASKET OR SOCKET: The conical portion
of a socket into which a splayed rope end is
inserted and secured with zinc.
BATTERY-ELECTRIC TRUCK: An electric
truck in which the power source is a storage
battery.
BECKET LOOP: A loop of small rope or a
strand of rope fastened to the end of a large wire
rope to facilitate installation.
BENDING STRESS: Stress on wires of a wire
rope imposed by bending. This stress need not
be added to direct load stresses. When sheaves
and drums are of suitable size, bending stress
does not affect the normal life of the wire rope.
BIRDCAGE: A colloquialism describing the
appearance of a wire rope that is forced into
compression. The outer strands form a “cage”
and at times displace the core.
BIRDCAGING: The twisting of fiber or wire
rope in an isolated area in the opposite direction
of the rope lay, causing it to take on the
appearance of a birdcage.
BOOM (Crane): A member hinged to the
rotating superstructure and used for supporting
the hoisting tackle.
BOOM LINE: A wire rope for supporting or
operating the boom on derricks, cranes,
draglines, shovels, and the like.
BRAKE: A device used for slowing or stopping
motion by fiction or electromagnetic means.
Section 21
BRAKE, DRAG: A brake that provides
stopping force without external control.
BRAKE, HOLDING: A brake that sets
automatically and that prevents motion when
power is off.
BRAKE, PARKING: A device to prevent the
movement of a stationary vehicle.
BRAKING, COUNTER TORQUE: A method
of stopping motion in which the power to the
DOE-STD-1090-2004
Chapter 1 1-2
Terminology and Definitions
motor is reversed to develop torque in the
opposite direction.
BRAKING, DYNAMIC: A method of
controlling crane motor speeds when in the
overhauling condition to provide a retarding
force.
BRAKING, MECHANICAL: A method of
slowing motion by friction.
BRAKING, REGENERATIVE: A form of
dynamic braking in which the electrical energy
generated is fed back into the power system.
BREAKING STRENGTH: The measured load
required to break a wire rope or chain.
BRIDGE: The part of a crane, consisting of
girders, walkways, railings, trucks, and drive
mechanisms, that carries the trolley or trolleys.
BRIDGE TRAVEL: Horizontal travel of the
crane parallel with runway rails.
BRIDLE SLING: A sling composed of multiple
legs (branches), the top ends of which terminate
in a fitting that latches onto the lifting hook.
BULL RING: The main large ring of a sling to
which sling legs are attached.
BUMPER (BUFFER): An energy-absorbing
device for reducing impact when a moving
overhead crane or trolley reaches the end of its
permitted travel, or when two moving cranes or
trolleys come into contact.
CAB: The operator’s compartment.
CABLE: A term loosely applied to wire ropes,
wire strands, manila ropes, and electrical
conductors.
CABLE-LAID WIRE ROPE: A type of wire
rope consisting of several independent wire
ropes laid into a single wire rope.
CABLE CROWD ROPE: A wire rope used to
force the bucket of a power shovel into the
material being handled.
CANTILEVER TRUCK: A self-loading
counterbalanced or noncounterbalanced truck
equipped with a cantilever load-engaging means,
such as forks (see Figure 10-3).
CARRIAGE: A support structure for forks or
attachments, generally roller-mounted, traveling
vertically within the mast of a cantilever truck.
CENTER: A single wire or fiber in the center
of a strand around which the wires are laid.
CENTER CONTROL: The position near the
center of a truck cab from which the operator
controls movement of the truck.
CHOKER ROPE: A short wire-rope sling used
to form a slip noose around the object to be
moved or lifted (see Figure 1-1).
Figure 1-1. Choker Rope.
CIRCUMFERENCE: Measured perimeter of a
circle circumscribing the wires of a strand or the
strands of a wire rope.
CLAMP, STRAND: A fitting used to form a
loop at the end of a length of strand; consists of
two grooved plates and bolts.
CLEARANCE: The distance by which one
object clears another, or the clear space between
them.
CLEVIS: A U-shaped fitting with pins.
CLIP: A fitting used to clamp two parts of wire
rope.
CLOSED SOCKET: A wire-rope fitting
consisting of an integral becket and bail.
CLOSING LINE: Wire rope that closes a
clamshell or orange-peel bucket and then
operates as a hoisting rope.
COIL: Circular bundle of wire rope not packed
on a reel.
DOE-STD-1090-2004
1-3 Chapter 1
Terminology and Definitions
COLLECTOR: Contacting device mounted on
a bridge or trolley and used to collect current
from the conductor system.
COME-ALONG: A portable, hand-operated
device consisting of a housing, a length of chain
or wire rope, two hooks, and a ratcheting lever,
that is used for miscellaneous pulling.
Section 22
CONDUCTOR: Wire, angles, bars, tees, or
special sections mounted to transmit current to
the collectors.
CONICAL DRUM: Grooved hoisting drum of
varying diameter.
CONSTRUCTION (WIRE ROPE): Refers to
the design of wire rope, including number of
strands, number of wires per strand, and
arrangement of wires in each strand.
CONTINUOUS BEND: Reeving of wire rope
over sheaves and drums so that it bends in one
direction (as opposed to reverse bend).
CONTROLLER: An operator’s device for
regulating the power delivered to a motor or
other equipment.
CONTROLLER, SPRING RETURN: A
controller that, when released, will return
automatically to a neutral position.
CORE: The center member of a wire rope
around which the strands are laid. It may be
fiber, a wire strand, or an independent wire rope.
CORING LINE: Wire rope used to operate the
coring tool for taking core samples during the
drilling of a well.
CORROSION: Chemical decomposition by
exposure to moisture, acids, alkalies, or other
destructive agents.
CORRUGATED: A term used to describe the
grooves of a sheave or drum when worn so as to
show the impression of a wire rope.
COUNTERBALANCED TRUCK: A truck
equipped with load-engaging means wherein,
during normal transporting, all the load is
external to the polygon formed by the wheel
contacts (see Figure 10-3).
COVER WIRES: The outer layer of wires.
CRANE: A machine used for lifting and
lowering a load vertically and moving it
horizontally and that has a hoisting mechanism
as an integral part of it.
CRANES, TYPES OF:
Automatic Crane: A crane that, when
activated, operates through a preset cycle or
cycles.
Cab-Operated Crane: A crane controlled by
an operator in a cab located on the bridge or
trolley.
Cantilever Gantry Crane: A gantry or
semigantry crane in which the bridge girders
or trusses extend transversely beyond the crane
runway on one or both sides.
Floor-Operated Crane: A crane whose
operation is controlled by use of a pendant in
the hands of an operator on the floor or on an
independent platform.
Gantry Crane: A crane similar to an overhead
crane, except that the bridge for carrying the
trolley or trolleys is rigidly supported on two
or more legs running on fixed rails or other
runway.
Jib Crane: A fixed crane with a vertical
rotating member supported at the bottom (also
at the top in some types) from which an arm
extends to carry the hoist trolley. Jib cranes
are most commonly mounted on a vertical
column, supplied as part of the jib crane, or on
existing structural members (e.g., a wall-
mounted jib crane).
Mobile Crane: For the purposes of this
chapter, mobile cranes are defined as wheel-
mounted cranes, truck cranes, and crawler
cranes.
A wheel-mounted crane consists of a
rotating structure with power plant, operating
machinery, and boom, mounted on a base or
platform equipped with axles and rubber-
tired wheels for travel. The base is usually
propelled by an engine in the superstructure,
but it may be equipped with a separate engine
controlled from the superstructure (see
Figures 15-1, 15-3, 15-5, 15-6, 15-7, 15-9,
and 15-10).
DOE-STD-1090-2004
Chapter 1 1-4
Terminology and Definitions
A truck-mounted crane consists of a
rotating superstructure with power plant that
operates machinery and boom, mounted on
an automotive truck equipped with a power
plant for travel. Commercial truck-mounted
cranes are included in this category (see
Figures 15-3, 15-7, 15-9, and 15-10).
Section 23
A crawler crane consists of a rotating
superstructure with power plant, operating
machinery and boom, mounted on a base
equipped with crawler treads for travel (see
Figures 15-2 and 15-8).
Overhead Traveling Crane: A crane with a
movable bridge carrying a movable or fixed
hoisting mechanism and traveling on an
overhead fixed-runway structure.
Power-Operated Crane: A crane whose
mechanism is driven by electricity, air,
hydraulics, or internal combustion.
Pulpit-Operated Crane: A crane operated
from a fixed operator station that is not
attached to the crane.
Remote-Operated Crane: A crane controlled
by an operator not in a pulpit or cab attached
to the crane, by any method other than pendant
or rope control (e.g., radio-controlled crane).
Semigantry Crane: A gantry crane with one
end of the bridge rigidly supported on one or
more legs that run on a fixed rail or runway,
the other end of the bridge being supported by
a truck running on an elevated rail or runway.
Shop Crane: A Portable Automotive Lifting
Device (PALD), self contained hydraulic and
pneumatic-hydraulic crane characterized by a
pair of laterally spaced legs, an upright mast, a
pivoting boom with a boom extension and
hook, and a hydraulic unit. The hydraulic unit
moves the boom up and down at a pivot point
for the purpose of raising, removing,
transporting in the lowered position, and
replacing automotive engines, transmissions
and other components. Shop cranes have a
capacity of 4 tons (8000 pounds) or less.
Wall-Mounted Crane: A crane having a jib,
with or without a trolley, supported from a
side wall or line of columns of a building. It is
a traveling-type crane and operates on a
runway attached to the side wall or line of
columns.
Wall-Mounted Jib Crane: See Cranes, Types
Of, Jib Crane.
CRITICAL DIAMETER: Diameter of the
smallest bend for a given wire rope that permits
the wires and strands to adjust themselves by
relative movement while remaining in their
normal positions.
CYLINDRICAL DRUM: Hoisting drum of
uniform diameter.
DECELERATION STRESS: Additional stress
imposed on a wire rope due to decreasing the
load velocity.
DEFLECTION:
Sag of a rope in a span, usually measured at
midspan as the depth from a chord joining
the tops of the two supports.
Any deviation from a straight line.
DESIGN FACTOR: Ratio of ultimate strength
to the design working stress.
DESIGNATED: Selected or assigned by the
employer or the employer’s representative as
being qualified to perform specific duties.
DESIGNATED LEADER: “An individual
assigned responsibility for hoisting and rigging
activities requiring more than one person.”
DIAMETER: Distance measured across the
center of a circle circumscribing the wires of a
strand or the strands of a wire rope.
DIESEL-ELECTRIC TRUCK: An electric
truck in which the power source is a generator
driven by a diesel engine.
DOCKBOARD: A portable or fixed device for
spanning the gap or compensating for the
difference in level between loading platforms
and carriers.
DOG-LEG: Permanent short bend or kink in a
wire rope caused by improper use.
DRAGLINE: Wire rope used to pull an
excavating or drag bucket.
DOE-STD-1090-2004
1-5 Chapter 1
Terminology and Definitions
DRIVE: Motor, coupling, brake and gear case,
or gear cases used to propel bridge, trolley, or
hoist.
DRIVE GIRDER: A girder on which is
mounted the bridge drive, cross shaft, walk,
railing, and operator’s cab.
Section 24
DRUM: A cylindrical-flanged barrel of uniform
(cylindrical drum) or tapering (conical drum)
diameter on which a wire rope is wound for
operation or storage. It may be smooth or
grooved.
ELASTIC LIMIT: Limit of stress beyond which
a permanent deformation takes place within the
material. This limit is approximately 55-65
percent of breaking strength of steel-wire ropes.
ELECTRIC TRUCK: A truck in which the
principal energy is transmitted from power
source to motor(s) in the form of electricity.
END CONTROL: An operator-control position
that is located at the end opposite the load end of
the truck.
EQUALIZER: A device used to compensate for
unequal length or stretch of a hoist rope.
EQUALIZING SLINGS: Slings composed of
wire rope and equalizing fittings.
EQUALIZING THIMBLES: A special type of
fitting used as a component part of some wire-
rope slings.
EYE OR EYE SPLICE: A loop with or
without a thimble formed in the end of a wire
rope.
FAIL-SAFE: A provision designed to
automatically stop or safely control any motion
in which a malfunction could occur.
FATIGUE: The tendency of a material to break
under repeated stress.
FIBER CENTERS: Cords or rope made of
vegetable fiber used in the center of a strand.
FIBER CORES: Cords or rope made of
vegetable fiber used in the core of a wire rope.
FIRST POINT: The first setting on the
operator’s controller that starts crane motion
(slowly) in each direction.
FITTING: Any accessory used as an attachment
for wire rope.
FLAG: Mark or marker on a rope to designate
position of load.
FLAT ROPE: Wire rope made of parallel
alternating right-lay and left-lay ropes sewn
together by relatively soft wires.
FLATTENED STRAND ROPE: A wire rope
with either oval or triangular strands that present
a flattened rope surface.
FLEET ANGLE: Angle between the position
of a rope at the extreme end wrap on a drum and
a line drawn perpendicular to the axis of the
drum through the center of the nearest fixed
sheave.
FORKS: Horizontal tine-like projections,
normally suspended from the carriage, used to
engage and support loads.
FORK HEIGHT: The vertical distance from the
floor to the load-carrying surface adjacent to the
heel of the forks with the mast vertical, and in
the case of reach trucks, with the forks extended.
FORKLIFT TRUCK: A high-lift self-loading
truck equipped with load carriage and forks for
transporting and tiering loads (see Figure 10-3).
GALVANIZE: To coat with zinc to protect
against corrosion.
GALVANIZED ROPE: Rope made of
galvanized wire.
GALVANIZED STRAND: Strand made of
galvanized wire.
GALVANIZED WIRE: Wire coated with zinc.
GAS-ELECTRIC TRUCK: An electric truck
in which the power source is a generator driven
by an LP-gas or gasoline engine.
GROMMET: A seven-strand wire-rope sling
made from one continuous length of strand or an
endless synthetic-web sling.
DOE-STD-1090-2004
Chapter 1 1-6
Terminology and Definitions
GROOVED DRUM: Drum with grooved outer
surface to accommodate and guide a rope.
GROOVES: Depressions in the outer surface
of a sheave or drum for positioning and
supporting a rope.
GUY LINE: Strand or rope, usually galvanized,
for holding a structure in position.
HANDLING FIXTURE: A cradle, structure,
shipping fixture, or container designed
specifically to facilitate supporting, lifting or
handling a component during fabrication,
loading, shipping, storage, or installation.
Section 25
HIGH-LIFT TRUCK: A self-loading truck
equipped with an elevating mechanism designed
to permit tiering. Popular types are high-lift
platform trucks (see Figure 10-3).
HIGH-LIFT PLATFORM TRUCK: A self-
loading truck equipped with an elevating
mechanism intended primarily for transporting
and tiering loaded skid platforms (see Figure
10-3).
HOIST: A device that applies a force for lifting
or lowering.
HOIST, LEVER OPERATED: A lever-
operated manual device used to lift, lower, or
pull a load and to apply or release tension.
HOLDING LINE: Wire rope on a clamshell or
orange-peel bucket that holds the bucket while
the closing line is released to dump the load.
HOOK LOAD: The total live weight supported
by the hook of a crane, derrick, or other hoisting
equipment, including the load, slings, spreader
bars, and other tackle not part of the load, but
supported by the hook and required for the
handling of the load.
IDLER: Sheave or roller used to guide or
support a rope.
INDEPENDENT WIRE-ROPE CORE: Wire
rope used as the core of a larger rope.
INNER WIRES: All wires of a strand except
surface or cover wires.
INTERNAL-COMBUSTION ENGINE
TRUCK: A truck in which the power source is a
gas or diesel engine.
INTERNALLY LUBRICATED: Wire rope or
strand having all wires coated with lubricant.
KINK: Permanent distortion of wires and
strands resulting from sharp bends.
LAGGING: External wood covering on a reel
of rope or a strand.
LANG-LAY ROPE: Wire rope in which the
wires in the strands and the strands in the rope
are laid in the same direction.
LAY LENGTH: The lengthwise distance on a
wire rope in which a strand makes one complete
turn around the rope’s axis (see Figure 1-2).
Figure 1-2. Rope Lay
Left Lay:
Strand: Strand in which the cover wires are
laid in a helix having a left-hand pitch,
similar to a left-hand screw.
Rope: Rope in which the strands are laid in
a helix having a left-hand pitch, similar to a
left-hand screw.
Right Lay:
Strand: Strand in which the cover wires are
laid in a helix having a right-hand pitch,
similar to a right-hand screw.
Rope: Rope in which the strands are laid in
a helix having a right-hand pitch, similar to
a right-hand screw.
LIFT:
• Maximum safe vertical distance through
which a hook can travel.
• The hoisting of a load.
DOE-STD-1090-2004
1-7 Chapter 1
Terminology and Definitions
LIFT, CRITICAL: A lift for which the
application of requirements applicable to
ordinary lifts would not adequately eliminate or
control the likelihood or severity of the
following:
• personnel injury or significant adverse
health impact (onsite or offsite).
• significant release of radioactivity or other
hazardous material or other undesirable
conditions.
• undetectable damage that would jeopardize
future operations or the safety of a facility.
• damage that would result in delay to
schedule or other significant program impact
such as loss of vital data.
LIFT, ORDINARY: Any lift not designated as
a critical lift or a preengineered production lift.
LIFT, PREENGINEERED PRODUCTION:
Repetitive, production-type lifting operation,
independent of the nature of the load to be lifted,
in which the probability of dropping, upset, or
collision is reduced to a level acceptable to the
responsible manager by preliminary engineering
evaluation, specialized lifting fixtures, detailed
procedures, operation-specific training, and
independent review and approval of the entire
process.
Section 26
LINE: A rope used for supporting and
controlling a suspended load.
LOAD: The total weight superimposed on the
load block or hook.
LOAD BLOCK: The assembly of hook or
shackle, swivel, bearing, sheaves, pins, and
frame suspended by the hoisting ropes.
LOAD-BACKREST EXTENSION: A device
extending vertically from the fork carriage
frame.
LOAD-BEARING PARTS: Any part of a
material-handling device in which the induced
stress is influenced by the hook load. A primary
load-bearing part is a part the failure of which
could result in dropping, upset, or uncontrolled
motion of the load. Load-bearing parts which, if
failed, would result in no more than stoppage of
the equipment without causing dropping, upset,
or loss of control of the load are not considered
to be primary load-bearing parts.
LOAD CENTER (FORKLIFTS): The
horizontal longitudinal distance from the
intersection of the horizontal load-carrying
surfaces and vertical load-engaging faces of the
forks (or equivalent load-positioning structure)
to the center of gravity of the load.
LOW-LIFT TRUCK: A self-loading truck
equipped with an elevating mechanism designed
to raise the load only sufficiently to permit
horizontal movement (see Figure 10-3).
MAGNET: An electromagnetic device carried
on a crane hook and used to pick up loads.
MAIN HOIST: The hoist mechanism provided
for lifting the maximum-rated load.
MAN TROLLEY: A trolley having an
operator’s cab attached to it.
MARLINE SPIKE: Tapered steel pin used in
splicing wire rope.
MESSENGER STRAND: Galvanized strand
or bronze strand used to support telephone and
electrical cables.
MODULUS OF ELASTICITY: Mathematical
quantity giving the ratio, within the elastic limit,
between a definite range of unit stress on a wire
rope and the corresponding elongation.
MOUSING: A method of bridging the throat
opening of a hook to prevent the release of load
lines and slings, under service or slack
conditions, by wrapping with soft wire, rope,
heavy tape, or similar materials.
NARROW-AISLE TRUCK: A self-loading
truck intended primarily for right-angle stacking
in aisles narrower than those normally required
by counterbalanced trucks of the same capacity
(see Figure 10-3).
NONDESTRUCTIVE EXAMINATION
(NDE): 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 discontinuities,
defects, and other imperfections; to assess
DOE-STD-1090-2004
Chapter 1 1-8
Terminology and Definitions
integrity, properties, and composition; and to
measure geometrical characteristics.
NONDESTRUCTIVE TESTING (NDT): See
NONDESTRUCTIVE EXAMINATION.
NONROTATING WIRE ROPE: See
ROTATION-RESISTANT WIRE ROPE.
OPEN SOCKET: A wire-rope fitting
consisting of a basket and two ears with a pin.
ORDER-PICKER TRUCK, HIGH-LIFT: A
truck, controllable by an operator stationed on a
platform, which is movable, has a load-engaging
means, and is intended for (manual) stock
selection. The truck may be capable of self-
loading and/or tiering (see Figure 10-3).
OVERHEAD GUARD: A framework fitted to
a truck over the head of a riding operator.
PALLET TRUCK: A self-loading, non-
motorized or motorized low-lift truck equipped
with wheeled forks of dimensions sized to go
between the top and bottom boards of a double-
faced pallet, the wheels fitting into spaces
between the bottom boards, so as to raise the
pallet off the floor for transporting (see Figure
10-3).
Section 27
PEENING: Permanent distortion of outside
wire in a rope caused by pounding.
PERSON-IN-CHARGE (PIC): The manager
or other responsible person (other than the
equipment operator) known to be qualified and
appointed to be responsible for the safe handling
of critical loads.
POWERED INDUSTRIAL TRUCK: A
mobile, power-driven vehicle used to carry,
push, pull, lift, stack, or tier material.
PRECISION LOAD POSITIONING
DEVICES: A rigging accessory designed
specifically to precisely raise and lower a load
through a limited range of lifting/lowering
motion (stroke). Standards units typically have
12 in. (30 cm) stroke and can position a load
within 0.001 in. (0.025 mm). These devices
commonly include a built-in load scale and in
such cases may also serve as a load-indicating
device.
PREFORMED WIRE ROPE: Wire rope in
which the strands are permanently shaped, before
being fabricated into the rope, to the helical form
they assume in the wire rope.
PREFORMED STRAND: Strand in which the
wires are permanently shaped, before being
fabricated into the strands, to the helical form
they assume in the strand.
PRESTRESSING: Stressing a wire rope or
strand before use under such a tension and for
such a time that stretch that would otherwise
occur once the load is picked up is largely
nonexistent.
PROOF TEST: A nondestructive tension test
performed to verify construction and
workmanship of slings or rigging accessories.
PUBLIC CARRIER: A for-hire company
engaged in the public transportation of goods.
QUALIFIED: A person who, by possession of a
recognized degree, certificate, or professional
standing, or who, by extensive knowledge,
training, and experience, has successfully
demonstrated an ability and competence to solve
or resolve problems relating to the subject matter
and work.
QUALIFIED ENGINEER/QUALIFIED
ENGINEERING ORGANIZATION: An
engineer or engineering organization whose
competence in evaluation of the type of
equipment in question has been demonstrated to
the satisfaction of the responsible manager.
QUALIFIED INSPECTOR: One whose
competence is recognized by the responsible
manager and whose qualification to perform
specific inspection activities has been
determined, verified, and attested to in writing.
QUALIFIED OPERATOR: One who has had
appropriate and approved training, including
satisfactory completion of both written and
operational tests to demonstrate knowledge,
competence, and skill, in the safe operation of
the equipment to be used.
QUALIFIED RIGGER: One whose
competence in this skill has been demonstrated
by experience satisfactory to the appointed
person.
DOE-STD-1090-2004
1-9 Chapter 1
Terminology and Definitions
NOTE: The term “rigger” or “qualified
rigger” in this standard refers to the function
performed, and in no way relates to the
worker’s classification in any union or
bargaining unit.
RATED CAPACITY: The maximum hook load
that a piece of hoisting equipment is designed to
carry; also the maximum load that an industrial
truck or a sling, hook, shackle, or other rigging
tackle is designed to carry.
NOTE: At the option of the user, a rated
capacity can be assigned that is less than the
design-rated capacity.
REACH TRUCK: A self-loading truck,
generally high-lift, having load-engaging means
mounted so it can be extended forward under
control to permit a load to be picked up and
deposited in the extended position and
transported in the retracted position (see Figure
10-3).
Section 28
REEL: The flanged spool on which wire rope
or strand is wound for storage or shipment.
REEVING: A system in which a rope travels
around drums or sheaves.
REGULAR-LAY ROPE: Wire rope in which
the wires in the strands and the strands in the
rope are laid in opposite directions.
REVERSE BEND: Reeving of a wire rope
over sheaves and drums so that it bends in
opposite directions.
RIDER TRUCK: A truck that is designed to be
controlled by a riding operator.
RIGGING: The hardware or equipment used to
safely attach a load to a lifting device. The art or
process of safely attaching a load to a hook by
means of adequately rated and properly applied
slings and related hardware.
ROLLERS: Relatively small-diameter
cylinders or wide-faced sheaves used for
supporting or guiding ropes.
ROTATION-RESISTANT WIRE ROPE:
Wire rope consisting of a left-lay, lang-lay inner
rope covered by right-lay, regular-lay outer
strands.
RUNNING SHEAVE: A sheave that rotates as
the load block is raised or lowered.
RUNWAY: Assembly of rails, girders, brackets,
and framework on which a crane operates.
SAFE WORKING LOAD: Load that a rope
may carry economically and safely.
SEALE: A strand construction having one size
of cover wires with the same number of one size
of wires in the inner layer and each layer having
the same length and direction of lay. Most
common construction is one center wire, nine
inner wires, and nine cover wires.
SEIZE: To securely bind the end of a wire rope
or strand with seizing wire or strand.
SEIZING STRAND: Small strand, usually of
seven wires, mad of soft-annealed-iron wire.
SEIZING WIRE: A soft-annealed-iron wire.
SELF-LOADER: A truck with tires that can fit
between the top and bottom boards of a double-
faced pallet.
SERVE: To cover the surface of a wire rope or
strand with a wrapping of wire.
SHACKLE: A type of clevis normally used for
lifting (see Figure 1-3).
Figure 1-3. Shackle
SHALL: A word indicating that an action is
mandatory.
SHEAVE: A grooved wheel or pulley used with
a rope to change direction and point of
application of a pulling force.
SHEAVE, NONRUNNING (EQUALIZER):
A sheave used to equalize tension in opposite
parts of a rope, called nonrunning because of its
slight movement.
Deleted: REMOTE-OPERATED
CRANE: A crane whose movements
are controlled by an operator through
the use of controllers contained in a
portable operating station not attached
to the crane.¶
¶
REMOTE-OPERATED CRANE: A
crane whose movements are controlled
by an operator through the use of
controllers contained in a portable
operating station not attached to the
crane.¶
¶
Deleted: The
DOE-STD-1090-2004
Chapter 1 1-10
Terminology and Definitions
SHEAVE, RUNNING: A sheave that rotates as
the load block is lifted or lowered.
SHOULD: A word indicating a recommended
action, the advisability of which depends on the
facts in each situation.
SIDE LOADER: A self-loading truck,
generally high-lift, having load-engaging means
mounted in such a manner that it can be extended
laterally under control to permit a load to be
picked up and deposited in the extended position
and transported in the retracted position (see
Figure 10-3).
SIDE PULL: That portion of a hoist pull acting
horizontally when the hoist lines are not operated
vertically.
SLINGS: Wire ropes, chains, synthetic web,
and metal mesh made into forms, and with or
without fittings, for handling loads.
SLINGS, BRAIDED: Very flexible slings
composed of several individual wire ropes
braided together.
Section 29
SMOOTH-FACED DRUM: Drum with a
plain, not grooved, face.
SPAN: The horizontal, center-to-center
distance of runway rails.
SPIRAL GROOVE: Groove that follows the
path of a helix around a drum, similar to the
thread of a screw.
SPLICING: Interweaving of two ends of rope
to make a continuous or endless length without
appreciable increasing the diameter. Also refers
to making a loop or eye in the end of a rope by
tucking the ends of the strands.
Splice, Hand Tucked: A loop or eye
formed in the end of a rope by tucking the
end of the strands back into the main body
of the rope in a prescribed manner.
Splice, Mechanical: A loop or eye formed
in the end of a wire rope by pressing or
swaging one or more metal sleeve over the
wire rope junction.
STAINLESS-STEEL ROPE: Wire rope made
of chrome-nickel steel wires having great
resistance to corrosion.
STEEL-CLAD ROPE: Rope with individual
strands spirally wrapped with flat steel wire.
STRAND: An arrangement of wires helically
laid about an axis or another wire or fiber center
to produce a symmetrical section.
SUSPECT/COUNTERFEIT ITEMS (S/CI):
A suspect item is one in which visual inspection,
testing, or other means indicate that it may not
conform to established Government or industry-
accepted specifications or national consensus
standards. A counterfeit item is a suspect item
that has been copied or substituted without legal
right or authority to do so or one whose material,
performance, or characteristics are knowingly
misrepresented by the vendor, supplier,
distributor, or manufacturer (see Figure 1-5).
NOTE: (refer to DOE G 440.1-6
“Implementation Guide For Use With
Suspect/Counterfeit Requirements” of DOE O
440.1, Worker Protection Management).
SWAGED FITTINGS: Fittings in which wire
rope is inserted and attached by a cold-forming
method.
SWITCH, ELECTRIC: A device for making,
breaking, or changing the connections in an
electrical circuit.
SWITCH, EMERGENCY STOP: A manually
or automatically operated electric switch to cut
off electric power independently of the regular
operating controls.
SWITCH, LIMIT: A switch that is operated by
some part or motion of a power-driven machine
or equipment to alter the electrical circuit
associated with the machine or equipment.
SWITCH, MAIN: A switch controlling the
entire power supply to a crane or other
equipment, often called the disconnect switch.
TAG LINE: A rope used to prevent rotation of a
load.
TAPERING AND WELDING: Reducing the
diameter of the end of a wire rope and welding it
to facilitate reeving.
DOE-STD-1090-2004
1-11 Chapter 1
Terminology and Definitions
THIMBLE: Grooved metal fitting to protect the
eye of a wire rope (see Figure 1-4).
Figure 1-4. Thimble
TIERING: The process of placing one load on
or above another.
TINNED WIRE: Wire coated with tin.
TROLLEY: A unit consisting of frame, trucks,
trolley drive, and hoisting mechanism moving on
the bridge rails in a direction at right angles to
the crane runway.
TROLLEY GIRTS: Structural members that
are supported on the trolley trucks and that
contain the upper sheave assemblies.
TROLLEY TRAVEL: Horizontal travel of a
trolley at right angles to runway rails.
TROLLEY TRUCK: An assembly consisting
of wheels, bearings, axles, and structural-
supporting hoist mechanism and load girts.
TRUCK, POWERED INDUSTRIAL: A
mobile, power-propelled truck used to carry,
push, pull, lift, stack, or tier material (see Figure
10-3).
TURNBUCKLE: A device attached to wire
rope for making limited adjustments in length. It
Section 30
consists of a barrel and right- and left-hand
threaded bolts.
TWO-BLOCKING: The act of continued
hoisting in which the load-block and head-block
assemblies are brought into physical contact,
thereby preventing further movement of the load
block and creating shock loads to the rope and
reeving system.
VERIFICATION: A procedure in which a
design, calculation, drawing, procedure,
instruction, report, or document is checked and
signed by one or more parties. The one or more
persons designated to sign verify, based on
personal observation, certified records, or direct
reports, that a specific action has been performed
in accordance with specified requirements.
WEDGE SOCKET: Wire-rope fitting in which
the rope end is secured by a wedge.
WHEEL BASE: Distance between centers of
outermost wheels for bridge and trolley trucks.
WHEEL LOAD: The load on any wheel with
the trolley and lifted load (rated load) positioned
on the bridge to give maximum-loading
conditions.
WIRE ROPE: Wire strands laid helically
around an axis or a core.
WIRE (ROUND): Single continuous length of
metal, cold drawn from a rod.
WIRE (SHAPED): A single continuous length
of metal either cold drawn or cold rolled from a
rod.
DOE-STD-1090-2004
Chapter 1 1-12
Terminology and Definitions
Figure 1-5
DOE-STD-1090-2004
CHAPTER 2
CRITICAL LIFTS
2-i Chapter 2
Critical Lifts
This chapter provides guidelines for critical-lift determination and requirements for planning and
performing a critical lift safely and judiciously.
2.1 CRITICAL-LIFT DETERMINATION ................................................................ 2-1
2.2 CRITICAL-LIFT REQUIREMENTS ............................................................. 2-2
DOE-STD-1090-2004
Chapter 2 2-ii
Critical Lifts
INTENTIONALLY BLANK
DOE-STD-1090-2004
2.1 CRITICAL-LIFT DETERMINATION
2-1 Chapter 2
Critical Lifts
a. An appointed person shall classify each lift
into one of the DOE categories (ordinary,
critical, or preengineered production) prior
to planning the lift.
b. A lift shall be designated critical if any of
the following conditions are met:
1. The load item, if damaged or upset
would result in a release into the
environment of radioactive or
hazardous material exceeding the
established permissible environmental
limits.
2. The load item is unique and, if
damaged, would be irreplaceable or not
repairable and is vital to a system,
facility or project operation.
3. The cost to replace or repair the load
item, or the delay in operations of
having the load item damaged would
have a negative impact on facility,
organizational, or DOE budgets to the
extent that it would affect program
commitments.
4. A lift not meeting the above criteria
shall also be designated critical if
mishandling or dropping of the load
would cause any of the above noted
consequences to nearby installations or
facilities.
c. Further site-specific criteria may be
developed to supplement those cited above
and may include loads which require
exceptional care in handling because of size,
weight, close-tolerance installation or high
susceptibility to damage as well as lifts
using multiple pieces of lifting equipment.”
.
DOE-STD-1090-2004
2.2 CRITICAL-LIFT REQUIREMENTS
Chapter 2 2-2
Critical Lifts
a. Ensure that the requirements are met for
ordinary lifts specified in each section of
this standard for each particular equipment
category.
b. The operating organization shall appoint a
Section 31
Person-In-Charge (PIC) for the entire
operation. This person shall meet the
definitions of appointed, designated, and
qualified as described in Chapter 1,
“Terminology and Definitions,” and shall be
present at the lift site during the entire lifting
operation.
c. The PIC shall ensure that a pre-job plan or
procedure is prepared that defines the
operation and includes the following:
1. Identification of the items to be moved,
the weight, dimensions, and center of
gravity of the load, and any hazardous
or toxic materials that are present.
2. Identification of operating equipment
to be used by type and rated capacity.
3. Rigging sketches that include (as
applicable):
i. Identification and rated capacity of
slings, lifting bars, rigging
accessories, and below-the-hook
lifting devices.
ii. Load-indicating devices.
iii. Load vectors.
iv. Lifting points.
v. Sling angles.
vi. Boom and swing angles.
vii. Methods of attachment.
viii. Crane orientations.
ix. Other factors affecting equipment
capacity.
4. Operating procedures and special
instructions to operators including
rigging precautions and safety measures
to be followed as applicable.
d. Experienced operators who have been
trained and qualified to operate the specific
equipment to be used shall be assigned to
make the lift.
e. Only designated, qualified signalers shall
give signals to the operator. However, the
operator shall obey a STOP signal at all
times, no matter who gives the signal.
f. The procedure and rigging sketches shall be
reviewed and approved by the responsible
manager (or designee) and the responsible
oversight organization (such as safety,
quality assurance, or quality control) before
the lift is made.
g. A pre-lift meeting involving participating
personnel shall be conducted prior to
making a critical lift. The critical lift
plan/procedure shall be reviewed and
questions shall be resolved.
h. If required by the critical lift procedure, a
practice lift shall be done before the critical
lift. Conditions for a practice lift should
closely simulate actual conditions involving:
weight, rigging selection and configuration,
load movement path, and other relevant
factors. Practice lifts should be done by the
same crew, using the same lifting
equipment.
DOE-STD-1090-2004
CHAPTER 3
PREENGINEERED PRODUCTION LIFTS
3-i Chapter 3
Preengineered Production Lifts
This chapter provides requirements for the design, evaluation, and performance of preengineered
production lifts. This lift designation may be used at the discretion of the contractor for selected
operations.
3.1 GENERAL ................................................................................................................................3-1
3.2 OPERATION EVALUATION................................................................................................3-2
3.2.1 Load Identification.......................................................................................................3-2
3.2.2 Task Determination......................................................................................................3-2
3.2.3 Hazards Evaluation ......................................................................................................3-2
3.2.4 Equipment/Rigging Selection ......................................................................................3-2
Section 32
3.3 LIFTING FIXTURES..............................................................................................................3-3
3.3.1 Design ..........................................................................................................................3-3
3.3.2 Fabrication ...................................................................................................................3-3
3.3.3 Inspection and Testing .................................................................................................3-3
3.3.4 Storage, Maintenance, and Control..............................................................................3-3
3.3.5 Modification and Repair ..............................................................................................3-4
3.4 PROCEDURES ........................................................................................................................3-5
3.4.1 Content.........................................................................................................................3-5
3.4.2 Development................................................................................................................3-5
3.4.3 Preparation and Revision .............................................................................................3-5
3.4.4 Approval ......................................................................................................................3-6
3.4.5 Review .........................................................................................................................3-6
3.4.6 Use ...............................................................................................................................3-6
3.5 DESIGNATED LEADER........................................................................................................3-7
3.6 TRAINING ...............................................................................................................................3-8
3.6.1 Equipment Operation...................................................................................................3-8
3.6.2 Procedure .....................................................................................................................3-8
DOE-STD-1090-2004
Chapter 3 3-ii
Preengineered Production Lifts
INTENTIONALLY BLANK
DOE-STD-1090-2004
3.1 GENERAL
3-1 Chapter 3
Preengineered Production Lifts
a. A preengineered production lift is a
repetitive, production-type lifting operation
that is independent of the nature of the load
to be lifted. Also, the probability of
collision, upset, or dropping is reduced to a
level acceptable to the responsible manager
by preliminary operation evaluation,
specialized lifting fixtures, detailed
procedures, operation-specific training, and
performance of independent review and
approval of the entire process.
b. The preengineered production lift is a
specialized lift performed by production
personnel. The required procedures and
controls ensure the safety of the operation
and set this category of lift apart from
traditional hoisting and rigging activities
DOE-STD-1090-2004
3.2 OPERATION EVALUATION
Chapter 3 3-2
Preengineered Production Lifts
The following procedure should be used to
determine if a lifting operation qualifies as a
preengineered production lift.
3.2.1 LOAD IDENTIFICATION
a. Identify the identical items or group(s) of
Section 33
identical items to be respectively lifted.
Items must have the same dimensions,
weight, and center of gravity to be
considered identical.
b. Determine the dimensions, weight, center of
gravity, and method of attachment of the
items.
3.2.2 TASK DETERMINATION
a. Determine the parameters of motion using
the following as applicable:
1. Lifting, rotation, speeds, and travel
directions.
2. Actions required with or adjacent to the
load.
3. Other lifting operation details that affect
safety and stability of the load.
3.2.3 HAZARDS EVALUATION
Determine the consequences that could result
from collision, upset, or dropping the load.
3.2.4 EQUIPMENT/RIGGING
SELECTION
a. Determine the type, class, and minimum
capacity of lifting equipment (hoist, crane,
forklift, etc.) required for the operation
based on the identified load, task, and
hazards.
b. Define the type of lifting fixtures required to
safely accomplish the required task.
DOE-STD-1090-2004
3.3 LIFTING FIXTURES
3-3 Chapter 3
Preengineered Production Lifts
3.3.1 DESIGN
a. Special lifting fixtures and rigging
accessories shall be designed according to
recognized consensus standards (29 CFR
1910, Occupational Safety and Health
Standards for General Industry: 29 CFR
1926, Occupational Safety an Health
Regulations for Construction; ASME B30.9,
“Slings,” B30.10, “Hooks,” B30.20,
“Below-the-Hook Lifting Devices,” etc.),
and the lifting fixture design requirements in
Chapters 12 and 14 (“Rigging Accessories”
and “Below-the-Hook Lifting Devices,”
respectively).
b. The designer of special lifting fixtures shall
be:
1. A member of a qualified engineering
organization.
2. Qualified in machine design.
3. Knowledgeable of special lifting fixture
design requirements.
c. The designer shall determine the
requirements for initial and periodic
inspections or tests, including
acceptance/rejection criteria and periodic
inspection/test intervals.
d. Special lifting fixture designs shall receive a
documented review by another member of a
qualified engineering organization and the
responsible oversight organizations (safety,
quality assurance, etc.).
e. Deviations in design that may result in
design factors less than consensus standard
requirements shall require documented
justification and approval of the designer’s
manager and the manager of the responsible
oversight organizations (safety, quality
assurance, etc.).
f. Applications not specifically addressed in
the ASME standards or in this standard may
be approved by the responsible manager and
oversight organizations (safety, quality
assurance, etc.) when justification and
documentation are provided and all other
provisions of this section are met.
3.3.2 FABRICATION
Special lifting fixtures shall be fabricated
according to the specifications of the approved
design package.
3.3.3 INSPECTION AND TESTING
a. Before initial use of each special lifting
fixture, a qualified inspector shall perform a
documented acceptance inspection and test
on it. This process shall include:
1. Verification of configuration of the
fixture against the design drawing
specifications.
2. Nondestructive examination as
specified in the approved design
package.
3. Proof-testing as specified in the
approved design package.
b. Personnel performing the lift shall visually
inspect special lifting fixtures before use for
visible signs of wear, deformation,
deterioration, or damage. Records are not
required.
c. A qualified inspector shall conduct periodic,
Section 34
documented inspections as required by the
design organization. In addition to looking
for visible signs of wear, deformation,
deterioration, or damage, these inspections
shall verify the current configuration of the
fixture against that specified in the approved
design package.
d. Equipment to be used (cranes, hoists,
forklifts, etc.) shall be inspected according
to the appropriate section requirements in
this standard for that type of equipment.
3.3.4 STORAGE, MAINTENANCE, AND
CONTROL
a. Lifting fixture users shall do the following:
DOE-STD-1090-2004
Chapter 3 3-4
Preengineered Production Lifts
1. Store special lifting fixtures in an
appropriate location to prevent damage
or deterioration.
2. Perform and document periodic
preventive maintenance as required by
the design organization.
3. Establish controls to ensure that special
lifting fixtures are used only in the
operations for which they were
designed.
4. Maintain equipment to be used (cranes,
hoists, forklifts, etc.) according to the
appropriate section requirements in this
standard for that type of equipment.
5. If equipment maintenance procedures
deviate from published manufacturer's
recommendations, the alternate procedures
shall be approved in advance by the
manufacturer or another qualified person
and be kept readily available.
3.3.5 MODIFICATION AND REPAIR
a. Modification to special lifting fixtures shall
be designed, approved, and fabricated
according to Sections 3.3.1, and 3.3.2,
(“Design,” and “Fabrication,” respectively).
b. Following modification or repair of a load-
bearing element of a special lifting fixture,
the fixture shall be inspected and tested
according to the initial use requirements in
Section 3.3.3, “Inspection and Testing.”
DOE-STD-1090-2004
3.4 PROCEDURES
3-5 Chapter 3
Preengineered Production Lifts
A detailed, approved, step-by-step procedure
shall be developed for the entire operation.
3.4.1 CONTENT
a. At a minimum, each procedure shall contain
the following information:
1. Identification of the load to be lifted.
2. Identification of the specific lifting
fixtures to be used in the operation.
3. Identification by class and capacity (if
applicable) of the types of equipment to
be used, such as cranes and hoists.
4. Verification that all equipment, fixtures,
and accessories are operative, up-to-
date on required periodic inspections
and maintenance, and are in good
condition before the operation begins.
5. Specific instructions for attachment of
the lifting fixtures to the load and to the
lifting equipment.
6. Parameters of motion required for the
operation.
7. Specific instructions for removal of the
lifting fixtures from both the load and
the lifting equipment.
3.4.2 DEVELOPMENT
a. The methods for developing new
procedures, including standard procedure
formats, should be clearly defined.
Administrative procedures or writers guides
should direct the development and review
process for procedures at each site to ensure
consistency at the site.
b. Qualifications for procedure writers shall be
considered, including operating organization
and experience.
c. Procedures should reference applicable
source documents, such as facility design
documents, safety analysis documents,
vendor technical manuals, and industry
standards.
d. Operating procedures should contain only
one action per step.
e. Any necessary warnings, cautions, or notes
Section 35
should be easily identifiable and should not
contain any action statements. These items
should precede the step to which they apply
and should appear on the same pate as the
step to which they apply.
f. The sequence of procedural steps should
conform to the normal or expected
operational sequence.
g. Procedures should be developed with
consideration for the human-factor aspects
of their intended use. For example,
references to components should exactly
match drawing and label-plate identifiers,
and units should be the same as those
marked on applicable instrumentation.
Important factors should be highlighted,
such as operating limits, warnings, and
cautions.
3.4.3 PREPARATION AND REVISION
a. Appropriately trained personnel shall
develop, review, and approve a step-by-step
procedure for each lifting operation. The
responsible oversight organizations (safety,
quality assurance, etc.) shall participate in
the review process.
b. Before its first use in the actual production
process, the procedure shall undergo a
formal verification and validation process
using walk-throughs or similar methods to
ensure that the steps are appropriate and
correct. Any discrepancies found during
this process shall be corrected and the
process repeated until the procedure is
correct.
c. Any changes to an existing, approved
procedure shall be performed according to
the process specified above. The change
shall be evaluated to determine whether the
revised procedure must be revalidated and
reverified.
DOE-STD-1090-2004
Chapter 3 3-6
Preengineered Production Lifts
3.4.4 APPROVAL
a. Before each procedure is validated, it shall
be reviewed and approved by the following
personnel:
1. Author of the procedure.
2. Representative of a qualified
engineering organization.
3. Representatives of the responsible
oversight organizations (e.g., safety,
quality assurance).
b. After each procedure is validated, it shall be
reviewed and approved by the following
personnel:
1. Author of the procedure.
2. Representative of a qualified
engineering organization.
3. Representatives of the responsible
oversight organizations (i.e., safety,
quality assurance).
4. Management of the facility where the
procedure will be performed.
5. Management of the production
organization performing the procedure.
c. Revisions of procedures shall receive the
same depth of review and level of approval
as the initial versions received.
All procedures, either new or revised, shall be
approved before use.
3.4.5 REVIEW
a. Approved procedures should be reviewed at
periodic intervals to ensure that their
information and instructions are technically
accurate and that appropriate human-factor
considerations have been included.
b. The frequency of reviews should be
specified for each procedure; it may vary
with the type and complexity of the activity
involved.
c. Applicable procedures should be reviewed
after an incident.
d. During each review, procedures should be
compared to source documents to verify
their accuracy.
3.4.6 USE
a. A copy of the current issue of the approved
procedure shall be in the work area when the
operation is performed.
b. Deviations from the approved procedure are
not allowed during normal operations.
c. The requirements for use of procedures
should be clearly defined and understood by
all personnel.
d. If a procedure is determined to be deficient,
a procedure change shall be initiated before
operations continue.
e. Personnel performing the procedure may
Section 36
take whatever action is necessary during
emergency conditions to return the process
to a safe and stable condition without first
initiating a procedure change.
DOE-STD-1090-2004
3.5 DESIGNATED LEADER
3-7 Chapter 3
Preengineered Production Lifts
a. Each time a preengineered production lift
requiring more than one person is
performed, a designated leader shall be
present at the lift site during the entire
operation.
b. Leadership designation may be by written
instructions, specific verbal instruction for
the particular job, or clearly defined
responsibilities within the crew’s
organizational structure.
c. The designated leader’s responsibility shall
include the following:
1. Ensure that the personnel involved have
received proper and current training and
qualification for the procedure.
2. Ensure that the equipment and
accessories specified in the procedure
are available.
3. Survey the lift site for hazardous or
unsafe conditions.
4. Ensure that equipment is properly set up
and positioned.
5. Ensure that a signaler is assigned, if
required, and identified to the
equipment operator.
6. Direct the lifting operation to ensure
that it is done safely and efficiently.
7. Stop the job when any potentially
unsafe condition is recognized.
8. Direct emergency stabilization
operations if an accident or injury
occurs.
DOE-STD-1090-2004
3.6 TRAINING
Chapter 3 3-8
Preengineered Production Lifts
Specialized training shall be conducted for
personnel involved in performing preeningeered
production lifts. This training shall be
periodically reviewed and approved by the
responsible operating and oversight
organizations (safety, quality assurance, etc.).
3.6.1 EQUIPMENT OPERATION
a. Personnel shall be trained and qualified on
the specific types of equipment required.
b. The equipment operation training shall
include:
1. A demonstration by the individual of
operational competence with the
equipment.
2. A demonstration of appropriate safe
operating practices.
3. Documented evidence of the
individual’s knowledge of safety-related
information.
c. Equipment-operation training shall be
repeated for personnel whenever a new or
different type of equipment is introduced
into the procedure.
3.6.2 PROCEDURE
a. Personnel shall be trained and qualified in
the proper execution of each specific
procedure.
b. The procedure training shall include:
1. A demonstration by the individual of
operational competence in performance
of the procedure.
2. Documented evidence of the
individual’s knowledge of the steps and
requirements of the procedure.
c. Training on a procedure shall be repeated
periodically or when a modification to the
procedure results in a significant change in
the operation.
DOE-STD-1090-2004
CHAPTER 4
LIFTING PERSONNEL
4-i Chapter 4
Lifting Personnel
This chapter describes requirements for lifting personnel.
4.1 GENERAL ................................................................................................................................4-1
4.1.1 Personnel Lifting Evaluation .......................................................................................4-1
4.1.2 Designated Leader .......................................................................................................4-1
4.1.3 Trial Lift.......................................................................................................................4-2
4.1.4 Lifting Operations........................................................................................................4-2
4.1.4.1 Pre-Lift Meeting ............................................................................................4-2
4.1.4.2 Pre-Lift Inspection.........................................................................................4-2
4.1.4.3 Lifting Personnel ...........................................................................................4-2
Section 37
4.2 MOBILE CRANES ..................................................................................................................4-5
4.3 OVERHEAD CRANES ...........................................................................................................4-6
4.4 PERSONNEL LIFT PLATFORM .........................................................................................4-7
4.4.1 Platform Design and Construction...............................................................................4-7
4.4.2 Platform Suspension System........................................................................................4-7
4.5 INSPECTIONS.........................................................................................................................4-9
4.5.1 Frequent Inspection......................................................................................................4-9
4.5.1.1 General ..........................................................................................................4-9
4.5.1.2 Personnel Lift Platform .................................................................................4-9
4.5.2 Periodic Inspection ......................................................................................................4-9
4.5.2.1 Personnel Lift Platform .................................................................................4-9
4.5.2.2 Hoisting Equipment.......................................................................................4-9
4.6 TESTING ................................................................................................................................4-10
4.6.1 Platform Manufacturer Test .......................................................................................4-10
4.6.2 Rated Load Test .........................................................................................................4-10
4.6.3 Hoisting Equipment ...................................................................................................4-10
4.7 LIFTING PERSONNEL NEAR ELECTRICAL POWER LINES ...................................4-11
4.7.1 General.......................................................................................................................4-11
4.7.2 Condition A ...............................................................................................................4-11
4.7.3 Condition B................................................................................................................4-11
4.7.4 Condition C................................................................................................................4-12
Exhibit I Personnel Lift Platform Pre-Lift Inspection...............................................................4-15
Exhibit II Personnel Lifting Planning and Authorization Form .................................................4-16
DOE-STD-1090-2004
Chapter 4 4-ii
Lifting Personnel
INTENTIONALLY BLANK
DOE-STD-1090-2004
4.1 GENERAL
4-1 Chapter 4
Lifting Personnel
This chapter specifies the operation, design,
testing, and inspection requirements for the use
of personnel lift platforms or baskets suspended
from mobile or overhead cranes. This chapter
implements the requirements of 29 CFR
1926.550(g) “Cranes and Derricks” and ASME
B30.23, “Personnel Lifting Systems.”
4.1.1 PERSONNEL LIFTING
EVALUATION
a. The use of a crane to hoist employees on a
Section 38
personnel lift platform is prohibited, except
when the erection, use, and dismantling of
conventional means of reaching the
worksite, such as a personnel hoist, ladder,
stairway, aerial lift, elevating work platform
or scaffold, would be more hazardous or is
not possible because of structural design or
worksite conditions.
b. The manager specifically responsible for the
overall work function to be performed shall
determine that the erection, use, and
dismantling of conventional means of
reaching the work site (i.e., scaffold, ladder,
stairway, aerial lift, or elevating work
platform) would be more hazardous or is not
possible because of structural design or
worksite conditions.
c. For each personnel lifting procedure, the
manager responsible for the task shall
authorize the use of a crane-suspended work
platform and attest to the need for the
operation through a written justification
attesting to that need. A statement
describing the operation and its time frame
shall be included. The statement, after being
approved by the authorizer, shall be retained
at the job site.
d. The manager specifically responsible for the
overall work function shall not allow or
require any operator to lift personnel under
the following circumstances:
1. The operator does not feel physically or
mentally fit to perform the operation.
2. The operator has been working for more
than 10 hours prior to the start of the lift
or the lift will not be completed before
the operator has been working for 12
hours.
3. The operator did not have at least eight
hours off, immediately prior to the work
shift containing the person.
4.1.2 DESIGNATED LEADER
a. The Authorizing Manager shall appoint a
Designated Leader for the entire personnel
lifting operation.
b. The Designated Leader shall ensure that a
pre-job plan is prepared that defines the
operation. The Designated Leader shall
ensure:
1. At each new job site prior to hoisting
personnel, the personnel lift platform,
rigging, and hook block shall be proof-
tested by a qualified inspector to 125
percent of the personnel platform’s
rated capacity by holding it suspended
for 5 minutes with the test load suitably
distributed on the personnel platform.
2. After proof-testing, any deficiencies
revealed by inspection, or by the proof
test, be corrected and another proof-test
conducted.
3. Any modification to the personnel lift
platform or rigging requires retesting.
4. Test reports be kept on file and be
readily available to appointed
personnel.
5. A meeting, with the qualified operator,
signaler, persons to be lifted, and the
person responsible for overall worksite
safety to plan is held prior to the trial
lift to review the procedure.
6. The procedures for entering and leaving
the personnel platform and the points at
which persons will enter and leave the
device be reviewed. This meeting shall
be held at each new work location, and
shall be repeated for any employees
newly assigned to the operation.
DOE-STD-1090-2004
Chapter 4 4-2
Lifting Personnel
c. The designated leader and the crane operator
shall determine that:
1. The crane is uniformly level within 1
percent of level grade and firm footing
exist under both crawler tracks or under
each outrigger float. Cribbing mats
under tracks or blocks under outrigger
floats are used as necessary to provide a
firm and substantial footing.
2. Cranes equipped with outriggers have
outriggers extended in accordance with
the manufacturer’s instructions.
Section 39
3. Crane systems, controls, operator aids,
and safety devices are activated and
functioning properly.
4. No interferences exist.
5. The total weight of the loaded personnel
lift platform (including personnel) and
related rigging does not exceed 50
percent of the crane rating under the
planned conditions of use.
6. The personnel lift platform is not loaded
in excess of its rated load capacity.
7. The number of employees occupying
the platform does not exceed the
number required for the work being
performed.
4.1.3 TRIAL LIFT
a. Each shift, before personnel initially enter
the personnel lift platform, the operator and
signaler shall conduct a trial lift. The trial
lift shall include:
1. Loading the unoccupied personnel
platform to at least the maximum
anticipated load. Materials and tools to
be used during the actual lift, if secured
to prevent displacement, can be in the
platform for the trial lift.
2. Making the trial lift from the location
where personnel will enter the platform
to each location where the platform will
be hoisted and positioned. It is
acceptable to perform a single trial lift
on each shift for all locations to be
reached from a single setup position.
b. The trial lift shall be repeated whenever:
1. The crane (mobile) is moved and set up
in a new location or returned to a
previously used location.
2. When the lift route is changed, unless
the operator determines that the safety
of the hoisted personnel is not affected.
3. If a different crane operator is assigned.
4.1.4 LIFTING OPERATIONS
4.1.4.1 Pre-Lift Meeting
a. A meeting attended by the operator, the
ground crew, signaler(s), person(s) to be
lifted, and the designated leader shall be
held each shift to plan and review
procedures to be followed, including:
1. Points at which persons will enter and
leave the platform.
2. Procedures for entering and leaving the
platform.
3. Special precautions if personnel will
perform work from the suspended
platform.
b. This meeting shall be held at each new work
location, and shall be repeated for any
employees newly assigned to the operation.
4.1.4.2 Pre-Lift Inspection
a. After the trial lift, prior to lifting personnel:
1. A visual inspection of the crane,
rigging, and personnel lift platform
shall be conducted by a qualified
inspector. Any defects found that create
a safety hazard shall be corrected prior
to hoisting personnel.
2. The platform shall be lifted a few inches
and inspected to ensure that it is secure
and properly balanced.
4.1.4.3 Lifting Personnel
a. Prior to hoisting personnel in a personnel lift
platform, ensure that:
DOE-STD-1090-2004
4-3 Chapter 4
Lifting Personnel
1. No hazardous conditions exist with the
platform and its associated rigging.
2. The hoist line is not wrapped around
any part of the platform.
3. Hoist ropes are free of kinks.
4. Multiple-part lines are not twisted
around each other.
5. The primary attachment is centered over
the platform.
6. Ropes are properly seated on drums and
sheaves.
7. The crane is within 1 percent of level.
8. The crane has an anti two-block device
installed and operational.
b. Employees being hoisted or working in a
personnel lift platform shall:
1. Remain in continuous sight of, and in
direct communication with, the operator
or signaler. In situations where direct
visual contact with the operator is not
possible, and the use of a signaler
would create a hazard for that person,
direct communication alone (such as a
two-way radio) may be used.
Section 40
2. Keep all parts of their bodies inside the
suspended personnel lift platform
during raising, lowering, and
positioning to avoid pinch points.
3. Wear body harnesses with lanyards
attached to the lower load block or
overhaul ball, or to a structural member
within the platform that is capable of
supporting a fall impact.
4. Not stand on or work from the tope rail,
midrail, or toe board of the suspended
personnel platform.
5. When working above water, the
requirements of 29 CFR 1926.106
(Occupational Safety and Health
Regulations for Construction) shall also
apply.
6. When welding is being performed from
the personnel lift platform, the electrode
holders shall be protected from contact
with metal components of the personnel
platform.
c. Operators of cranes hoisting personnel in a
personnel lift platform shall:
1. Before commencing or continuing the
lift, consult with the designated leader
whenever there is any doubt as to the
safety of the lift.
2. Remain at the controls when the
personnel lift platform is occupied.
3. Operate the crane so that lowering will
be power-controlled (no free-fall).
4. Ensure movement of the personnel lift
platform is performed in a slow,
controlled, cautious manner with no
sudden movements of the crane or the
platform. The lifting or lowering speed
shall not exceed 100 ft/min (30m/min).
5. After the personnel lift platform is
positioned, set all brakes and locks on
the lift crane before personnel perform
any work.
6. If the personnel lift platform cannot be
landed, ensure it is tied to the structure
before personnel get off or on.
7. Ensure that not lifts are made on
another of the crane’s load lines while
personnel are suspended on the
personnel lift platform.
d. Suspended personnel lift platforms shall be
used only for personnel, their tools, and
sufficient materials to do their work. They
shall not be used for transporting bulk
materials.
e. Personnel lift platforms should not be used
in winds greater than 20mph (32.2 km/hr),
electric storms, snow, ice, sleet, or other
adverse weather conditions that could affect
the safety of personnel.
f. Use tag lines to control motion of occupied
personnel lift platforms unless their use
creates an unsafe condition.
DOE-STD-1090-2004
Chapter 4 4-4
Lifting Personnel
g. Cranes shall not travel while personnel
are in the platform. Exceptions to this
provision shall be approved by the
manager specifically responsible for the
overall work function and precautions
to be taken documented in the personnel
lift plan.
DOE-STD-1090-2004
4.2 MOBILE CRANES
4-5 Chapter 4
Lifting Personnel
Mobile cranes are designed and intended for
handling materials, not personnel. In addition to
the general requirements in Section 4.1,
“General,” the following requirements shall be
met when lifting personnel with a mobile crane:
a. Personnel are permitted to ride only in one
of the following:
1. A personnel lift platform that is
supported from the crane’s hook which
meets the requirements of Section 4.4,
“Personnel Platform.”
2. A personnel basket attached directly to
the boom which is approved by the
crane manufacturer.
b. Cranes and derricks with variable-angle
booms shall be equipped with a boom-angle
indicator that is readily visible to the
operator.
c. Cranes with telescoping booms shall be
equipped with a device to indicate clearly to
the operator, at all times, the boom’s
extended length, or an accurate
determination of the load radius to be used
during the lift shall be made prior to hoisting
personnel.
Section 41
d. A positive-acting device shall be used that
prevents contact between the load block or
overhaul ball and the boom tip (anti-two-
blocking device), or a system shall be used
that deactivates the hoisting action before
damage occurs in the event of a two-
blocking situation (two-block damage-
prevention feature).
e. Cranes having booms in which lowering is
controlled by a brake without aid from other
devices which slow the lowering speeds is
prohibited.
f. Crane load lines shall be capable of
supporting, without failure, at least seven
times the maximum intended load, except
where rotation resistant rope is used, the
lines shall be capable of supporting without
failure, at least ten times the maximum
intended load.
g. Hydraulic cranes shall have check valves or
other devices that will prevent uncontrolled
movement in the event of system failure,
engine failure, or hose rupture.
h. Cranes shall have a means to prevent
retraction of hydraulically or pneumatically
activated outriggers or stabilizers in the
event a hydraulic or pneumatic line fails.
i. Pendant supported, jib type, boon extensions
without positive stops are prohibited for
personnel lifting.
Figure 4-1. Positive Hooks
j. Hooks on overhaul ball
assemblies, lower load blocks, or other
attachment assemblies shall be of the type that
can be closed and locked, eliminating the hook
throat opening. (See Figure 4-1). Alternatively,
an alloy anchor type shackle with a bolt, nut and
retaining pin may be used.
DOE-STD-1090-2004
4.3 OVERHEAD CRANES
Chapter 4 4-6
Lifting Personnel
Overhead cranes are designed and intended for
handling materials, not personnel. In addition to
the general requirements in Section 4.1,
“General,” the following requirements shall be
met when lifting personnel with an overhead
crane.
a. Personnel are permitted to ride only in a
personnel lift platform that is supported
from the crane’s hook which meets the
requirements of Section 4.4.
b. A hoist-limit switch/device shall be
provided in the hoisting direction to stop the
hoisting motion to prevent two-blocking.
DOE-STD-1090-2004
4.4 PERSONNEL LIFT PLATFORM
4-7 Chapter 4
Lifting Personnel
4.4.1 PLATFORM DESIGN AND
CONSTRUCTION
There is no attempt to comprehensively address
platform design and construction in this chapter.
Nevertheless, because many platform design and
construction features can be observed and should
be known by the platform user (see Figure 4-2),
the following key design and construction
requirements are presented:
a. The personnel lift platform and suspension
system shall be designed by a qualified
person competent in structural design and
familiar with national consensus standards
governing personnel platform design.
Figure 4-2. Personnel Lift Platform
b. All welding of the platform shall be
performed by a qualified welder in
accordance with ANSI/AWS D1.1. Where
special steels or other materials are used, the
manufacturer shall provide welding
procedures. Welds shall be inspected by a
qualified inspector.
c. The personnel lift platform shall have:
1. A minimum design factor of five.
2. A plate specifying its empty weight and
its rated load capacity or maximum
intended load.
3. Perimeter protection consisting of a top
rail approximately 45 in. (10 cm) high,
and a midrail approximately halfway
between the top rail and the toe board.
4. A grab rail inside the personnel lift
platform to minimize hand exposure.
Section 42
5. Anchorage points within the platform
for attaching personnel fall protection
lanyards.
6. The sides of the platform enclosed from
the toe board to the midrail with solid
construction or expanded metal having
openings no greater than ½ in. (1.27
cm).
7. Platform access gates, including sliding
or folding types, if installed, shall have
a positive acting device to restrain the
gate from accidental opening.
Swinging type access gates shall open
only to the interior of the personnel lift
platform.
8. Rough edges exposed to contact by
employees surfaced (ground smooth) to
prevent injury.
9. High-visibility color or marking for
easy identification.
d. In addition to wearing hard hats, personnel
shall be protected by overhead protection on
the personnel lift platform when there is an
overhead hazard. Sufficient headroom shall
be provided to allow employees to stand
upright in the platform.
4.4.2 Platform Suspension System
a. Wire rope, shackles, rings master links, and
other rigging hardware must be capable of
supporting, without failure, at least five
times the maximum intended load applied or
transmitted to that component and guided by
the following:
DOE-STD-1090-2004
Chapter 4 4-8
Lifting Personnel
1. One-leg system – design factor of
seven.
2. Two- or three-leg system – design
factor of five for each leg.
3. Four-leg system – design factor of five
with only three legs under stress.
4. Where rotation resistant rope is used,
the slings shall be capable of supporting
without failure at least ten times the
maximum intended load.
b. Sling suspension systems shall utilize a
master link or safety type shackle to connect
the personnel lift platform to the load line to
ensure that the load is evenly divided among
the suspension system legs.
c. The suspension system shall be designed to
minimize tipping of the platform due to
movement of employees occupying the
platform.
d. The sling suspension system attaching the
personnel lift platform to the hoist line shall
not be used for any other purpose when not
hoisting personnel.
e. Shackles used in any part of the suspension
system shall be a safety type (bolt-type
shackle with nut and cotter pin).
f. All eyes in wire rope slings shall be
fabricated with thimbles.
g. Wire rope clips, wedge sockets, or knots
shall not be used in suspension system sling
assemblies.
h. Synthetic webbing, natural or synthetic fiber
rope shall not be used for the suspension
systems.
i. Chain sling suspension systems shall use a
minimum of grade 80 chain.
DOE-STD-1090-2004
4.5 INSPECTIONS
4-9 Chapter 4
Lifting Personnel
All equipment used in the lifting of personnel
shall be inspected, tested, and maintained to
protect against failure during lifting operation.
4.5.1 FREQUENT INSPECTION
4.5.1.1 General
a. The platform manufacturer shall furnish
complete inspection criteria for the platform
users. The criteria shall address all
inspection frequency classifications and
shall cover:
1. The platform
2. Rigging components
3. Fasteners
4. All safety features and attachments.
4.5.1.2 Personnel Lift Platform
a. Prior to initial use, and at each new job, the
platform shall be inspected by a qualified
inspector in accordance with the instructions
provided by the manufacturer.
b. The platform, suspension system,
Section 43
attachment points, and any motion controls
shall be inspected at least each day, before
use, by a designated person. The inspection
is to identify conditions that have been
specifically indicated by the platform
manufacturer, or a qualified person, as
potentially creating a hazardous operating
condition. Visually inspect items such as
the following:
1. Platform and suspension system
markings to ensure all information is
legible.
2. Platform structure:
i. Load supporting members, welds
and bolts.
ii. Perimeter protection; top rail,
midrail, toe board, and barrier from
toe board to midrail.
iii. Fall protection device anchorage
points.
iv. Gate locking mechanisms.
v. Platform flooring.
vi. Suspension attachment points.
3. Attachment mechanisms.
i. Master links, shackles, slings, bolt-
ups, etc.
4. Special purpose items:
i. Overhead protection.
ii. Platform controls
c. For frequent inspections, dated records for
the hoisting equipment and personnel lift
platform shall be made and kept by the
platform user for the duration of the
personnel lift operation.
4.5.2 PERIODIC INSPECTION
4.5.2.1 Personnel Lift Platform
a. At least once every 12 months, or as
required by the personnel lift platform
manufacturer, a periodic inspection of the
platform shall be performed by a qualified
inspector in accordance with the instructions
provided by the manufacturer.
b. Platforms which have been out of service for
12 or more consecutive months shall receive
a periodic inspection prior to use.
c. Dated inspections records for the platform
shall be made. The last periodic inspection
records shall be kept with the platform and
available for review.
4.5.2.2 Hoisting Equipment
a. Hoisting equipment shall be inspected in
accordance with requirements of Chapter 7,
“Overhead & Gantry Cranes,” or Chapter 9,
“Mobile Cranes.”
DOE-STD-1090-2004
4.6 TESTING
Chapter 4 4-10
Lifting Personnel
4.6.1 PLATFORM MANUFACTURER
TEST
a. The platform manufacturer shall perform the
following testing:
1. Test the personnel lift platforms:
i. Suspension mechanisms or
attachment components.
ii. Occupant safety features.
iii. Platform rating.
iv. When the complete production
platform is not supplied by one
manufacturer, the manufacturers
platform test shall be conducted at
final assembly by the platform
assembler or a qualified inspector.
2. Slings (wire rope or chain) shall receive
an initial load test before installation by
applying a test load to each individual
leg equal to twice the rated load of the
leg. If a master link or safety shackle is
used in the suspension system, it shall
be tested to at least the weight of the
platform plus the platform rating.
i. All tested components shall be
visually inspected after testing.
ii. Any components showing damage
shall be replaced and the test
procedure repeated.
3. Non-destructive testing of the
platform’s suspension system attaching
points.
4.6.2 RATED LOAD TEST
a. At least annually and at each new job site,
before personnel are hoisted, the personnel
platform and suspension system shall be
load-tested to 125 percent of the personnel
platform’s rated capacity.
b. The platform shall be held in a suspended
position for 5 minutes with the load suitably
distributed.
c. Load-testing may be done concurrently with
the trial lift.
d. After load-testing, any deficiencies revealed
during the inspection shall be corrected and
another load test shall be conducted.
e. Structural repair or modification to the
Section 44
platform requires load-testing to 150 percent
of the rated capacity.
f. When feasible, the hoisting equipment to be
used for lifting personnel should be the
equipment used to perform the load-test at
the job site.
g. Dated test reports shall be kept on file and
shall be readily available to appointed
personnel.
4.6.3 HOISTING EQUIPMENT
a. Hoisting equipment shall be tested in
accordance with requirements of Chapter 7,
“Overhead & Gantry Cranes,” or Chapter 9,
“Mobile Cranes.
DOE-STD-1090-2004
4.7 LIFTING PERSONNEL NEAR ELECTRICAL POWER LINES
4-11 Chapter 4
Lifting Personnel
4.7.1 GENERAL
a. When lifting personnel near electrical power
lines, it is advisable to perform the lift so
there is not possibility of the crane, load
line, or personnel platform becoming a
conductive path.
b. Cranes shall not lift personnel under
electrical power line if any combination of
boom, personnel platform, load line, or
machine components will enter the
prohibited zone (See figure 4-3).
c. Lifting personnel near electrical power lines
is not allowed unless there is no less
hazardous way to perform the job. The
following conditions must be considered
when lifting personnel near electrical power
lines:
4.7.2 CONDITION A
a. Power Lines are de-energized and grounded.
(The safest and preferred condition). The
following steps shall be taken when lifting
personnel in Condition A:
1. The electrical utility organization shall
de-energize the power lines.
2. As a minimum, the power lines shall be
visible grounded to avoid the possibility
of electrical feedback.
3. Before lifting personnel, a qualified
representative from the electrical utility
organization shall be on site to verify
that the power lines are de-energized
and grounded.
4. In addition to Electrical Hazard
Warning Signs required on all mobile
cranes, Electrical Hazard Warning
Signs shall be posted inside the
personnel lift platform.
5. Proximity warning devices, insulated
links or boom cages, if used, shall not
be a substitute for any requirements of
this section.
4.7.3 CONDITION B
a. Power lines are energized with the
equipment outside the prohibited zone, but
working within a fully extended boom
length of the prohibited zone. Regardless of
whether the crane boom will be fully
extended, the fully extended boom length
shall be considered (see figure 4-4). The
following steps shall be taken when lifting
personnel in Condition B:
1. A meeting, on the job site, between the
Personnel Lift Authorizing Manager,
the Designated Leader, and a qualified
representative of the electrical utility
organization shall take place.
Procedures to safely complete the lift
shall be established.
2. The clearance specified in Table 4-1
shall be considered.
3. Power line movements, horizontal and
vertical, caused by wind shall be
considered.
4. The required clearances to the power
lines shall be continuously monitored
by a signal person, also called a “wire
watcher,” whose sole responsibility is to
maintain proper clearance. The “wire
watcher” shall be in constant
communication with the crane operator.
5. Tag lines to the personnel platform,
when used, shall be of a nonconductive
type, such as dry rope made of
polypropylene or polyethylene fiber.
6. No person outside the platform or crane
cab shall be permitted to touch the
crane, load line or platform unless the
“wire watcher” indicates it is safe.
7. Operation of the boom or the platform
Section 45
over power lines should be avoided.
Poor perception of distance and
multiple potential contact points make
this very hazardous.
DOE-STD-1090-2004
Chapter 4 4-12
Lifting Personnel
8. Consider attaching ribbons, balls, or
other visibility enhancing devices, to
the power line to aid in visually locating
the prohibited zone.
9. In addition to Electrical Hazard
Warning Signs required on all mobile
cranes, Electrical Hazard Warning
Signs shall be posted inside the
personnel lift platform.
10. Proximity warning devices, insulated
links or boom cages, if used, shall not
be a substitute for any requirements of
this section.
4.7.4 CONDITION C
a. Power lines are energized with the
equipment inside the prohibited zone (See
Table 4-1). Lifting personnel in the
condition is strictly prohibited.
Table 4-1. Safe working distance from power lines
a. When operating near high-voltage power lines:
Normal voltage
(phase to phase)
Minimum required
clearance
to 50 kV
Over 50 to 200 kV
Over 200 to 350 kV
Over 350 to 500 kV
Over 500 to 750 kV
Over 750 to 1000 kV
10 ft ( 3.1 m)
15 ft ( 4.6 m)
20 ft ( 6.1 m)
25 ft ( 7.6 m)
35 ft (10.7 m)
45 ft (13.7 m)
a. While in transit with no load and boom or mast lowered:
Normal voltage
(phase to phase)
Minimum required
clearance
to 0.75 kV
Over 0.75 to 50 kV
Over 50 to 345 kV
Over 345 to 700 kV
Over 750 to 1000 kV
4 ft (1.2 m)
6 ft (1.3 m)
10 ft (3.5 m)
16 ft (4.9 m)
20 ft (6.1 m)
DOE-STD-1090-2004
4-13 Chapter 4
Lifting Personnel
Figure 4-3. Danger Zone for Cranes and Lifting Personnel Near Electrical Transmission
Line
DOE-STD-1090-2004
Chapter 4 4-14
Lifting Personnel
Figure 4-4. Danger Zone for Cranes Lifting Personnel Near Electrical Transmission
Lines
DOE-STD-1090-2004
4-15 Chapter 4
Lifting Personnel
Page 1 of 1
EXHIBIT I
(SAMPLE FORM ONLY)
PERSONNEL LIFT PLATFORM PRE-LIFT INSPECTION
Inspector: ____________________________________Date: ________________________
Platform Identification Number: _______________________________________________
1. Trial Lift Completed with anticipated lift weight: ______________________(lbs. or kg)
2. Markings Satisfactory Unsatisfactory
Platform (All Information Legible) ( ) ( )
Suspension System ( ) ( )
3. Structure
Load Supporting Welds/Bolts ( ) ( )
Load Supporting Members ( ) ( )
Barrier From Toe Board to Intermediate Rail ( ) ( )
Hand Rail ( ) ( )
Fall Protection Device Anchorage Points ( ) ( )
Gate Locking Mechanisms ( ) ( )
Platform Flooring ( ) ( )
Suspension Attachment Points ( ) ( )
4. Attachment Mechanisms
Pins/Ears/Bolt-Up’s/eyes (circle) ( ) ( )
Wire Rope/Chains/Rigid Leg (circle) ( ) ( )
Master Links ( ) ( )
5. Special Purpose Items
(i.e., Overhead Protection, Floatation, Platform Controls)
List: 1) __________________________ ( ) ( )
2) __________________________ ( ) ( )
3. __________________________ ( ) ( )
6. General Comments:
Designated Leader Signature: ___________________________ Date: ________________
DOE-STD-1090-2004
Chapter 4 4-16
Lifting Personnel
Page 1 of 1
EXHIBIT II
(SAMPLE FORM ONLY)
PERSONNEL LIFTING PLANNING AND AUTHORIZATION
1. Location: __________________________________Date:__________________________
2. Purpose of Lift: ___________________________________________________________
3. Hoisting Equipment Manufacturer: ____________________________________________
Section 46
Model Number: ___________________________________________________________
Serial Number: ____________________________________________________________
4. Expected Radius: ________________________________________________ (Maximum)
_____________________________________________________________(At Work Location)
5. (A) Rated Load at Radius: ___________________________________________________
(B) Maximum Lifted Load (50% of 5A) ________________________________________
6. (A) Platform Identification: __________________________________________________
(B) Platform Rating: _______________________________________________________
7. Platform Weight: __________________________________________________________
8. (A) Number of Platform Occupants: ___________________________________________
(B) Approximate Weight (with equipment): _____________________________________
9. Total Lift Weight: _____________________________[(7 + 8B)(No more than 5B above)]
10. Personnel Lift Supervisor: __________________________________________________
11. What are the alternatives to this personnel lift? __________________________________
____________________________________________________________________________
____________________________________________________________________________
12. Why are they not being used? ________________________________________________
____________________________________________________________________________
____________________________________________________________________________
13. Pre-Lint Briefing Held:______/____/________ Time:_______________________AM/PM
Attendees: _______________________________________________________________
____________________________________________________________________________
14. Anticipated Hazards (wind, weather, visibility, power lines): _______________________
____________________________________________________________________________
15. Lift Accomplished Date: :______/____/________ Time:_____________________AM/PM
16. Remarks: ________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
Designated Leader Signature:_____________________________ Date: ________________
DOE-STD-1090-2004
CHAPTER 5
HOSTILE ENVIRONMENTS
5-i Chapter 5
Hostile Environments
This chapter describes provisions for hoisting and rigging operations in hostile work environments.
5.1 GENERAL ................................................................................................................................5-1
5.2 HOSTILE ENVIRONMENT PLAN ......................................................................................5-2
5.2.1 Marking and Posting....................................................................................................5-2
5.2.2 Inspection and Testing .................................................................................................5-2
EXHIBIT I Hostile Environment Plan ............................................................................................5-3
DOE-STD-1090-2004
Chapter5 5-ii
Hostile Environments
INTENTIONALLY BLANK
DOE-STD-1090-2004
5.1 GENERAL
5-1 Chapter 5
Hostile Environments
Section 47
a. This chapter contains the special provisions
for hoisting and rigging operations and
equipment in hostile environments where
standard operating, maintenance, inspection,
or test procedures cannot be followed as a
result of radiation or radioactive
contamination, toxic/hazardous chemicals or
gases, or temperature extremes.
b. Hoisting and rigging activities can usually
be accomplished where the environment will
allow normal operations with access for
hands-on equipment contact. In those
situations, operations, maintenance,
inspections, and tests shall be done in
accordance with regular provisions of this
standard.
c. Hoisting and rigging equipment or
operations shall be reviewed by a designated
person to determine compliance with the
requirements of this standard. If it is
determined to be impossible or unreasonable
for the requirements of this standard to be
met as a result of hostile environmental
conditions, a hostile environment plan shall
be prepared to document alternative
compliance methods and procedures.
d. All hoisting and rigging operations shall be
consistent with DOE’s policy of as-low-as-
reasonably achievable (ALARA) radiation
exposure.
e. Safety of personnel shall remain the first
priority.
DOE-STD-1090-2004
5.2 HOSTILE ENVIRONMENT PLAN
Chapter 5 5-2
Hostile Environments
a. A hostile environment plan shall be prepared
by a designated person and shall cover
operations, equipment, inspection, testing,
and maintenance. See Exhibit I, Hostile
Environment Plan, at the end of this chapter.
b. At a minimum, the plan shall be reviewed
and approved by responsible management at
the facility where the crane, hoist, or other
equipment is located and by responsible
management of an overview organization
such as safety or quality assurance. While
the site-specific organizational structure will
determine other required reviews and
approvals, approval by the following is
recommended:
1. Responsible operations manager.
2. Equipment custodian.
3. Cognizant engineer.
c. The plan shall address only those actions or
features that require deviation from the
requirements of this standard due to a hostile
environment. At a minimum, it shall
contain the following information:
1. The specific requirements that cannot
be met.
2. The difference between the requirement
and actual conditions.
3. Justification for not meeting this
standard’s requirements.
4. A statement of actions or features to be
used to compensate for the differences.
5. Specific maintenance, inspections, and
tests to be performed whenever access
is possible.
6. Replacement or retirement criteria for
equipment that is designed to operate
with little or no maintenance.
d. Detailed operation, inspection, testing, and
maintenance procedures that state specific
requirements and acceptance criteria shall be
prepared, based on the hostile environment
plan.
e. The responsible manager shall ensure that
the approved hostile environment plan is
distributed as follows:
1. DOE Field Office or equivalent (for
information).
2. Equipment operators, maintenance
organizations, and other
organizations/personnel affected by the
plan.
3. Equipment history file.
f. Hostile environment plans in the equipment
history file shall be readily available to
appointed personnel.
5.2.1 MARKING AND POSTING
Equipment the use of which is required by a
hostile environment plan shall be posted with the
following information: “Special Maintenance
and Operating Instructions Required – see
Hostile Environment Plan.”
Section 48
5.2.2 INSPECTION AND TESTING
a. Handling fixtures and rigging accessories
shall be qualified in accordance with
Chapters 11, 12, and 14 (“Wire Rope and
Slings,” “Rigging Accessories,” and
“Below-the-Hook Lifting Devices,”
respectively) of this standard prior to being
exposed to the hostile environment.
b. Nylon (rope or webbing) slings should not
be used in a radiation area unless absolutely
necessary. When it is necessary to use a
nylon or polyester sling in a radiation area,
the responsible manager shall ensure that
radiation exposure does not exceed 100,000
rad during the life of the sling.
DOE-STD-1090-2004
5-3 Chapter 5
Hostile Environments
EXHIBIT I
HOSTILE ENVIRONMENT PLAN
Building:______________________________ Location:____________________________
Type crane/hoist:_____________________________________________________________
(e.g., overhead top-running bridge and trolley, top-running bridge with underhung hoist, jib crane, monorail
hoist, overhead hoist)
Capacity:_____________________ (Auxiliary):____________________________________
Power method:_______________________________________________________________
Manufacturer:________________________________________________________________
1.a H&R standard requirement that will not be met
Section number:_________________________
(copy the applicable section)
_____________________________________________________________________
_____________________________________________________________________
_____________________________________________________________________
1.b Difference between standard requirement and what is to be allowed by this plan:
_____________________________________________________________________
_____________________________________________________________________
1.c Justification for not meeting the standard requirement: _________________________
_____________________________________________________________________
_____________________________________________________________________
1.d Actions or features to compensate for differences: _____________________________
______________________________________________________________________
Include information regarding replacement or retirement criteria for this equipment. Include information
regarding any special design, maintenance, or test considerations that apply to this equipment.
____________________________________________________________________________
____________________________________________________________________________
____________________________________________________________________________
APPROVAL (Signature/date)
*Facility Manager: __________________________________Date:______________________
*Manager, Oversight Organization: _______________________Date:____________________
Other: ____________________________________ Date: ____________________________
____________________________________ Date: ____________________________
____________________________________ Date: ____________________________
*means approval is mandatory
DOE-STD-1090-2004
Chapter 5 5-4
Hostile Environments
INTENTIONALLY BLANK
DOE-STD-1090-2004
CHAPTER 6
PERSONNEL QUALIFICATION AND TRAINING
6-i Chapter 6
Personnel Qualification and Training
This chapter describes personnel qualification and training. Only qualified personnel shall operate the
equipment covered in this standard.
6.1 GENERAL ................................................................................................................................6-1
Section 49
6.2 QUALIFICATION...................................................................................................................6-2
6.2.1 General.........................................................................................................................6-2
6.2.2 Operators of Cap-Operated and Pulpit-Operated Cranes .............................................6-2
6.2.3 Operators of Mobile Cranes.........................................................................................6-2
6.2.4 Operators of Truck Mounted Cranes – Capacity 1 Ton or Less ..................................6-4
6.2.5 Operators of Floor-Operated Cranes and Hoists ..........................................................6-4
6.2.6 Operators of Remote Operated Cranes ........................................................................6-4
6.2.7 Operators of Forklift Trucks ........................................................................................6-4
6.2.8 Riggers.........................................................................................................................6-4
6.2.9 Person-In-Charge (PIC) ...............................................................................................6-4
6.2.10 Designated Leader .......................................................................................................6-5
6.2.11 Inspectors .....................................................................................................................6-5
6.2.12 Instructors ....................................................................................................................6-5
6.2.13 First-Line Supervisors..................................................................................................6-5
6.2.14 Maintenance Personnel ................................................................................................6-5
6.3 TRAINING ...............................................................................................................................6-7
6.3.1 General.........................................................................................................................6-7
6.3.2 Operators of Cap-Operated, Pulpit-Operated, and Floor-Operated Cranes..................6-7
6.3.3 Mobile Crane Operators...............................................................................................6-8
6.3.4 Operators of Truck Mounted Cranes – Capacity 1 Ton or Less ..................................6-8
6.3.5 Forklift Truck Operators ..............................................................................................6-8
6.3.6 Riggers.......................................................................................................................6-10
6.3.7 Inspectors ...................................................................................................................6-10
6.3.8 Instructors ..................................................................................................................6-11
6.3.9 Maintenance Personnel ..............................................................................................6-11
6.4 REQUALIFICATION ...........................................................................................................6-12
6.5 RECORDS ..............................................................................................................................6-13
DOE-STD-1090-2004
Section 50
Chapter 6 6-ii
Personnel Qualification and Training
INTENTIONALLY BLANK
DOE-STD-1090-2004
6.1 GENERAL
6-1 Chapter 6
Personnel Qualification and Training
a. This chapter delineates the requirements for
the qualification and training of operators,
riggers, inspectors, maintenance personnel,
trainers, person-in-charge (PIC), designated
leaders, and first-line supervisors.
b. Personnel who are designated to operate
equipment or perform work covered by this
standard shall be qualified and trained to the
level of proficiency consistent with assigned
tasks.
DOE-STD-1090-2004
6.2 QUALIFICATION
Chapter 6 6-2
Personnel Qualification and Training
6.2.1 GENERAL
Only qualified personnel or trainees, under the
direct supervision of qualified personnel, who
meet the following requirements shall be allowed
to rig, operate, inspect, or perform maintenance
on cranes, hoists, or powered forklift trucks:
a. Be at least 18 years old.
b. Understand spoken and written English or a
language generally in use at the work
location.
6.2.2 OPERATORS OF CAB-
OPERATED AND PULPIT-
OPERATED CRANES
a. Operators and operator trainees shall meet
the following physical qualifications.
1. Have vision of at least 20/30 Snellen in
one eye and 20/50 in the other, with or
without corrective lenses. Operators
whose jobs do not require binocular
vision (operation of cranes with
television cameras or periscope optics)
shall have distant visual acuity of 20/30
in one eye and no specific visual
requirement for the other eye.
2. Be able to distinguish colors, regardless
of position, if color differentiation is
required for operation.
3. Have adequate hearing, with or without
a hearing aid, for specific operation.
4. Have physical strength, coordination,
and sufficient reaction speed to meet the
demands of equipment operation.
5. Show no evidence of physical defects or
of emotional instability that could be a
hazard to themselves or others, or
which, in the opinion of the examiner,
could interfere with their safe
performance; such evidence may be
sufficient cause for disqualification. In
these cases, medical judgments and
tests may be required.
6. Show no evidence of being subject to
seizures or to loss of physical control;
such evidence shall be sufficient reason
for disqualification. Medical
examinations may be required to
determine these conditions.
7. Have normal depth perception, field of
vision, manual dexterity, coordination,
and no tendencies to dizziness or
similar potentially hazardous
characteristics.
8. Have no detectable or known disease or
physical restriction that would render
them incapable of safely operating
equipment or carrying out rigging
duties. Where any deficiency of an
upper or lower extremity exists, the
acceptability of a candidate shall be the
decision of the supervisor, after
consulting with the designated
physician.
b. Operators shall be required by the employer
to satisfactorily pass a written examination
covering operational characteristics,
controls, and emergency control skills.
c. Operators shall be required by the employer
to pass a practical operating skill evaluation.
Qualification shall be limited to the type of
equipment for which the operator is being
evaluated. The actual or simulated
operation shall enable trainees to
demonstrate basic knowledge and skills at a
level that ensures the safety of personnel and
equipment.
6.2.3 OPERATORS OF MOBILE
CRANES
a. Operators and operator trainees shall meet
Section 51
the following physical qualifications:
1. Have vision of at least 20/30 Snellen in
one eye and 20/50 in the other, with or
without corrective lenses.
2. Be able to distinguish colors, regardless
of position, if color differentiation is
required for operation.
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3. Have adequate hearing, with or without
a hearing aid, for a specific operation.
4. Have physical strength, coordination,
and sufficient reaction speed to meet the
demands of equipment operation.
5. Show no evidence of physical defects or
of emotional instability that could be a
hazard to themselves or others, or
which, in the opinion of the examiner,
could interfere with their safe
performance; such evidence may be
sufficient cause for disqualification. In
these cases, medical judgments and
tests may be required.
6. Show no evidence of being subject to
seizures or to loss of physical control;
such evidence shall be sufficient reason
for disqualification. Medical
examinations may be required to
determine these conditions.
7. Have normal depth perception, field of
vision, manual dexterity, coordination,
and no tendencies to dizziness or
similar potentially hazardous
characteristics.
8. Have no detectable or known disease or
physical restriction that would render
them incapable of safely operating
equipment or carrying out rigging
duties. Where any deficiency of an
upper or lower extremity exists, the
acceptability of a candidate shall be the
decision of the supervisor, after
consulting with the designated
physician.
9. Shall successfully pass with a negative
result, a substance abuse test. The level
of testing will be determined by the
standard practice for the industry where
the crane is employed and this test shall
be confirmed by a recognized
laboratory service.
10. Operator physical examinations shall be
required every three years or more
frequently if supervision deems it
necessary.
b. Operators shall be required by the employer
to satisfactorily pass a written examination
covering operational characteristics,
controls, and emergency control skills such
as response to:
1. Fire.
2. Power line contact.
3. Loss of stability.
4. Control malfunction.
5. As well as characteristic and
performance questions appropriated to
the crane type for which qualifications
is sought.
c. Operators shall demonstrate their ability to
read, write, comprehend and exhibit
arithmetic skills and load/capacity chart
usage, in the language of the crane
manufacturer’s operation and maintenance
instruction materials.
d. Operators shall satisfactorily complete a
combination written and verbal test on
load/chart usage that covers a selection of
the configurations (the crane may be
equipped to handle) for the type crane for
which qualification is being sought.
e. The operator shall complete a practical
operating skill evaluation test (actual or
simulated), demonstrating proficiency and
basic knowledge in handling the specific
type crane for which the operator is being
evaluated, including:
1. Pre-start and post-start inspection.
2. Maneuvering skills.
3. Shutdown.
4. Securing the crane.
f. Qualification shall be limited to the type of
equipment for which the operator is being
evaluated.
g. Trainee qualification requirements shall
include, but are not limited to the following:
1. Satisfactory completing of a written
examination covering safety,
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Section 52
operational characteristics and
limitations, and controls of the type
crane for which they are being
qualified.
2. Demonstrate their ability to read, write,
comprehend, and exhibit arithmetic
skills and load/capacity chart usage, in
the language of the crane
manufacturer’s operations and
maintenance instruction materials.
3. Satisfactory completion of a
combination written and verbal test on
load/capacity chart usage covering
various crane configurations.
6.2.4 OPERATORS OF TRUCK
MOUNTED CRANES – CAPACITY
1 TON OR LESS
a. Physical qualifications shall be based on
specific job requirements.
b. Operators shall be required by their
employer to pass a practical operating skill
evaluation. Qualification shall be limited to
the type of equipment for which the operator
is being evaluated.
6.2.5 OPERATORS OF FLOOR-
OPERATED CRANES AND
HOISTS
a. Physical qualifications shall be based on
specific job requirements.
b. Operators shall be required by their
employer to pass a practical operating skill
evaluation. Qualification shall be limited to
the type of equipment for which the operator
is being evaluated.
c. The actual or simulated operation shall
enable operators to demonstrate basic
knowledge and skills at a level that ensures
the safety of personnel and equipment.
6.2.6 OPERATORS OF REMOTE
OPERATED CRANES
a. The use of remote-controlled equipment
involves such a wide variety of service
requirements and conditions that each
installation should be carefully analyzed and
operation reviewed to determine whether
sections 6.2.2.a or 6.2.5.a should apply.
b. Operators shall be required by the employer
to satisfactorily pass a written examination
covering operational characteristics,
controls, and emergency control skills.
c. Operators shall be required by their
employer to pass a practical operating skill
evaluation. Qualification shall be limited to
the type of equipment for which the operator
is being evaluated.
d. The actual or simulated operation shall
enable operators to demonstrate basic
knowledge and skills at a level that ensures
the safety of personnel and equipment.
6.2.7 OPERATORS OF FORKLIFT
TRUCKS
a. Physical qualifications shall be based on
specific job requirements.
b. Operators shall be required by the employer
to pass a practical operating skill evaluation.
Qualification shall be limited to the type of
forklift for which the operator is being
evaluated.
c. The actual or simulated operation shall
enable operators to demonstrate basic
knowledge and skills at a level that ensures
the safety of personnel and equipment.
6.2.8 RIGGERS
Riggers shall be required to pass a practical
rigging skill evaluation that requires the use of
rigging equipment in safe configurations. The
actual or simulated operation shall enable
personnel to demonstrate basic knowledge and
skills at a level that ensures the safety of
personnel and equipment.
6.2.9 PERSON-IN-CHARGE (PIC)
The PIC shall have the necessary knowledge and
experience of the specific type of equipment and
completion of the operation. The PIC shall
understand the rules and procedures
implemented at the site to ensure that the
following are completed:
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a. Necessary administrative requirements.
b. Personnel assignments and responsibilities.
c. Selection of proper equipment/tools.
d. Recognition and control of hazardous or
unsafe conditions.
e. Job efficiency and safety.
Section 53
f. Critical-lift documentation.
In addition, the PIC shall:
a. Direct operations in the case of an accident.
b. Exercise authority to start and stop work
activities.
6.2.10 DESIGNATED LEADER
The designated leader shall have sufficient
knowledge and experience to accomplish the
following responsibilities:
a. Ensure that personnel involved understand
how the lift is to be made.
b. Ensure that the weight of the load is
determined and that proper equipment and
accessories are selected.
c. Survey the lift site for hazardous or unsafe
conditions.
d. Ensure that equipment is properly set up and
positioned.
e. Ensure that a signaler is assigned, if
required, and is identified to the operator.
f. Direct the lifting operation to ensure that the
job is done safely and efficiently.
g. Stop the job when any potentially unsafe
condition is recognized.
h. Direct operations if an accident or injury
occurs.
6.2.11 INSPECTORS
a. Qualified inspectors shall have the necessary
knowledge and experience to properly
inspect hoisting and rigging equipment.
b. Employees who operate cranes to perform
crane inspections shall be trained and
qualified to operate the crane on which the
inspection is being performed. See general
and crane specific qualification requirements
in Section 6.2., “Qualification.”
c. Crane operation by crane inspectors shall be
limited to those crane functions necessary to
perform the inspection on the crane.
6.2.12 INSTRUCTORS
Instructors responsible for developing or
presenting hoisting and rigging training
programs shall meet the qualification standards
specified by the responsible training
organization.
6.2.13 FIRST-LINE SUPERVISORS
The first-line supervisor of hoisting and rigging
operations should be knowledgeable of the
specific types of hoisting and rigging operations
under their supervision and their operational
hazards. The supervisor shall be familiar with
applicable rules and procedures implemented at
the site to ensure that hoisting and rigging work
under their control is done efficiently and safely,
with safety as top priority. Supervisors should
ensure that employees fully understand the
importance of safety and that they recognize
their own authority and responsibility to stop
work when safety is questionable.
6.2.14 MAINTENANCE PERSONNEL
a. Employees who operate cranes to perform
crane maintenance shall be trained and
qualified to operate the cranes on which
maintenance is being performed.
b. Crane operation by maintenance personnel
shall be limited to those crane functions
necessary to perform maintenance on the
crane or to verify the performance of the
crane after maintenance has been performed.
c. Employees who perform maintenance
activities on equipment covered by this
standard should have an understanding of
the following criteria:
1. The tools to safely accomplish their
work.
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2. Access to operating instructions to
perform adjustments.
3. Parts information furnished by the
manufacturer or the responsible
maintenance/engineering organization.
4. Manufacturers’ recommendations as to
points and frequency of lubrication and
levels and types of lubricant to be used.
5. Maintenance and repair procedures
recommended by the manufacturer or
responsible maintenance/engineering
organization.
6. Wiring diagrams.
7. Documentation requirements for
maintenance and repair.
DOE-STD-1090-2004
6.3 TRAINING
Section 54
6-7 Chapter 6
Personnel Qualification and Training
6.3.1 GENERAL
a. Organizations that employ personnel who
operate, rig, inspect, or perform maintenance
on equipment covered in this standard shall
provide training programs, including a
means of evaluation, to ensure that the
personnel are competent to perform the
operations. This training shall also include
applicable site-specific hoisting and rigging
procedures which address abnormal or
emergency operations as well possible
equipment failure.
b. The training organization shall use training
methods best suited for the students and the
subject material. This may include, but is
not limited to, computer-aided training,
classroom training, simulated field training,
on-the-job training (OJT), and training by
equipment manufacturer or commercial
training companies.
c. Score standards shall be set for each
examination by the training organization.
The minimum passing score will depend on
the subject, testing technique, and test
difficulty. Management shall determine the
course of action for persons receiving
negative evaluations.
6.3.2 OPERATORS OF CAP-
OPERATED, PULPIT-OPERATED,
AND FLOOR-OPERATED
CRANES
a. Only qualified and authorized operators or
operator trainees under the direct
supervision of a qualified operator shall be
permitted to operate cab-operated, pulpit-
operated, and floor-operated cranes.
b. The initial training of operators shall
include:
1. Applicant training on equipment for
which qualification is sought, under the
direction of a qualified operator or
instructor who is designated by
management to instruct in the operation
of hoisting equipment.
2. Instructor review of the applicant’s
knowledge, including results of written
and oral evaluation, and witnessing a
demonstration of the operator’s skills.
c. Operators should be able to demonstrate a
knowledge of equipment operating
characteristics, capabilities, limitations,
effects of variables, safety features, and
operating procedures. The following
checklist contains basic factors with which
an operator should be familiar. This
checklist must be tailored to suit actual
conditions.
1. Operating characteristics.
2. Environmental hazards – weather.
3. Electrical hazards.
4. Traveling with load.
5. Traveling without load.
6. Lifting personnel.
7. Inspections/tests.
8. Load weight estimation.
9. Emergency procedures.
10. Rigging.
11. Lessons learned.
12. Hand signals.
13. Load dynamics.
14. Applicable standards and regulations.
15. Critical lifts.
16. Safety features of equipment.
17. Terminology and definitions.
18. Ropes and reeving.
19. Two-blocking.
20. Records and documents.
21. Limit switches, warning signals.
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22. Operating practices.
23. Fire protection.
24. Crane components.
25. Access and egress.
26. Warning devices.
6.3.3 MOBILE CRANE OPERATORS
a. Only qualified and authorized operators or
operator trainees under the direct
supervision of a qualified operator shall be
permitted to operate mobile cranes.
b. Operators shall meet the criteria specified in
paragraphs 6.3.2.b and c, and they should
also be able to demonstrate an understanding
of the following:
1. Stability.
2. Load charts.
3. Crane setup.
4. Refueling.
5. Lifting operations involving multiple
cranes.
6. Assembly and disassembly.
7. Outriggers.
8. Operator aids.
6.3.4 OPERATORS OF TRUCK
MOUNTED CRANES – CAPACITY
1 TON OR LESS
Section 55
a. Only qualified and authorized operators or
operator trainees under the direct
supervision of a qualified operator shall be
permitted to operate truck mounted cranes –
capacity 1 ton or less.
b. The initial training of operators shall include
applicable training on equipment for which
qualification is sought, under the direction
of a qualified operator or instructor.
c. Instructor review of the applicant’s
knowledge, shall include results of written
and/or oral evaluation, and witnessing a
demonstration of the operator’s skills.
d. Operators should be able to demonstrate a
knowledge of equipment operating
characteristics, capabilities, limitations,
effects of variables, safety features, and
operating procedures.
6.3.5 FORKLIFT TRUCK OPERATORS
a. Only qualified and authorized operators
shall be permitted to operate powered
forklift trucks. Operator trainees may
operate powered forklift trucks under the
direct supervision of a qualified operator or
trainer and only where such operation does
not endanger the trainee or other employees.
b. The initial training of operators shall
include:
1. A combination of formal instruction
(e.g., lecture, discussion, interactive
computer learning, videotape, written
material).
2. Practical training (demonstrations
performed by the trainer and practical
exercises performed by the trainee).
3. Evaluation of the operator’s
performance in the workplace including
results of written and oral evaluation,
and witnessing a demonstration of the
operator’s skills.
c. The following checklist contains basic
factors with which a forklift truck operator
should be familiar. This checklist must be
tailored to suit actual conditions.
1. Operating instruction, warnings, and
precautions for the type of forklift truck
the operator will be authorized to
operate.
2. Differences between the forklift truck
and the automobile.
3. Forklift truck controls and
instrumentation:
i. Where they are located.
ii. What they do.
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iii. How they work.
4. Engine or motor operation.
5. Steering and maneuvering.
6. Visibility, including restrictions due to
loading.
7. Fork and attachment adaptation,
operation, and use limitations.
8. Forklift truck capacity and load weight
determination.
9. Forklift truck stability and load
dynamics.
10. Forklift truck inspections and
maintenance that the operator will be
required to perform.
11. Refueling and/or charging and
recharging of batteries.
12. Operatin