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RIIMPO320D Conduct Civil Construction Excavator Operations
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© www.pertrain.com.au — J/N 10941-5J — August, 2015Page ii
Conduct Civil Construction Excavator Operations
CONDUCT CIVIL CONSTRUCTION EXCAVATOR OPERATIONS
ContentsGlossary of Terms and Acronyms .............................................................................................................. viii
1. Introduction ......................................................................................................................................... 1
2. Operator Obligations ........................................................................................................................... 2
2.1 Comply with Legislation and Site Procedures ....................................................................... 2
2.1.1 Environmental Legislation ........................................................................................ 4
2.1.2 Cultural Heritage Legislation .................................................................................... 4
2.2 Meet Quality Requirements ................................................................................................... 5
2.3 Safety Obligations ................................................................................................................. 5
2.3.1 Fit For Work.............................................................................................................. 6
3. Civil Construction Sequences ............................................................................................................. 6
3.1 Geological Information ........................................................................................................... 7
3.2 Basic Principles of Soil Technology ....................................................................................... 7
3.2.1 Visual and Feel Moisture Test .................................................................................. 8
3.2.2 Compaction and Swell ............................................................................................. 9
3.3 Levelling .............................................................................................................................. 10
3.4 Survey Information .............................................................................................................. 10
3.4.1 Plans, Drawings and Maps .....................................................................................11
3.5 Earthworks and Load Calculations ...................................................................................... 14
3.5.1 Step 1: Calculate the Area ..................................................................................... 14
3.5.2 Step 2: Calculate the Volume ................................................................................. 15
3.5.3 Step 3: Calculate Load Quantities .......................................................................... 15
3.6 Road Construction Principles .............................................................................................. 16
4. Plan and Prepare for Operations ...................................................................................................... 16
4.1 AttendWorkBriefings .......................................................................................................... 16
4.1.1 Job Requirements ................................................................................................. 17
4.1.2 Site and Task Procedures ...................................................................................... 17
4.2 Interpret Information and Plan Work ................................................................................... 17
4.3 Conduct Site Safety Inspections .......................................................................................... 18
4.4 Exclusion Zone .................................................................................................................... 18
5. Work with Others ............................................................................................................................... 19
5.1 Communication .................................................................................................................... 19
5.1.1 Verbal Communication ........................................................................................... 20
5.1.2 Written Communication .......................................................................................... 21
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5.1.3 Signals ................................................................................................................... 21
5.2 Making Decisions ................................................................................................................ 25
5.2.1 Decision Making Process ....................................................................................... 25
5.3 Directing Operations ............................................................................................................ 25
6. Safety ................................................................................................................................................ 26
6.1 Safety and Health Management System ............................................................................. 26
6.2 Safe Work Method Statements ............................................................................................ 26
6.3 Permit to Work Systems ...................................................................................................... 27
6.4 Personal Protective Equipment (PPE) ................................................................................. 27
6.5 First Aid ................................................................................................................................ 28
6.6 Evacuation Procedures ....................................................................................................... 29
6.7 Manual Handling .................................................................................................................. 29
6.7.1 Team Lifting ............................................................................................................ 30
6.8 Vehicle Safety ...................................................................................................................... 30
6.8.1 Mounting and Dismounting .................................................................................... 30
6.8.2 Housekeeping ........................................................................................................ 31
6.8.3 Seatbelts ................................................................................................................ 31
6.9 GeneralTrafficRules ........................................................................................................... 31
6.10 TrafficManagement ............................................................................................................. 32
7. Hazards ............................................................................................................................................. 33
7.1 HazardIdentification ............................................................................................................ 34
7.1.1 Job Safety Analysis ................................................................................................ 34
7.1.2 Hazard Report ........................................................................................................ 35
7.1.3 Types of Hazards ................................................................................................... 35
7.2 Explosives ........................................................................................................................... 36
7.3 Noise ................................................................................................................................... 36
7.4 Dust and Fumes .................................................................................................................. 37
7.5 Contamination ..................................................................................................................... 37
7.6 Hazardous Chemicals ......................................................................................................... 38
7.6.1 Classes of Hazardous Chemicals .......................................................................... 38
7.6.2 Spillage .................................................................................................................. 39
7.7 Activities with High Risk Potential ........................................................................................ 39
7.8 Electrical Conductors ........................................................................................................... 40
7.9 Underground Services ......................................................................................................... 41
7.9.1 Location of Underground Services ......................................................................... 42
7.9.2 Underground Service Markers ............................................................................... 43
7.10 Working in Trenches and Excavations ................................................................................ 43
7.11 Hazard Control Options ....................................................................................................... 44
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8. Select and Evaluate Equipment for the Job ...................................................................................... 44
8.1 Perform Equipment Checks and Inspections ...................................................................... 45
9. Equipment Isolation and Tagging ...................................................................................................... 46
9.1 Isolation ............................................................................................................................... 46
9.1.1 Electrical Isolation .................................................................................................. 47
9.1.2 Mechanical Isolation ............................................................................................... 47
9.2 General Isolation Procedure ................................................................................................ 48
9.3 Tagging ................................................................................................................................ 48
9.3.1 Personal Danger Tags and Locks .......................................................................... 49
9.3.2 Out of Service Tags ................................................................................................ 49
9.3.3 Information Tags ..................................................................................................... 49
10. Maintenance ...................................................................................................................................... 50
10.1 Preventative Maintenance ................................................................................................... 50
10.1.1 Walkaround Inspections ......................................................................................... 50
10.1.2 Inspection/Defect Reporting ................................................................................... 51
10.2 Operational Maintenance .................................................................................................... 51
10.2.1 Working with Pressure Operated Systems............................................................. 52
10.2.2 Working with Fluids ................................................................................................ 52
10.2.3 Refuelling ............................................................................................................... 54
10.2.4 Fuel Handling ......................................................................................................... 55
10.3 Scheduled Servicing and Operator Maintenance ................................................................ 55
10.3.1 Field Servicing ........................................................................................................ 55
10.3.2 Servicing Safety ..................................................................................................... 56
11. Equipment Familiarisation ................................................................................................................. 56
11.1 General Arrangement .......................................................................................................... 57
11.2 Conduct Pre-Start Inspection .............................................................................................. 59
11.2.1 Walkaround Inspection ........................................................................................... 59
11.2.2 Pre-start Check ...................................................................................................... 59
11.3 Start-up ................................................................................................................................ 59
11.4 Post Start Checks ................................................................................................................ 60
11.5 Moving Off ........................................................................................................................... 60
11.6 Monitor Systems and Alarms ............................................................................................... 60
11.7 Park-up and Shutdown ........................................................................................................ 60
11.8 Emergency Shutdown ......................................................................................................... 61
11.9 Equipment and Procedures Checklists ................................................................................ 61
11.10 Equipment Checklist ............................................................................................................ 62
12. EfficientExcavatorOperations .......................................................................................................... 66
12.1 ProductionEfficiency ........................................................................................................... 67
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13. Moving the Excavator ........................................................................................................................ 67
13.1 Turning................................................................................................................................. 68
13.2 Moving Short Distances ....................................................................................................... 69
13.3 Forward Travel ..................................................................................................................... 69
13.4 Spin Turns ........................................................................................................................... 70
13.5 Reverse Travel .................................................................................................................... 71
13.6 Walking Up an Incline .......................................................................................................... 72
13.7 Walking Down a Decline ...................................................................................................... 72
13.8 Using the Retarder .............................................................................................................. 73
14. Positioning the Excavator .................................................................................................................. 73
14.1 Climbing Up Work Benches ................................................................................................. 73
14.2 Climbing Off Work Benches................................................................................................. 74
14.3 Relocating the Excavator ..................................................................................................... 75
15. Excavator Operating Techniques ...................................................................................................... 76
15.1 Dig Phase ............................................................................................................................ 76
15.1.1 Raising the Bucket ................................................................................................. 77
15.2 Swing Phase ........................................................................................................................ 78
15.3 Dump Phase ........................................................................................................................ 78
15.4 Return Phase ....................................................................................................................... 79
16. Loading Trucks .................................................................................................................................. 79
16.1 Preparation to Load ............................................................................................................. 79
16.2 Loading Method ................................................................................................................... 80
16.3 Load Distribution .................................................................................................................. 81
17. Stockpiling ......................................................................................................................................... 81
17.1 Stockpile Safety ................................................................................................................... 81
17.2 Angle of Repose .................................................................................................................. 82
17.3 Preparation for Stockpiling .................................................................................................. 82
17.4 Stacking Material on a Stockpile ......................................................................................... 83
18. Trenching Techniques ....................................................................................................................... 83
18.1 Trench Digging Technique ................................................................................................... 84
18.2 Trench Grade....................................................................................................................... 84
18.3 Trench Depth ....................................................................................................................... 84
18.4 TrenchProfile ..................................................................................................................... 85
18.5 Technique for Finishing a Straight Trench Wall ................................................................... 85
19. Constructing Drains ........................................................................................................................... 86
19.1 Temporary Drains ................................................................................................................ 86
19.2 Permanent Drains ................................................................................................................ 86
19.3 Catch Drains ........................................................................................................................ 87
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19.4 Diversion Drains .................................................................................................................. 87
19.5 Batter Toe Drains ................................................................................................................. 87
20. BackfillingTrenchesandExcavations ............................................................................................... 88
20.1 Calculating Excavation Fill ................................................................................................... 88
21. Work Area Clean-up Techniques ....................................................................................................... 89
21.1 Clean-up Outside Swing Radius .......................................................................................... 89
21.2 Clean-up Inside Swing Radius ............................................................................................ 89
22. Constructing a Bench ........................................................................................................................ 90
22.1 Levelling .............................................................................................................................. 90
23. Cutting Batters .................................................................................................................................. 91
23.1 Hazard Assessment ............................................................................................................. 91
23.2 Battering Technique ............................................................................................................. 91
24. Preparing to Lift and Carry Materials ................................................................................................ 92
24.1 Lift Operations Plan ............................................................................................................. 92
24.2 Inspect and Control Hazards ............................................................................................... 93
24.3 ConfirmCommunicationMethods ....................................................................................... 93
24.4 Position the Excavator Correctly ......................................................................................... 94
24.5 Check the Load Radius ....................................................................................................... 94
24.6 Establish the Weight of the Load ......................................................................................... 95
24.7 Check the Excavator Lifting Capacity .................................................................................. 95
25. Select and Attach Lifting and Slinging Equipment ............................................................................. 97
25.1 Inspect the Equipment ......................................................................................................... 97
25.2 Check the Working Load Limit ............................................................................................. 98
25.3 Determine the Method of Slinging ....................................................................................... 98
25.4 Attach the Lifting Equipment .............................................................................................. 100
26. Lifting and Carrying Materials ......................................................................................................... 101
26.1 Conduct a Trial Lift ............................................................................................................. 101
26.2 Lift and Carry the Load ...................................................................................................... 101
26.3 Lifting on Side Slopes ........................................................................................................ 102
27. Dipper Arms .................................................................................................................................... 102
28. Excavator Attachments ................................................................................................................... 103
28.1 Selecting Attachments ....................................................................................................... 104
28.2 Fitting and Removing Attachments .................................................................................... 104
28.3 Testing the Attachments .................................................................................................... 105
28.4 Using the Attachments ....................................................................................................... 105
28.5 Cleaning and Storing Attachments .................................................................................... 106
29. Loading the Excavator for Transport ............................................................................................... 106
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29.1 Unloading the Machine ...................................................................................................... 107
30. Environmental Conditions ............................................................................................................... 107
30.1 Dusty Conditions ............................................................................................................... 107
30.2 Rain/Wet Conditions .......................................................................................................... 107
30.3 Fog .................................................................................................................................... 108
30.4 Lighting Hazards ................................................................................................................ 108
30.5 Operating at Night ............................................................................................................. 109
31. Responding to Emergency Situations ............................................................................................. 109
31.1 Emergency Response ....................................................................................................... 109
31.2 On-board Fires ...................................................................................................................110
31.3 Loss of Control ...................................................................................................................110
31.4 Rollover ..............................................................................................................................110
31.5 Breakdown .........................................................................................................................111
31.5.1 Recovering Your Machine .....................................................................................111
31.6 Incidents Involving Vehicles ................................................................................................111
32. Post Operational Tasks ....................................................................................................................112
32.1 Storing Tools and Equipment ..............................................................................................112
32.2 Work Area Clean-up ...........................................................................................................112
32.2.1 Waste Management ..............................................................................................113
32.2.2 Hazardous Chemical Disposal ..............................................................................113
32.3 End of Shift Reports ...........................................................................................................114
33. Completing Your Training Program ..................................................................................................114
33.1 Formal Assessment Process ..............................................................................................114
34. Summary ..........................................................................................................................................114
1. Lifting and Slinging Equipment .........................................................................................................116
1.1 Natural Fibre Rope .............................................................................................................116
1.1.1 Fibre Rope Inspection ...........................................................................................116
1.2 Synthetic Rope ...................................................................................................................117
1.3 Synthetic Webbing Slings ...................................................................................................118
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Disclaimer
This resource has been developed after extensive consultation with industry partners. It is a collaborative view anddoesnotnecessarilyrepresenttheviewofanyspecificbody.Forthesakeofbeingconcise,itmayomitfactors that could be pertinent in particular cases. This product is meant for educational purposes only and is not a substitute or replacement for the workplace's existing policy and procedures.
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1. IntroductionThis training resource is provided to introduce you to equipment operations, the obligations you have as an operator and the procedures used while performing work. It also outlines the ways in which you canimprovesafetyandefficiencybycorrectlyusingthemachineyouareoperating.
Usethistrainingresourceinconjunctionwiththeequipmentmanufacturer'smanualforthespecificoperating procedures of the machine and refer to the site operating procedures.
This resource contains information that will assist you to:• plan and prepare for operations• select and maintain appropriate plant and equipment• work safely on site• work with others to achieve the required outcomes• identify hazards and apply controls• respond appropriately in an emergency.
NOTE This training resource is a guide only. Always follow site procedures when performing your work.
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2. Operator ObligationsAs an operator you have an obligation to ensure the safety and health of yourself and others and to protect the environment in which you work.
The following actions will help you to do this.• Ensurethatyouarephysicallyandmentallyfitforworkbefore
starting any job.• Comply with your organisation's Code of Conduct
on how you interact with others, for example, no bullying, discrimination, unethical or unsafe behaviour.
• Donotattemptanytaskunlessyouarequalifiedandauthorisedto perform the task.
• Make sure that you have the required licences and permits to perform your work and that they are current. Advise your supervisor immediately if you lose your licence or permit.
• Select, check and use the correct personal protective equipment (PPE). Make sure that the PPEfitsproperlyandissuitableforthetask.
• Report unsafe conditions, activities, incidents or near misses to your supervisor or safety representative.
• Report damaged or defective equipment for repair.• Operateequipmentwithinmanufacturerspecificationsandlimitationsandaccordingtosite
procedures.• Use your site lock and tag system.• Adhere to site environmental guidelines to prevent damage to the natural environment and
designated heritage sites.
2.1 Comply with Legislation and Site ProceduresDuringyourgeneralandsitespecificinductionsyouwouldhave been familiarised with organisational and site policies and procedures. These have been developed in accordance with legislation and are designed to ensure that work is undertaken safely.
Gather and read the relevant documents and procedures for the task that you are doing. Ensure that you understand the documents and how they apply to your work.
The general hierarchy of statutory and organisational compliance documentation is shown in the following table.
HERE‛S TO A SAFEDAY‛S WORK !
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Hand Signals
The following table illustrates some common hand, whistle and horn signals used when on worksites.
Motion Hand SignalWhistle /
Horn SignalMotion Hand Signal
Whistle / Horn Signal
Raise
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2 Short
• •
Lower
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1 Long
—
Luff Up
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3 Short
• • •
Luff Down
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4 Short
• • • •
Slew Right
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1 Long
2 Short
— • •
Slew Left
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1 Long
1 Short
— •
Travel and Traverse
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Not Applicable
Stop
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1 Short
•
NOTE All hand signals must be clearly understood. If there is a signal you do not understand, stop the task and ask for the meaning before proceeding.
Signage
A sign displays a distinct message about how to protect personnel from exposure to hazards. A sign displaying a safety message carries the same authority as a direct instruction from your supervisor. Failure to obey a sign can result in injury or death.
NOTE Signs are placed for your protection. Always keep signs clean and in good condition. Do not remove a sign unless you are authorised to do so.
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The following table displays a sample of each type of sign along with a brief description.
Description Example
Mandatory Signs
Indicate an instruction that must be carried out.
SAFETY FOOTWEARMUST BE WORN
IN THIS AREA
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Prohibitory Signs
Indicate an action or activity that is not permitted.
SMOKINGPROHIBITED
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Warning Signs
Indicate a hazard or hazardous condition that is not likely to be life threatening.
SLIPPERYSURFACE
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Danger Signs
Warn of a hazard or hazardous condition that is likely to be life threatening.
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Emergency Information Signs
Indicate the location of, or direction to, emergency related facilities suchasexits,safetyequipmentorfirstaidfacilities.
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11.1 General ArrangementThe major components of a typical excavator are shown in the following photographs.
ROPS/FOPS
Air Cleaner
Operator Cabin
Engine Compartment
Work Lights
Arm Cylinder
Boom
Boom Cylinder
Bucket Cylinder
Dipper Arm
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Counterweight
Centre Girder
Swing Ring
Exhaust
Boom Cylinder
Front IdlerDrive Sprocket
Carrier Roller
BucketTrack Side Frame
Track
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11.10 Equipment ChecklistEQUIPMENT MAKE _________________________________ MODEL ______________________
EQUIPMENT ID ____________________________ SITE ________________________
It is your responsibility to familiarise yourself with the equipment you will be operating. This may include carrying out pre-start checks, routine operator servicing, maintenance and housekeeping tasks according to the equipment manufacturer recommendations and your site procedures.
NOTE Work with your trainer/supervisor and use these notes to familiarise yourself with the components and operations of the equipment.
Item Description/Notes DemonstratedApplied Under Supervision
Dimensions / Specifications
Height:
Length:
Width:
Weight:
Fuel Capacity:
Other:
Operating Parameters
Engine Speed:
Load Limit:
Other:
Isolations:
• Electrical
• Mechanical
For example: Battery isolation point, Guards
Walkaround Inspection Points
For example: Vehicle components, Fluid levels
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Procedures ChecklistEQUIPMENT MAKE _________________________________ MODEL ______________________
EQUIPMENT ID ____________________________ SITE ________________________
Itisyourresponsibilitytooperatetheequipmentsafelyandefficientlywithintheequipmentcapabilityand limitations, and according to site procedures. You must monitor the equipment during operations and respond appropriately to all indicators and alarms.
NOTE Refer to the equipment Manufacturer’s Manual (MM) instructions for information and required operator responses.
Item Reference Notes on Operating Procedure
Pre-start Procedure
For example: Site Pre-start procedure
Start Up Procedure For example: MM, page .........
Post Start Checks For example: MM, page .........
Monitoring and Responding to Alarms
For example: MM, page .........
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Observe the following guidelines when travelling the excavator.• Monitor ground conditions, especially
if you are travelling near bench edges. Edges may collapse under the machine weight.
• Position the bucket so that it is raised above the ground level and away from the machinery base. This will help machine stability.
• Do not travel with a loaded bucket.• Crowd the bucket in.• Do not swing the upper structure while
travelling.• If you need to reposition the boom
or bucket during travelling, stop the machinefirst.Repositiontheequipment,and then continue travelling.
• Use the high-speed travel mode when travelling, if it is safe to do so.
• Travel in a straight line as much as possible.• Stop the machine frequently to check the temperature of the track rollers.
DANGER Do not hoist or carry personnel in the bucket.
13.1 TurningFollow these guidelines when turning.
• Avoid sharp turns. Make several small turns of 15° to 20° instead.
• When turning, swing the machine to face the direction of travel.
• Avoid reverse propelling. Do not propel in reverse up inclines.
NOTE Move the pedals to neutral and pause before changing directions.
Direction of Travel
Direction of travel
Direction of travelRIGHT
WRONG
FinalDrives
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15 to 20°
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13.2 Moving Short DistancesApply the following steps when moving a short distance, for example moving out from the working face.
1. Keep the stick near vertical when moving short distances.
2. Carry the bucket high enough to avoid collision with the ground.
3. Reverse about half a machine length away from the face.
4. Slew the superstructure 60º to 90º to the undercarriage to clear the face and provide maximum visibility.
5. Continue slewing in the direction of travel.
6. Start to reposition the excavator as you approach the new location.
13.3 Forward TravelWhen travelling forward or changing direction, use the following steps.
Forward
To travel forward, push down on the top of both pedals at the same rate.
Speed is proportional to the distance the pedals are moved from the neutral position.
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Forward Left
To steer to the left while travelling forward, push the right travel pedal forward from the neutral position.
Depending on the degree of turn required, position the left pedal at:
• neutral for a cornering turn
• slightly forward for a sweeping turn.
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Forward Right
To steer right while travelling forward, push the left travel pedal forward from the neutral position.
Depending on the degree of turn required, position the right pedal at:
• neutral for a cornering turn
• slightly forward for a sweeping turn.
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13.8 Using the RetarderThe retarder prevents the travel motors over-speeding and acts as a speed governor when travelling down a decline.
• Press the travel pedals fully in order for the retarder to operate.• Do not reduce engine speed (rpm), as this will stop the retarder from operating.
CAUTION Operate the excavator controls correctly when travelling downhill. If the retarder does not operate correctly, the excavator may accelerate to an uncontrollable speed.
14. Positioning the ExcavatorPositionthemachinecorrectlyandplancarefullyforefficientdiggingoperations.Observethefollowing points when positioning the excavator for digging.
• Check that the excavator is positioned on stable, even ground.
• Do not operate with either track on top of a rock.
• Ensure that there is adequate swing clearance, especially at the rear.
• Position the excavator so that the dig zone is limited to 15° either side of the centreline.
• Ensurethatthereissufficientclearanceto position haul trucks correctly.
14.1 Climbing Up Work BenchesDuring operation of the excavator, you will need to climb up the work bench. Use the following technique to ensure safety and prevent machine damage.
Approach the bench at a 90° angle.
Use the bucket to pull the top section of earth down to lessen the angle of the climb.
Do not exceed a maximum angle of 30° or 59%.
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Push the stick out and place the bucket on top of the bench.
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Dig Zone
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16.3 Load DistributionPoor load placement reduces truck life by increasing wear on the frame, body, engine and suspension. Distribute the load over the axles of the truck (and dog trailer if applicable).
17. StockpilingExcavated material is often stockpiled for storage and later removal by tip trucks, or redistributed asfillintoexcavationsandotherconstructionareas. Before you construct a stockpile, check the stockpiling plan with your supervisor.
17.1 Stockpile SafetyAccess to excavator stockpiling areas is restricted to authorised personnel to prevent incidents occurring due to excavator operations and collapse of stockpiled material, especially after a heavy rainfall. Stockpiles are potentially hazardous due to:
• rilling and erosion• cave-ins• slumping• unseen cavities• poor visibility due to dust.
In hot and dry conditions, water may be sprayed at the stockpile site to prevent excessive dust generation.
Load Placement - Side View
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Stockpiling Excavated Material
Eroded Stockpile
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25.2 Check the Working Load LimitTheSafeWorkingLoad(SWL)andWorkingLoadLimit(WLL)aredefinedasthemaximumloadthata lifting device or arrangement can safely lift, suspend or lower. The term SWL has been replaced by WLL to describe the capacity of lifting equipment.
• Check that WLL tags are attached or load markings are visible where required.• Check the WLL of all lifting and slinging equipment. • You may need to calculate the WLL of FSWR and chains. Check your site documentation for
the appropriate formulae.• Include the weight of the lifting and slinging equipment in the load calculations.• The load radius, equipment rating and lift conditions will affect the WLL.• The WLL of lifting equipment is the lowest rated WLL of all components.
NOTE The WLL of lifting equipment must be clearly marked on the manufacturer’s tag. If the tag is missing, report and isolate the defective item for retagging.
25.3 Determine the Method of SlingingDetermine the safest and most effective method of rigging and slinging the load. The slinging method affects the WLL of the lifting arrangement.
• Use short slings to prevent excessive load swing.
• When two slings are attached to a load and lifting hook, the included angle between the legs determines the load or tension on the individual legs.
• The larger the included angle between the legs, the greater the load is applied to the legs.
• A sling may be capable of lifting a load vertically but when acting with a similar sling, both slings may be overloaded if the angle between is too large.
• A choke hitch on a square load will reduce the WLL by 50%, and on a round load by 25%.
Typical Sling Label
A sewn-on label givesinformation on liftingcapacities in variousconfigurations. It is protected fromabrasion by an overlap. Each sling is clearly stencilled with its Working Load Limit (WLL) in a vertical hitch.
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Correct Sling Use
Not more than 30°
If the sling angle is too great the web can tear at
the nip point
Sling to be protected at these points
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Appendix
APPENDIX
Contents1.3.1 Inspection of Synthetic Fibre Slings ......................................................................119
1.3.2 Sling Storage .........................................................................................................119
1.4 Flexible Steel Wire Rope (FSWR) ..................................................................................... 120
1.4.1 FSWR Inspection ................................................................................................. 120
1.4.2 Calculating SWL/WLL of FSWR ........................................................................... 121
1.5 Chains ............................................................................................................................... 121
1.5.1 Inspection of Chain .............................................................................................. 122
1.5.2 Calculating SWL/WWL of Chain ........................................................................... 122
2. Lifting and Slinging Accessories ...................................................................................................... 123
2.1 Hooks ................................................................................................................................ 123
2.2 Shackles ............................................................................................................................ 123
2.3 Eyebolts ............................................................................................................................. 124
3. Guidelines for Slinging and Lifting ................................................................................................... 125
4. Terms and Acronyms ....................................................................................................................... 126
5. Supporting Documentation Register ............................................................................................... 128
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1. Lifting and Slinging EquipmentLifting and slinging loads correctly is essential to avoid accidents involving personnel and equipment. Lifting and slinging equipment includes:
• naturalfibreropes• synthetic rope • synthetic slings and webbing
• FSWR• chain.
NOTE All lifting equipment and slings must be inspected before and after use.
1.1 Natural Fibre RopeFibre ropes are sometimes used to restrain load movement. Allfibreropesizesaredefinedbytheirdiameterinmm.Theminimumsizefibreropethatcanbe used as a tagline on loads is 16 mm.
CAUTION Always check the WLL and calculate the weight of the loadbeforeusingfibreropeforlifting.
1.1.1 Fibre Rope Inspection
Inspect rope before each use. Examine the entire length of the rope at intervals of about 30 cm, checking all sides and carefully untwisting the strands slightly. Do not kink the ropes. You should look for:
• cutorbrokenfibres,yarnsorstrands• knots• signs of over-stretching, including broken
yarns and reduced diameter• discolouration due to excessive heat• sunrot• scorched rope• high stranding
• brittle yarns or strands• faulty splices• mildew• acid burns or effects from corrosive
agents• powdery dust, which is a sign of internal
wear.
NOTE If there is doubt about rope condition, tag it as defective or destroy the rope immediately.
Naturalfibreropeissubjecttodeteriorationandweakeningifitisnotstoredandmaintainedcorrectly.
Three Strand Rope
Right HandLay on rope
Right HandLay on rope
Left HandLay on rope
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Thecorrectstorageandcarewillextendtheservicelifeofnaturalfibreropes.• Alwaysstorenaturalfibreropeinadryplace.• Do not store in closed containers.• Donotstoreonthegroundorfloor.• Do not store in direct sunlight or exposed to the weather.• Neverstoreropenearfire,excessiveheat,acidsandotherchemicals.
1.2 Synthetic RopeSynthetic rope generally has superior strength andhandlingcharacteristicstonaturalfibrerope but the surface of the rope presents a smooth, slippery surface. This makes synthetic rope more prone to slipping and can lead to the failure of knots and bends.
NOTE In the absence of positive identification,theWLListhesameasnaturalfibreropeofequivalent size.
The following list of generally available synthetic ropes together with a comparison of breaking strengths can be used as a guide to their lifting properties.
Type Guide Only
Nylon(Polyamidefilament) Has approximately 2.25 times the breaking strength of natural fibrerope(sizeforsize).Nylonisveryelasticwithaboutfourtimes more stretch than natural rope so has little value for lifting.
Dacron-terylene (Polyester filament)
Hasabouttwicethebreakingstrengthofnaturalfibrerope,butis not as elastic as nylon.
Taniklon(Polyethylenefilament) Hasabout1.45timesthebreakingstrengthofnaturalfibrerope.
Kuralon (Polyvinyl Alcohol)
Hasabout1.25timesthebreakingstrengthofnaturalfibrerope.
Silver Rope (FlatSplitTaniklonfibre)
Hasabout1.16timesthebreakingstrainofnaturalfibrerope,butis30percentlighterthannaturalfibreropeornylon.
Polypropylene The breaking strength is approximately 1.6 times that of natural fibrerope.
Constructions
Three Strand Hawser Laid Rope
Eight Strand Square Rope
Solid Braided Cords
Three stands twisted or laid together to form the rope. This construction is the most commonly encountered. Available in 3 mm diameter upwards.
The balance achieved by platting four right hand and four left hand strands results in a tough kink resistant rope providing increased flexibility wet or dry. Available in 16 mm diameter upwards.
Solid braided cords are constructed from either 12 or 18 strands braced together normally over a centre core. Unlike platted cords, the strands lie in one direction in a spiral direction. Available in 3 mm to12 mm diameter.
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4. Terms and AcronymsThe following are terms commonly used on construction and extractive sites. Space is provided over the page for you to add terms and acronyms common to your site:
Term Meaning
Chainage Thedistancealongasurveylinefromafixedstartingpoint.
Datum Point An arbitrary point to which all other points are referred.
Earthworks Material that must be removed or added to the natural surface.
Grade Level Grade of the roadway surface from the datum point.
Job Safety Analysis (JSA)
A risk management process that focuses on job tasks to identify potential hazards, assess risks and determine suitable controls to manage risks.
A JSA:
• must be completed before a high risk task commences
• is a written record that could be used in a court of law if a serious incident occurs in the workplace
• must be signed off by all parties who have responsibility for the work to be performed under the JSA.
Also called a Job Step Analysis (JSA), Job Safety and Environment Analysis (JSEA) or Job Hazard Analysis (JHA).
Longitudinal Section A cross section of the control line between two chainage measurements.
Permits Permits are required for certain jobs that have high risk potential. Some permits used on work sites include Hot Work Permit, Permit to Dig/Penetrate,ConfinedSpaceandWorkatHeightsPermits.
Site Procedures Site procedures are documented ways of working to achieve an acceptable level of risk. A procedure can be a Standard Work Procedure (SWP), Safe Work Instruction (SWI) or Standard Operating Procedure (SOP). Procedures are a legal requirement and outline the workplace method and processes for carrying out tasks safely and in an environmentally sustainable way. Procedures are developed after consultation with workers and are monitored and amended as required. Procedures contain detailed information such as:
• a description of the task
• a list of tools and equipment required
• informationonidentifiedhazardsassociatedwiththetask
• risk controls, including training requirements
• sequentialstepstoperformthetasksafelyandefficiently
• references to applicable workplace health and safety acts, regulations and policies.
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Appendix
5. Supporting Documentation RegisterUse this register to note the location of important supporting documents such as site operating and safety procedures, work instructions, relevant standards, equipment manuals and safety alerts/bulletins.
Supporting Documentation Register
Document Name Document Description Document Location/How to Access Document
P +61 7 5445 2233 F +61 7 5445 2245
PostalPO Box 713
Buderim Qld 4556Australia
Office8 Ure Court
Buderim Qld 4556Australia
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