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ESH Manual Page: 7000: Occupational Health and Safety
1.0 POLICY

It is the policy of the Sanford Underground Laboratory at Homestake (hereafter referred to as Sanford Lab), that all slings, rigging hardware and Below-the-Hook lifting devices will be load rated and certified by an outside vendor, or by the Sanford Laboratory Engineering Department. Slings, rigging hardware, and Below-the-Hook lifting devices will be inspected regularly, including an initial inspection, pre-use inspection, monthly inspection, and documented annual inspection by a qualified individual. All hoisting activity will be performed and supervised by individuals with documented training. All hoisting and rigging conducted on site will be performed by, supervised by, or reviewed by, the Operations Department.

2.0 SCOPE

This policy applies to any work and individuals at the Sanford Laboratory involved with hoisting and rigging activities. This includes employee, contractors, consultants, and scientists.

3.0 RESPONSIBILITIES

3.1. Operations Department is responsible for overseeing, by performing, supervising, or reviewing all major hoisting and rigging activities at Sanford Laboratories. This does not include activities that are considered routine and are specifically addressed by training requirements.

  • Maintaining a slings, rigging hardware, and Below-the-Hook Rigging device inspection program, and appointing supervisors and foreman to administrate this program.

3.2. The Director of Operations is responsible for:

  • Appointing a qualified individual(s) as the “Subject Matter Expert” with respect to hoisting and rigging.
  • Maintaining a hoisting and rigging training program and establishing training requirements for all Operations personnel involved in hoisting and rigging. This training program will include the incorporation of Lessons Learned from Hoisting and Rigging incidents on a ongoing basis.
  • Conducting a yearly audit of the slings, rigging, and Below-the-Hook Rigging device records.
  • In conjunction with the EH&S Department, conducting a biennial review of the Hoisting and Rigging Program, including a review of this policy to ensure it still meets Sanford Laboratory needs.

3.3. The EHS Department is responsible for:

Auditing Operations for compliance with the requirements of this Policy on an annual basis.

3.4. The Director of Engineering is responsible for appointing a qualified engineer(s) to assist Operations by providing engineering support with respect to the certification and load rating of all the Below-the-Hook lifting devices.

In conjunction with the Operations Department, conducting a biennial review of the Hoisting and Rigging Program, including a review of this policy to ensure it still meets Sanford Laboratory needs.

3.5. Project Managers are responsible for communicating to contractors under their supervision the requirements of this policy. They must also ensure that contractors under their supervision, involved in hoisting and rigging activities are properly trained.

3.6. Supervisor/Forman is responsible for arranging for inspections and the maintenance of inspection records for slings, rigging hardware, and Below-the-Hook lifting devices located in the area under their supervision. Also ensuring that only properly trained individuals are allowed to actively participate in work tasks involving hoisting and rigging activities.

4.0 DEFINITIONS

Additional definitions and terminology are contained in the standards and/or manuals listed below:

  • ASME B30.20 – Below-the-Hook Lifting Devices
  • ASME B30.26 – Rigging Hardware
  • ASME B30.9 – Slings
  • ASME BTH-1 – Design of Below-the-Hook Lifting Devices
  • 29 CFR 1910 and 1926
  • OSHA 1910 and 1926
  • Sanford Lab EHS Manual

Below-the-Hook Lifting Device - equipment (other than slings or rigging accessories) for attaching loads to hoists. These devices are arranged in the following four (4) groups per ASME B30.20.

  • a. Group I Structural and Mechanical Lifting Devices
  • b. Group II Vacuum Lifting Devices
  • c. Group III Magnets, Close Proximity Operated
  • d. Group IV Magnets, Remote Operated

Qualified Person - a person who, by possession of a recognized degree or certificate of professional standing, or who, by extensive knowledge, training and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work (ASME B30.20)

Rigging Qualified Person – A person, who by possession of a recognized degree or certificate of professional standing in applicable field, or who by extensive knowledge, rigging training and experience has successfully demonstrated the ability to solve or resolve problems related to rigging and associated rigging work.

5.0 BELOW-THE-HOOK DEVICES PROGRAM DESCRIPTION

5.1. Engineering Note Procedure

  • A. All Below-the-Hook lifting devices shall meet the requirements of this policy.
  • B. Lifting Fixtures provided and used by outside contractors in execution of their contract work are outside the scope of this engineering note procedure but must adhere to the balance of this document, and be approved/reviewed by Operations prior to use.
  • C. Engineering Notes: An Engineering Note shall be prepared by a qualified person for all Below-the-Hook lifting devices owned by Sanford Lab or collaborating institutions used at Sanford Lab whether purchased or fabricated at Sanford Lab or a collaborating institution. The minimum format for the Engineering Note is shown in the Reference section of this document. The purpose is to allow a reviewer to check the design and to inform future users of the lifting device's limitations.
  1. Engineering Notes for fixtures designed at Sanford Lab or other non-commercial institutions such as Universities or other Laboratories shall include design compliance calculations to verify that the lifting fixture meets as a minimum the requirements of ASME B30.20 and 29 CFR 1910 and 1926.
  2. Engineering Notes for specialized fixtures purchased from a commercial source engaged in the manufacturing of lifting fixtures shall include the manufacturer’s Certificate of Test, copies of the Operator’s Manual and Inspections and Maintenance Instructions.
  3. Modifications to Below-The-Hook Lifting Devices (whether designed at Sanford Lab or other non-commercial institutions such as Universities or other Laboratories or purchased from a commercial source engaged in the manufacturing of lifting fixtures) shall be documented in the Engineering Note.
  4. All Engineering Notes shall include all safety precautions, operating, and maintenance procedures, service or duty cycle rating (if applicable), recommended inspection frequency, and complete nameplate data required for the lifting device.
  5. Where any fixture lifts a load at a point below the center of gravity, the engineering note must explicitly address the issue of the stability of the load and fixture combination.
  6. All Below-the-Hook lifting devices are subject to the test requirements of ASME B30.20, the manufacturer, and this policy. Operational and Load tests shall be performed using hoisting equipment of the proper size and capacity for the device being tested. Load tests shall be documented in the engineering note.
  7. Initial Inspection (per Inspection section of this policy) shall be performed and documented in the note.
  • D. Review of Engineering Notes: All lifting device Engineering Notes shall be reviewed by a qualified person for compliance with the requirements of this policy.
  • E. Amendment of Engineering Notes: All subsequent changes in usage that could affect the safety of personnel or the capability of performance of the lifting device shall require an amendment to the original engineering note. This amendment shall be reviewed in the same manner as the original note.
  • F. Similar Lifting Devices: Lifting devices that are manufactured or fabricated to meet previously engineered, fabricated and reviewed lifting devices need not have the full engineering analysis repeated. Documentation shall be provided by reference to an existing approved Engineering Note and the detailing of all differences. A "Rated Load" test shall be required.
  • G. Director's Exception: A written exception, signed by the Laboratory Director or his designee, allowing for the use of a lifting device is required for use of a lifting device which does not meet the requirements of this policy.
  1. 1) The Supervisor/Foreman head or their designee shall provide a statement showing the necessity for a Director's Exception.
  2. 2) The engineer or designer shall provide a stress analysis of the lifting device.
  3. 3) The lifting device must be tested per the Testing Section of this policy.
  4. 4) The engineer shall provide a fabrication procedure, a list of planned and/or completed record of inspections and any other quality control procedures used.
  5. 5) The engineer shall provide a description of personnel and equipment hazards associated with operation of this lifting device. The hazard analysis shall address the lifting device application, operating limits controls, and inherent safeguards provided.
  6. 6) The EHS Director must concur on such exception.
  • H. Engineering Note for Existing Lifting Devices: Lifting devices currently in use at Sanford Lab shall be inspected and reviewed with an Engineering Note prepared. Lifting devices without an Engineering Note shall not be used.

5.2. Manufacture

  • A. Below-the-Hook lifting devices shall be manufactured to comply with this policy and ASME B30.20.
  • B. Identification shall be a part of the manufacturing process. Each device in service at Sanford Lab shall be permanently labeled with a Sanford Lab lifting device number and other nameplate data. The manufacturer of purchased devices shall affix its nameplate data and label the device with the Sanford Lab device number. (All documentation shall reference the Sanford Lab device number.)

5.3. Testing

  • A. The load rating should not be more than 80% of the maximum load utilized during the test. The tests details shall conform to the specific requirements for the device Group within ASME B30.20 and shall be documented in the Engineering Note. This test shall be conducted and a record signed and dated with the signature of the qualified person. The test documentation shall be included in the Engineering Note.
  • B. Specialized commercially manufactured lifting devices which have certificates of test or existing devices which have documented evidence of having successfully passed a load test do not need to be re-load tested. The only deviation to this occurs when the lifting device had been altered, repaired, or modified. In this case a qualified person must be consulted; they may require further testing.

5.4. Inspections

  • A. All Below-the-Hook lifting devices shall be inspected in accordance with this policy, ASME B30.20, and the manufacturer’s recommendations.
  • B. Initial Inspection - An initial inspection by a qualified person of all new and reinstalled devices is required for commissioning to verify that unit is built and operates to specifications. This inspection shall be documented in the engineering note.
  • C. Per Use Inspection - All devices shall be visually inspected by the operator per B30.20 prior to each use. This is not a documented inspection but will cover the following:
  1. Verification of nameplate, load rating, and validation date of previous annual inspection. The device shall not be used if the nameplate is missing, rated load is insufficient for the lift, or annual inspection is older than one year.
  2. Surface of the load for debris
  3. Condition and operation of controls
  4. Condition and operation of the indicators and meters when installed
  • D. Monthly Inspection – A monthly inspection is required for devices with frequent/regular use. It is a visual, non-documented inspection by a qualified person inspecting the following:
  1. Structural members for deformation, cracks or excessive wear on any part of the lifter
  2. Loose or missing guards, fasteners, covers, stops, or nameplates
  3. All functional operating mechanisms and automatic hold-and-release mechanisms for maladjustments interfering with operation.
  • E. Annual Inspection - An annual inspection must be completed for all devices in use and those to be used that may have been in storage for longer than a 12-month period. The inspection must be documented and records kept by the Supervisor/Foreman and available for review by operators and others requiring access to inspection data and information. The date of the last annual inspection shall be recorded on the lifting fixture. The inspection shall consist of items listed in Monthly Inspection and the following:
  1. Loose bolts or fasteners
  2. Cracked or worn gears, pulleys, sheaves, sprockets, bearings, chains, and belts
  3. Excessive wear of friction pads, linkages, and other mechanical parts
  4. Excessive wear at hoist hooking points and load support clevises or pins
  • F. Infrequently Used Devices
  1. Stored devices do not require monthly and annual inspections until the device is returned to service.
  2. An Annual Inspection must be completed prior to use if such an inspection has not been done in the previous 12-month period. If an inspection is required it must be documented, and records kept by the Supervisor/Foreman and available for review by operators and others requiring access to inspection data and information.
  3. If a device has been inspected in the previous 12-month period then a Per Use Inspection is required prior to use.
6.0 SLINGS AND RIGGING HARDWARE PROGRAM DESCRIPTION

6.1. Manufacture

  • A. Slings and rigging hardware shall be manufactured to comply with the applicable sections of ASME B30.20, ASME B30.26, and ASME B30.9.
  • B. Identification shall be a part of the manufacturing process.
  1. Each sling shall be marked per B30.9 to show the following:
    • a. Name or trademark of manufacturer
    • b. Rated loads for the type of hitch used and the angle upon which it is based
    • c. Diameter or size of sling
  2. Rigging hardware shall be marked per B30.26, including manufacturer’s name or trademark, size or rated load. See B30.26 for marking requirements of specific hardware types.

Note: Hardware labeled with only country of origin does not comply with this standard.

6.2. Use

  • A. All slings and rigging hardware shall be used in accordance with the latest editions of ASME B30.20, ASME B30.26, ASME B30.9, OSHA and the Sanford Lab EHS Manual.
  • B. Slings and rigging hardware that appear to be damaged will not be used for any reason. They are to be destroyed and discarded.
  • C. All slings shall be assigned unique identifying IDs by the responsible Supervisor/Foreman to facilitate sling inspections. All slings shall legibly display the ID as well as the manufacturers load rating tag or be removed from service. All sling ID information shall be recorded on inspection documents.
  • D. The rigging qualified person/operator is responsible for ensuring the sling identification is legible and shows the rated capacities for each type of hitch (vertical, basket and choke), prior to each use.
  • E. Refer to ASME B30.20, ASME B30.26, and ASME B30.9 for further information on use and maintenance.

6.3. Inspections

  • A. Inspections and maintenance of inspection records are the responsibility of the Supervisor/Foreman responsible for the slings.
  • B. All slings and rigging hardware are to be visually inspected prior to every use by the operator [29 CFR 1910.184(d)]. Documentation of pre-use inspections is not required.
  • C. Periodic, documented inspections shall be conducted on all slings and rigging hardware (ASME B30.9 and B30.26) by a qualified person. Inspection forms are provided in the appendices B and C of this policy. Determination of inspection frequency shall be the responsibility of the Supervisor/Foreman responsible for the slings, but such documented inspections shall be conducted at least annually. The frequency of these inspections is to be based on:
  1. frequency of use
  2. severity of service conditions
  3. nature of lifts being made
  4. experience gained on the service life of slings used in similar applications
  • D. Requirements for pre-use and periodic inspection of slings are contained in ASME B30.9 and 29 CFR 1910.184.
  • E. When rigging hardware is in a condition that is questioned by the inspector, a conservative disposal policy should be utilized and the item in question destroyed and discarded.
  • F. On occasion, a particular piece of equipment will come with its own rigging. It is permissible to use this rigging as long as the pre-use and annual inspection criteria are utilized for this equipment.

6.4. Maintenance

Slings and rigging hardware shall be stored in an area where they will not be subjected to mechanical damage, corrosive action, moisture, and extreme temperatures or kinking. Some slings, when stored in extreme temperatures will experience reduced performance. Further consideration should be made with regard to storage and use in extreme conditions.

7.0 REFERENCE AND RELATED DOCUMENTS

7.1. Related Documents

  • Overhead Cranes and Hoists

7.2. References

  • Engineering Note
  • Slings, Rigging Hardware and Below-the-Hook Devices Inspection Form