DOE Standard - Hoisting and Rigging - 2020 Update
DOE Standard - Hoisting and Rigging - 2020 Update
DOE Standard - Hoisting and Rigging - 2020 Update
SENSITIVE
DOE-STD-1090-2020
DOE STANDARD
Foreword
The U.S. Department of Energy (DOE) Hoisting and Rigging Standard is intended to be used by
supervisors, line managers, safety personnel, equipment operators, riggers and other personnel
responsible for the safety of hoisting and rigging operations at DOE sites. It may be used as
either a contract document or as a best practice guide at the site’s or program office’s
discretion.
This Standard establishes planning considerations that apply to industrial load handling
equipment as they pertain to hoisting and rigging operations such as cranes, hoists, gantries,
jibs, monorails, shop cranes, jacks, industrial dollies or rollers, forklifts, slings, rigging hardware,
below-the-hook lifting devices and other associated equipment, covered by the American
Society of Mechanical Engineers (ASME) and the American National Standards Institute (ANSI)
standards when moving loads vertically and/or horizontally. The term “lift” includes all “load
handling activities” (LHA) as defined in ASME B30 Safety Standard: Cranes and Related
Equipment.
The standard invokes applicable OSHA, ASME, ANSI, and national consensus standards but also
defines more stringent provisions necessary to accomplish the 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 referenced industry or
OSHA standards:
• Definition of critical lifts and the additional requirements for making them
• The need for and responsibilities of a lift director for ordinary lifts
As a Technical Standard, this document is not mandated for use at DOE sites. However, this
standard and its predecessor documents have been used for many years by DOE and its
contractors as a valuable resource for conducting hoisting and rigging safely and efficiently. Full
implementation of the provisions of this standard should dramatically strengthen hoisting and
rigging programs throughout the DOE complex and decrease the probability of serious accidents
resulting in personnel injury or death or severe property damage.
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The use of the word “shall” within this standard connotes a mandatory action, whereas use of
the word “should” or “may” connotes a recommended action.
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 a 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 lifting loads with
construction equipment not normally intended for lifting purposes (e.g., excavators,
payloaders). When using rigging hardware or slings with lifting equipment not covered by this
standard, the applicable sections of this standard shall still apply to the rigging hardware and
slings.
In addition, this Standard does not repeat other DOE nuclear regulations, 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 during
hoisting and rigging activities.
This standard requires classification of each lift into one of the DOE categories (ordinary, critical,
or pre-engineered production) before the lift is planned. Sections 1, 2, and 3 of this standard
provide the requirements for ordinary, critical and pre-engineered production lifts.
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CONTENTS
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1.1.2 Hoisting and rigging operations for all lifts require a lift director,
however named, who shall be present at the lift site during the entire
lifting operation. If only one person is making the lift, that person
assumes all responsibilities of the lift director. The lift director shall
have the necessary knowledge and experience of the specific type of
equipment and assigned lifting operations.
1.2.1 Identify the objective of the lift by defining what is being lifted, and the type
of equipment being used to perform the lift.
1.2.2 Ensures that personnel involved understand how the lift is to be made.
1.2.5 Ensures that that lifting equipment, rigging and other accessories are
properly selected such that their rated capacities are not exceeded.
1.2.6 Checks all cranes/hoists to ensure that they are still within the
inspection interval.
1.2.8 Ensures that a preoperational check of all lifting equipment and rigging
is performed to validate compliance with the appropriate sections of
this standard.
1.2.10 Ensures that hoisting routes minimize exposure to personnel and critical
equipment from the hoisted load and that only essential personnel are
allowed within the fall zone.
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1.2.12 Ensures that the load hook is directly over the center of gravity of the
load to the extent possible. Checks the load lines after a strain is put on
them but before the load is lifted clear of the ground; if load lines are
not plumb, repositions the slings or equipment so that the lines are
plumb before continuing.
1.3.1 Lift planning should comply with ASME P30.1, “Planning for Load
Handling Activities,” and shall comply with 48 CFR 970.5223-1,
“Integration of Environment, Safety, and Health into Work Planning and
Execution,” aka Integrated Safety Management System (ISMS). The
following additions and exceptions to the above cited standard should
also be implemented.
1.3.2 A written lift plan beyond normal site work planning and control
documents is not required for ordinary lifts. However, the Lift Director
may determine that a written plan is prudent.
1.3.3 The lift director shall ensure that in addition to the P30.1 “Standard Lift
Plan” considerations, the following pre-lift planning issues are
addressed, as applicable, prior to the lift.
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• Lifting Personnel.
2.1.2 A lift shall be classified critical if any of the following conditions are
met:
OR
2. The lift requires the use of more than one crane or derrick
(refer to § 851.23).
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2.1.5 Lifting Personnel: Though lifting personnel may meet the above
criteria, personnel lifts are addressed by 29 CFR 1926.1431 and ASME
B30.23. Personnel lift planning shall be per ASME B.30.23. The
procedure and rigging sketches shall be reviewed and approved by a
qualified person (technical authority), the responsible manager (or
designee) and the lift director before the lift is made. Subsequent
revisions shall be approved per site-specific procedures.
2.2.1 Ensure that the requirements are met for lifts specified in each section
of this standard for each particular equipment category.
2.2.2 The operating organization shall appoint a person who meets the
criteria for both a competent and a qualified person, 29 CFR 1926.32(f),
or a competent person who is assisted by one or more qualified
persons e.g. Lift Director. The Competent/Qualified person/Lift
Director, however named, shall be present at the lift site during the
entire lifting operation.
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2. Load-indicating devices.
3. Load vectors.
4. Lifting points.
5. Sling angles.
6. Required lifting equipment movement (e.g., boom and
swing angles, trolley and bridge motions).
7. Methods of attachment.
8. Crane orientations.
9. Other factors affecting equipment capacity (e.g., load path
sketch, key point heights, floor or soil bearing capacity).
2.2.5 All rigging equipment used in critical lifts (i.e., slings, below-the-hook
lifting devices, and rigging hardware) shall be proof load tested in
accordance with applicable ASME standards.
2.2.6 Experienced operators who have been trained and qualified to operate
the specific equipment to be used shall be assigned to make the lift.
2.2.7 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.
2.2.8 The procedure and rigging sketches shall be reviewed and approved by
the lift director (however named), a qualified person (technical
authority), the responsible manager (or designee) and provide the
responsible oversight, which should include a competent safety person,
and qualified rigging engineer before the lift is made. Subsequent
revisions shall be approved per site-specific procedures.
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2.2.10 Prior to executing a critical lift, a qualified person shall verify that the
as-installed rigging matches the configuration in the approved lifting
plan.
2.2.11 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 performed by the same crew using the same lifting
equipment that will be used in the lift. The crane/equipment should be
operated through the full range of motion prior to performing the lift.
2.2.12 Although individual plans are generally prepared for critical lifts,
multi-use plans should be employed to accomplish recurrent critical
lifts. For example, a multi-use plan may be used to lift an item or series
of similar items that are handled repeatedly in the same manner.
However, if the lifting equipment or rigging must change to accomplish
the lift, the critical lift plan must be revised and approved accordingly.
3.2.2 Deviations from the national consensus standard requirements for the
inspection, testing, maintenance, modification or repair of specialized
lifting fixtures cannot diminish the level of protection afforded by the
consensus standard and shall also require documented justification and
approval of the:
3.3 Procedures
3.3.1 Content
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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.
3.3.3 Approval
3.4 Training
4.1.1 This section describes provisions for hoisting and rigging operations in
hostile work environments.
4.1.2 This section contains 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 or
other hazards. Hostile environments are environments that have
been rendered inaccessible to workers during hoisting or rigging
operations due to these health hazards.
4.1.3 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 the balance of
this standard or other applicable regulatory requirements.
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4.2.3 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:
4.2.5 The responsible manager shall ensure that the approved hostile
environment plan is distributed as follows:
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4.2.6 Hostile environment plans and the equipment history file shall be
readily available to affected workers and other appointed personnel.
Equipment used under a hostile environment plan shall be posted with the
following information: “Special Maintenance and Operating Instructions
Required – see Hostile Environment Plan.”
4.4.2 Lifting equipment, slings, rigging accessories and fixtures that have been
removed from hostile environments shall be inspected and maintained
per the applicable provisions of this standard prior to their reuse
outside of hostile environments.
4.5.1.1 Occasionally cranes and hoists in hot cells are used as assist
tools rather than as hoisting and rigging equipment. This is
necessary in areas where personnel access is impeded by
radiological conditions. Such cases are considered the
equivalent of hand-carrying material.
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- Injury to personnel
- Damage to equipment
- Environmental impacts
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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:
1a. H&R standard requirement that will not be met
Section number:
(copy the applicable section):
1b. Difference between standard requirement and what is to be allowed by this plan:
1e. Actions to be taken (e.g., inspections, maintenance) for lifting equipment, slings, rigging
accessories and fixtures that will be removed from hostile environments and subsequently reused
to ensure compliance with this Standard, applicable regulatory requirements and manufacturer’s
recommendations prior to their reuse (if applicable):
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:
Other: Date:
Other: Date:
*Approval is mandatory.
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NOTE: Hoisting and rigging personnel includes, but is not limited to, crane
operators, forklift operators, riggers, signal persons, trainees,
inspectors, maintenance personnel, assembly/disassembly
director, and lift directors.
5.2 Qualifications
5.2.3 Each site shall develop a requalification program for hoisting and rigging
personnel. The requalification program shall reflect the complexity or
changing nature of the site’s hoisting and rigging operations and shall,
at a minimum, comply with the qualification requirements referenced
by OSHA, ASME, Industrial Truck Standards Development Foundation
(ITSDF) standards.
5.3 Certification
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5.3.2 A practical operating skill evaluation shall be conducted for the specific
equipment type and/or assigned function. This evaluation shall be
conducted before initial work assignment and must meet OSHA
requirements.
5.4 Records
New, reinstalled, altered, repaired, and modified cranes shall be load tested
prior to initial use. All other provisions of the referenced ASME standard
pertaining to load tests apply.
6.3 Maintenance
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6.4 Operation
6.4.1.2 In those cases where the crane operator cannot see the
signal person, a second person (relay signalperson) shall be
stationed where he or she can see both the signal person
and the crane operator and signals can be relayed to the
operator. The relay signal person shall also be clearly
identified to the crane operator.
7. SECTION – HOISTS
7.1 General Requirements
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7.3 Installation
7.3.1 Procedures
7.3.2 Support
7.4 Inspections
Prior to initial use all new, repaired, or modified hoists shall be inspected by a
qualified person to ensure compliance with applicable standards.
Inspection records shall be kept on file and shall be readily available. For
subsequent periodic inspections, an external coded mark on the hoist is an
acceptable inspection record in lieu of written records.
7.5 Maintenance
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8.2 Maintenance
8.3.1 The signal person shall be clearly identified to the crane operator.
Options for improving signaler visibility include high visibility contrasting
color on hardhats, gloves, or vests.
8.3.2 In those cases where the crane operator cannot see the signal person, a
second person (relay signal person) shall be stationed where he or she
can see both the signal person and the crane operator and signals can
be relayed to the operator. The relay signal person shall also be clearly
identified to the crane operator.
8.4.1 A “dry run” (i.e., without a load or with a mockup load) should be
conducted in areas where clearance is limited or if the complexity of the
lift is deemed sufficiently complex.
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9. SECTION – FORKLIFTS
9.1 General Requirements
Forklift truck operators shall perform a pre-use inspection. Defects found that
effect the safe operation shall be reported and corrected before operation.
Forklift repairs shall be made by authorized personnel.
9.2.1 When a forklift truck is equipped with an attachment, the rated capacity
of the truck/attachment combination shall be established by the truck
manufacturer.
The design, manufacture, use, inspection, and maintenance of slings shall comply
with OSHA 29 CFR 1910.184, 29 CFR 1926.251, ASME B30.9, “Slings,” as well as
manufacturer’s literature, whichever is more stringent. Prior to use, slings shall
be inspected and verified that the periodic inspection is current.
Additions/exceptions to these requirements are provided in this section.
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Individual site programs shall describe how inspections are recorded. These
records may include an external coded mark on the individual sling tag (e.g.,
date, annually changed color stripe, etc.) indicating both periodicity and the
satisfactory completion of the required inspection, or a written record as
acceptable documentation.
The load rating must be determined by the cut protection product manufacturer
or a qualified person.
This section provides direction for the use of rigging hardware plus any DOE
specific requirements related to rigging hardware. Rigging hardware for the
purposes of this chapter includes shackles, eyebolts, eye nuts, links, rings, swivel
hoist rings, swivels, turnbuckles, rigging hooks, compression hardware (wire rope
clips and wedge sockets), rigging blocks, load-indicating devices, and precision
load positioners. Use, inspection, maintenance or repair of rigging hardware
shall comply with applicable OSHA standards, ASME B30.26, “Rigging Hardware,”
or ASME B30.10, “Hooks,” as well as manufacturer’s requirements, whichever is
more stringent. Additions/exceptions to these requirements are provided in this
section.
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11.2.2 Rigging hardware that has been damaged and removed from service
shall be made unusable for hoisting and rigging operations before being
discarded.
12.2 Marking
12.2.1 Product safety labels are not required for site fabricated
below-the-hook lifting devices.
12.2.2 Rated load markings are required. However, cases may exist where a
lifting device cannot be marked with its rated capacity and weight. This
may be due to the security classification of the load to be lifted or other
reasons approved by the responsible manager. In these cases, the lifting
device shall be marked with an identification number, and its
documentation shall describe both its rated capacity and weight.
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This section provides requirements for the operation, inspection, testing, and
maintenance of miscellaneous lifting devices; truck mounted cranes with a
capacity of 1 ton or less not covered in ASME B30.5, “Mobile and Locomotive
Cranes;” and self-contained shop cranes as addressed by ASME PASE, “Portable
Automotive Service Equipment.” Miscellaneous lifting devices may also include
custom lifting hardware where such hardware either does not fall under an
applicable standard or does not have criteria for operation or inspection.
Additions/exceptions to these requirements are provided in this section.
13.3.2 Markings, or decals, etc. must be provided and affixed by the use of
durable materials in a location visible to the operator in order to
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13.3.3 Small cranes 1 ton or less shall have load ratings clearly marked or a
durable rating chart attached in a location accessible to the operator.
13.4 Modifications
A miscellaneous lifting device shall not be loaded beyond its rated capacity,
except for test purposes as described in Subsection 13.11.
Operating controls shall be readily visible and accessible to the operator and
shall not subject the operator to pinch points, sharp edges, or snagging hazards.
Latch-equipped hooks shall be used for all operations unless the application
makes using the latch impractical, unnecessary, or unsafe.
13.8.1 Wire rope, (single line capacity) used on small cranes 1 ton or less
should have a minimum design factor of 3.5:1, based upon breaking
strength.
13.8.2 Small cranes 1 ton or less shall be equipped with properly sized wire
rope sheaves in lieu of flat spools.
13.9 Inspections
Equipment shall operate with a smooth, regular motion without any hesitation,
abnormal vibration, binding, or irregularity. There shall be no apparent damage,
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13.10.1 Prior to initial use, all new miscellaneous devices including small truck
cranes (1 ton or less) and those upon which load-sustaining parts have
been modified, replaced, or repaired shall be load-tested by a qualified
inspector or under the direction of that inspector.
13.10.2 Test loads shall not be less than 100 percent or more than 125 percent
of the rated capacity, unless otherwise recommended by the
manufacturer or a qualified person.
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14. REFERENCES
It is generally recommended that the most recent ASME standards referenced here be
invoked by contract to accompany this standard. However, there may be circumstances
where a site decides to invoke the referenced standards on a periodic basis (e.g., upon
award of a site-wide management contract) and not on an ongoing basis (with running
updates for each minor site contractor or subcontractor.) This decision is left to the site
or Program Office’s discretion.
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Department of Labor:
U.S. Department of Labor. 29 CFR 1910, 2019. Occupational Safety and Health
Standards for General Industry.
U.S. Department of Labor. 29 CFR 1926, 2019 Occupational Safety and Health
Regulations for Construction
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CONCLUDING MATERIAL
Site Offices:
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