NSS/GO-1740.9B

NOVEMBER 1991

NASA

National Aeronautics and Space Administration

SAFETY STANDARD FOR

LIFTING DEVICES AND EQUIPMENT

Office of Safety and Mission Quality

Washington, D.C. 20546

Enclosure 1

NSS/GO-1740.9B

NASA Safety Standard for Lifting Devices and Equipment

Page Changes Dated March 1993

NSS/GO-1740.9B

[NASA SAFETY STANDARD FOR LIFTING DEVICES AND EQUIPMENT]{.underline}

PREFACE

EFFECTIVE DATE: November 1991

The NASA Safety Standard for Lifting Devices and Equipment establishes
uniform design testing inspection maintenance, operational personnel
certification and marking requirements for lifting devices and
associated equipment used in support of NASA operations.

This standard expands on NHB 1700.1(V1), \"NASA Basic Safety Manual\"
policy and guidelines for safety assurance. It is a compilation of
pertinent requirements from the Occupational Safety and Health
Administration (OSHA), American National Standards Institute (ANSl),
Crane Manufacturers Association of America (CMAA), and unique NASA
requirements. The intent is to provide an opportunity to combine the
knowledge of all NASA centers standardize definitions, clarify/document
OSHA interpretations, address the subject of criticality, and develop
standardized requirements. The intent is not to be a substitute for OSHA
requirements as OSHA requirements apply to NASA operations in full

Compliance with this standard is mandatory for all NASA-owned and NASA
contractor-supplied equipment used in support of NASA operations at NASA
installations. The individual installation safety organizations are
responsible for implementation and enforcement. This document
establishes minimum safety requirements; NASA installations are
encouraged to assess their individual programs and develop additional
requirements as needed.

This standard is issued in loose-leaf form and will be revised by page
changes.

Comments or suggestions concerning the application of these requirements
to specific projects should be referred to the National Aeronautics and
Space Administration Headquarters, Director, Safety Division, Office of
the Associate Administrator for Safety and Mission Quality, Washington,
DC 20546.

This Safety Standard cancels NSS/GO-1740.9, dated July 1988.

George A Rodney

Associate Administrator for

Safety and Mission Quality

[DISTRIBUTION:]{.underline}

SDL 1(SIQ)

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(Change Page: 3/93)

RECORD OF CHANGES

**Change Page(s)**

**[Number]{.underline} [Date]{.underline} [Affected]{.underline}
[Description]{.underline}**

1 3/93 iii Update Record of Changes.

2 3/93 vi Update Table of Contents for Chapter 7.

3 3/93 2-20 In Paragraphs 207a, 307a, and 407a; second to

> 3-18 the last sentence; change "open propellant
>
> 4-17 grain" to " exposed propellant grain."

4 3/93 3-13 In Paragraph 306a(9) change "crane" to

"crane/derrick."

5 3/93 6-2 In the first sentence of Paragraph 602c(1) change "test
weight" to "test load."

6 3/93 7-4 through Expand the operational test requirements in

> 7-12 Paragraph 702c.

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[TABLE OF CONTENTS]{.underline}

[Par. Page]{.underline}

CHAPTER 1: INTRODUCTION

100 General Policy 1-1

101. Policy 1-1

102. Recordkeeping and Trend Analysis 1-2

103. Applicability and Exclusions 1-3

104. Deviations and Waivers 1-3

105. Reference Documents 1-4

CHAPTER 2: OVERHEAD CRANES

200. General 2-1

201. Safety Aspects 2-1

202. Testing 2-8

203. Inspection 2-10

204. Maintenance 2-12

205. Personnel Certification 2-15

206. Operations 2-16

207. Special Criteria 2-19

CHAPTER 3: MOBILE CRANES

300. General 3-1

301. Safety Aspects 3-1

302. Testing 3-4

303. Inspection 3-7

304. Maintenance 3-9

305. Personnel Certification 3-11

306. Operations 3-12

307. Special Criteria 3-18

CHAPTER 4: HOISTS

400. General 4-1

401. Safety Aspects 4-1

402. Testing 4-6

403. Inspection 4-8

[TABLE OF CONTENTS]{.underline}

[Par. Page]{.underline}

CHAPTER 4: HOISTS (Continued)

404. Maintenance 4-12

405. Personnel Certification 4-13

406. Operations 4-15

407. Special Criteria 4-17

CHAPTER 5: HOISTS HOOKS

500. General 5-1

501. Testing 5-1

502. Inspection 5-1

503. Maintenance 5-2

504. Operations 5-2

CHAPTER 6: HYDRA-SETS

600. General 6-1

601. Safety Aspects 6-1

602. Testing add Inspections 6-2

603. Maintenance 6-3

604. Operator Certification 6-3

605. Operation 6-3

CHAPTER 7: SPECIAL HOIST SUPPORTED PERSONNEL LIFIWG DEVICES

700. General 7-1

701. Safety Aspects 7-1

702. Testing 7-3

703. Inspection 7-5

704. Maintenance 7-8

705. Personnel Certification 7-9

706. Operations 7-10

[TABLE OF CONTENTS]{.underline}

[Par. Page]{.underline}

CHAPTER 8: SLINGS

CHAPTER 8: SLINGS

800. General

801. Safety Aspects

802. Testing

803. Inspection

804. Maintenance

805. Operations

LIST OF TABLES

1.  Proofload Test Factors

2.  Periodic Load Test Factors

3.  Minimum Safety Factors for Slings

APPENDICES

Appendix A: Acronyms and Definitions

Appendix B: NASA Alternate Standard for Suspended Load Operations

Appendix C: Hand Signals

CHAPTER 1: INTRODUCTION

100 GENERAL

> This publication establishes NASA\'s minimum safety requirements for
> the design testing inspection, personnel certification/recertification
> maintenance, and use of overhead and gantry cranes (including top
> running monorail, underhung and jib cranes), mobile cranes, derricks,
> hoists and special hoist supported personnel lifting devices (these do
> not include elevators, ground supported personnel lifts, or powered
> platforms; see Chapter 7). It also addresses minimum requirements for
> the testing inspection, and use of Hydra-sets hooks, and slinks.

101 POLICY

a.  Compliance with this standard is mandatory for all NASA-owned and
    NASA contractor-supplied equipment used in support of NASA
    operations at NASA installations. The individual installation safety
    organizations are responsible for implementation and enforcement
    This document establishes minimum safety requirements; NASA
    installations should assess their individual programs and develop
    additional requirements as needed. -The need for compliance with
    this standard at contractor installations performing NASA work
    should be evaluated and made a contractual requirement where deemed
    necessary by the contracting officer and the responsible NASA
    installation/program safety office.

b.  This document is not a substitute for OSHA requirements. OSHA
    requirements apply to all NASA operations. This document meets or
    exceeds Federal OSHA requirements. Some States have their own OSHA
    programs that must comply with Federal OSHA and may be stricter. Ah
    NASA installations are responsible for keeping up to date with the
    Federal and State OSHA requirements that apply to their operations.
    This standard contains some OSHA requirements where deemed necessary
    to stress the importance of the requirement, clarify the
    requirement, document interpretation of the requirement, and/or
    define NASA\'s program for meeting the requirement The NASA Safety
    Division, with assistance from the field installations, shall
    monitor subsequent OSHA requirements for any impact on NASA\'s safe
    lifting program.

c.  There are two categories of lifting operations for the purposes of
    this standard critical and noncritical.

> \(1\) [Critical lifts]{.underline} involve lifting and lowering
> operations with special, high dollar items, such as spacecraft,
> one-of-a-kind articles, or major facility components, etc., whose loss
> would have serious programmatic impact. Critical lifts also include
> operations with special personnel and equipment safety concerns beyond
> normal lifting hazards.

(a) Each installation or program shall develop a process to identify
    critical lifting operations and lifting devices/equipment that must
    meet critical lift requirements. Input shall be gathered from
    facility, program user, and assurance personnel. The results of the
    process shall be documented and approved as a minimum, by the
    installation NASA Safety Director.

(b) It is NASA policy that the comprehensive safeguards outlined in this
    standard be provided for critical lifting operations. This includes
    special design features maintenance, inspection and test intervals
    for the lifting devices/equipment used to make critical lifts.

(c) Specific written procedures shall be prepared and followed for all
    critical lifts.

(d) Individuals with a designated safety responsibility (NASA or
    contractor) shall be present to monitor critical lift operations for
    compliance with this document.

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(2) Noncritical lifts typically involve routine minimal hazard lifting
    operations and are governed by standard industry rules and practices
    except as supplemented with unique NASA testing operations,
    maintenance, inspection and personnel licensing requirements
    contained in this standard.

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d.  The requirements for critical and noncritical lifts outlined in this
    standard shall be followed unless a specific deviation/waiver is
    approved as outlined in Paragraph 104. Different levels of risks
    associated shall be evaluated using the risk determination criteria
    in NHB 1700.1(V1).

102 RECORDKEEPING AND TREND ANALYSIS

> A data collection system shall be established at each installation or
> location to support NASAwide lifting device trend and data analysis.
> Data entered locally would typically be associated with type and
> manufacturer of the equipment, age, maintenance history, operational
> problem and their corrective actions, lifting mishaps, safety notices,
> inspection discrepancies waivers and proof and load rest results The
> data shall be provided to the NASA Safety Information System (NSIS)
> for me in analyzing the overall state of NASA and NASA contractor
> support lifting equipment and in establishing a historical data base.
> The NSIS is currently in development at NASA Headquarters Safety
> Office. Further guidance on the effect of the NSIS on this document
> shall be provided upon system implementation.

103 APPLICABILITY AND EXCLUSIONS

a.  The testing, inspection, maintenance, operational, and operator
    certification/recertification/licensing requirements apply to new
    and existing lifting devices.

b.  The design/hardware requirements contained in this document are
    applicable to new lifting devices/equipment purchased after 6 months
    from the issue date of this document Existing equipment and that
    purchased during the first 6 months from issue of this document
    shall be reviewed for compliance with all design/hardware aspects of
    this standard within 12 months of its issue and the need to update
    such equipment shall be evaluated.

c.  Deviations/waivers from the requirements of this document (including
    design/hardware requirements for both new and existing equipment)
    shall be approved as outlined in Paragraph 104. The deviation/waiver
    documentation shall include any alternate or special criteria or
    procedures that will be imposed to ensure safe design and operations
    for those devices that do not meet the applicable requirements.

d.  Portions of this standard refer to various national consensus
    codes/standards for equipment design/hardware requirements (e.g.,
    ANSI CMAA, etc.). Lifting devices and equipment purchased after the
    initial review required in Paragraph 103b shall comply with the
    specified codes/standards in effect at the time of manufacture. Each
    installation shall periodically review subsequent codes/standards
    and evaluate the need to update existing equipment. Based on an
    evaluation of NASA\'s overall safe lifting program and any
    significant changes in the consensus codes/standards, the NASA
    Safety Division with concurrence from the field installations shah
    decide when the next complete review (as described in Paragraph
    103b) is warranted.

e.  This document does not include coverage for winches, forklifts,
    front-end loader5 elevators, aerial buckets, boom supported work
    platforms, scissor lifts, and manlifts.

104 DEVIATIONS AND WAIVERS

a.  If a mandatory requirement cannot be met a deviation/waiver package
    shall be prepared according to MIB 1700.1(V1). NASA
    deviations/waivers to requirements in this document shall be
    approved, as a minimum by the installation NASA Safety Director.

b.  The deviation/waiver package shall be forwarded to NASA Headquarters
    Safety for concurrence if it falls into one or both of the following
    categories:

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(1) Deviations/waivers of OSHA requirements. OSHA requirements

> may not be circumvented by a NASA deviation/waiver unless approved by
> OSHA (e.g. NASA Alternate Standard for Suspended Load Operations,
> Appendix B). After review by Headquarters, the deviation/waiver will
> be forwarded to OSHA for approval.

(2) Deviations/waivers that apply to the installation\'s lifting safety
    program/policy as a whole (not just a specific lifting device or
    operation) and will be in effect for more than a total of 45 days
    (including any extensions). For example:

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(a) An installation prefers to perform rated load rests on cranes every
    5 years ether than every 4.

(b) An installation prefers not to perform periodic load tests on
    slings.

(c) An installation prefers that the minimum approval authority for
    deviations/waivers be someone other than the installation NASA
    Safety Director.

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c.  A1l deviation/waiver documentation shall be provided to NASA
    Headquarters for incorporation into the NSIS.

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106. REFERENCE DOCUMENTS

> a\. [Department of Labor]{.underline}. Occupational Safety and Heath
> Administration (OSHA); Occupational Safety and Health Standards 29 CFR
> 1910.

(1) 1910.179, Overhead and Gantry Cranes.

(2) 1910.180, Crawler, Locomotive, and Truck Cranes.

(3) 1910.181, Derricks.

(4) 1910.184, Slings.

(5) 191029, Manually Propelled Mobile Ladder Stands and Scaffolds
    (Towers).

(6) 1910.67, Vehicle-Mounted Elevating and Rotating Work platforms.

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b.  [American National Standards Institute (ANSI).]{.underline}

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(1) B30.2, Overhead and Gantry Cranes (multiple girder).

(2) B30.5, Crawler, Locomotive, and Truck Cranes.

(3) B30.6, Derrick

(4) B30.7, Base Mounted Drurn Hoists.

(5) B30.9, Slings.

(6) B30.10, Hooks

(7) B30.11, Monorails and Underhung Cranes

(8) B30.16, Overhead Hoists

(9) B30.17, Overhead and gantry Cranes (single girder).

(10) MH27.1, Specification for Underhung Cranes and Monorails.

(11) A58.1, Minimum Design Loads for Buildings and Other Structures

(12) A10.4, Safety Requirements for Personnel Hoists.

(13) A10.22, Safety Requirements for Rope Guided and Nonguided Workman's
     Hoist.

(14) A10.28, Safety Requirements for Workplatforms Suspended from cranes
     or Derricks.

(15) A39.1, Safety Requirements for Window Cleaning

(16) ANSI/NFPA 12904-1975, American national Standard Practice for the
     Maintenance, Care, Testing, and Use of Fire Department Aerial
     Ladders and Elevating Platforms.

(17) ANSI/ASME HST-1M-1982, Performance Standard for Electric Chain
     Hoists.

(18) ANSI/ASME HST-2M-1983, Performance Standard for Hand Chain Manually
     Operated Chain Hoist.

(19) ANSI/ASME HST-3M-1985, Performance Standard for Overhead Electrical
     Wire Rope Hoists.

(20) ANSI/ASME HST-4M-1985, Performance Standard for Overhead Electric
     Wire Rope Hoists.

(21) ANSI/ASME HST-5M-1985, Performance Standard for Air Chain Hoists.

(22) ANSI/ASME HST-6M-1986, Performance Standard for Air Wire Rope
     Hoists.

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c.  [National Aeronautics and Space Administration (NASA).]{.underline}

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(1) NHB 1700,1 (V-1A), Basic Safety Manual.

(2) NHB 7320.1, Facilities Engineering Handbook.

(3) NASA SPECSINTACT, Standard Construction Specification System.

(4) NASA SPECSINTACT, Section 14370, Monorails and Hoists.

(5) NASA SPECSINTACT, Section 14380, Electric Overhead Cranes.

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d.  [Crane Manufacturers Association of America, Inc.
    (CMAA).]{.underline}

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(1) CMAA Specifications No. 70, Specifications for Electric Overhead
    Traveling Cranes.

(2) CMAA Specifications No. 74, Specification for Top Running and Under
    Running Single Girder Electric Overhead Traveling Cranes.

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e.  [Other.]{.underline}

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(1) NFPA No. 70, National Electric Code.

(2) NEMA -- National Electrical Manufacturers Association.

(3) SAE J765, Crane Load Stability Test Code.

(4) American Welding Society (AWS) D1.1-86, Structural Welding and
    Cutting Code.

(5) ANSI/AWS D14.1-82, Specifications for Welding Industrial and Mill
    Cranes.

(6) American Institute of Steel construction, Inc. (AISC) "Manual of
    Steel Construction," 400 North Michigan Avenue, Chicago, Illinois
    60611.

(7) PCSA -- Power Crane and Shovel Association, Standards No. 1, No. 2,
    No. 4, and No. 5

CHAPTER 2: OVERHEAD CRANES

200 GENERAL

> This chapter establishes safety standards for the design, test,
> inspection, maintenance, operation, and personnel
> certification/recertification for overhead and gantry cranes,
> including underhung, monorail, and jib cranes.

201. SAFETY ASPECTS

> Generally, high quality off-the-shelf, Original equipment manufacturer
> (OEM) type equipment is acceptable for critical and noncritical lifts
> if it is designed, maintained, operated, etc., according to this
> standard.

a.  [Safety Design Criteria]{.underline} that should be emphasized
    during overhead crane design are contained in the documents listed
    in Paragraph 105.

b.  [Labeling/Tagging of Cranes]{.underline}

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(1) The rated load of all cranes shall be plainly marked on each side of
    the crane. If the crane has more than one hoisting unit, each hoist
    load block shall be marked with its rated load. This marking shall
    be clearly legible from the ground floor (OSHA requirement for all
    overhead cranes).

(2) Cranes that have the specified design features,
    maintenance/inspection, and test intervals to life critical loads
    shall be marked conspicuously so that the operator and assurance
    personnel can distinguish that the crane is qualified for critical
    lifts.

(3) A standard system of labeling shall be established and used
    throughout the installation.

(4) A standard tag-out system shall be established and used throughout
    the installation to indicate equipment that is not to be used due to
    inspection discrepancies, ongoing maintenance operations, etc.

(5) Certification/recertification tags are required as described in
    Paragraph 202e.

> c\. [Safety Analysis and Documentation of Cranes Used for Critical
> Lifts]{.underline}. A hazard analysis shall be performed on all cranes
> used for critical lists. The analysis shall, as a minimum, determine
> potential sources of danger, identify most probable failure modes, and
> recommend resolutions for those conditions found in the
> hardware-facility-environment-human relationship that could cause loss
> of life, personal injury, or loss of crane, facility, or load. The
> analysis also shall include crane description, reference
>
> documentation, severity assessment, assessment of specified passive
> and structural components between the hook and the holding brakes.
> Hazards that are identified shall be tracked (recorded and current
> status maintained) until final closure is verified. A system of risk
> acceptance is required for hazards that cannot be eliminated. The
> hazard analysis shall be done as part of the initial crane
> certification process, included in the crane documentation, and
> updated as required to reflect any changes in operation and /or crane
> configuration.

d.  [Performance.]{.underline} Operational life, crane service
    classification, load capability, and the desired control
    characteristics with which the crane handles the load shall be
    addressed for all designs. The expected operational life shall be
    specified or detailed for system components. Crane service
    classification requirements shall be based on the worst expected
    duty the unit will encounter. Each load-bearing component shall be
    specified or detailed to lift the maximum imposed loads resulting
    from zero to rated hook load with appropriate safety factors.
    Operational requirements shall be considered in the design phase to
    ensure load and function are adequately defined and critical crane
    design features are incorporated on the delivered units.

e.  [Structural]{.underline}. Structural design shall be in accordance
    with industry standards for material selection, welding, allowable
    stresses, design limitations, framing, rails, wheels, and other
    structural elements. Refer to ANSI and CMAA standards for specific
    design details.

f.  [Mechanical.]{.underline}

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(1) The use of high quality, off-the-shelf, OEM type equipment is
    acceptable for critical and noncritical lift applications if it
    meets all user requirements and the requirements of this document.
    This high quality commercial equipment employs a modular type
    construction of the hoist unit with standard frame sizes and
    interchangeable gear boxes, drums, motors, brakes, and controls to
    achieve a wide range of capacities, lifts, operating speeds, reeving
    arrangements, and controls. These interchangeable parts are
    standardized for each manufacturer's product line and the hoists are
    built to order.

(2) The mechanical design requirements for crane components are as
    follows:

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(a) They shall meet all applicable requirements of OSHA, ANSI, and CMAA.

(b) For critical lift application, speed reduction from the motor to the
    drum on the hoist should be achieved by enclosure in a gear case. If
    open gears are required, they shall be guarded with a provision for
    lubrication and inspection.

(c) Gearing shall e designed and manufactured to comply with the latest
    American Gear Manufacturers Association (AGMA) gear standards.

(d) Hooks shall meet the manufacturer's recommendations, and shall not
    be overloaded. Swiveling hooks should rotate 360 degrees on
    antifriction bearings with means for lubrication. If grease is a
    contamination concern, drip funnels (cups) or nonlubricated bearings
    should be provided. Latch-equipped hooks shall be used unless the
    application makes the use of a latch impractical or unnecessary.
    When required, a latch or mousing shall be provided to bridge the
    throat opening of the hook to retain slings, chains, or other
    similar parts under slack conditions.

(e) Each hoisting unit shall be provided with at least two means of
    braking: a holding brake and a control brake. The torque ratings,
    physical characteristics, and capabilities of the brakes shall be in
    accordance with CMAA specifications.

(f) For cranes used for critical lifts, two means of braking shall be
    provided, each capable of bringing a rated load to zero speed and
    holding it (with and without power). If the control brake and
    holding brake are designed to operate as a system and cannot
    independently stop and hold a rated load, then another means of
    braking is required for cranes used for critical lifts (e.g.,
    emergency brake). The brakes shall be designed so that they can be
    tested as required in Paragraph 202c(4).

(g) Worm gears shall not be used as a braking means unless the lead
    angle is sufficient to prevent back driving. The braking properties
    of a worm gear tend to degrade with use; the design engineer shall
    consider this when purchasing new equipment or in existing
    installations where the hoist is subject to heavy use.

(h) In the procurement of new lifting equipment, the use of cast iron
    components in the hoist load path shall be approved, as a minimum,
    by the installation NASA Safety Director. The material properties of
    cast iron allow catastrophic failure and should not be considered as
    reliable as steel or cast steel. The engineer shall consider this
    when selecting equipment and avoid the use of load bearing cast iron
    materials where possible.

(i) Safe and adequate access to crane components to inspect, service,
    repair, or replace equipment shall be provided for during design.
    The design shall provide for visual and physical accessibility.

(j) Pneumatic cranes shall have the capability to lock out the supply
    air pressure to prevent unauthorized use.

(k) Based on the sensitivity of the loads to be lifted, cranes shall
    have appropriate speed modes that provide for safe, smooth starting
    and stopping to preclude excessive "G" forces from being applied to
    the load.

(l) All wire rope hoists shall have not less than two wraps of hoisting
    rope on the drum when the hook is in its extreme low position. Drum
    grooves, when provided, shall be as recommended by CMAA. The rope
    ends shall be anchored securely by a clamp or a swaged terminal in a
    keyhole slot, provided a keeper is used to prohibit the swage from
    moving out of the narrow slot. Other methods recommended by the
    hoist or wire rope manufacturer are acceptable if the rope
    termination anchor together with two wraps of rope on the drum will
    give an anchor system equal to or greater than the breaking strength
    of the wire rope.

(m) Manually operated (nonpowered) hoist cranes that are off-the-shelf
    OEM type are acceptable for critical and noncritical lift
    applications. They shall comply with applicable ANSI requirements.
    These hoists need only be equipped with at least one brake as
    described in industry standards and no limit switches, if proper
    over-travel restraint is provided.

(n) Air operated chain hoists can be equipped with over-travel
    protection devices instead of the hoist travel limit switches.

(o) Initial and final upper limit switches (limit control valves) shall
    be provided and tested for critical air operated hoists as described
    in Paragraph 201g(9). The final upper limit switch (limit control
    value) shall exhaust air from the crane hoist, set the brakes, and
    require reset at the upper limit switch (limit control valve) level.

(p) A minimum clearance of 3 inches overhead and 2 inches laterally
    shall be provided and maintained between the crane and all
    obstructions.

> \(3\) When the use of high quality, off-the-shelf, OEM type equipment
> is not possible due to unique design and operation requirements, then
> built-up type equipment must be used. These built-up cranes generally
> use many commercially available or made-to-order motors, brakes,
> couplings, gear reducers, etc. These components are then custom
> engineered together as an assembly mounted on custom designed and
> built equipment frames. In many cases, gear reducers, drums, and drive
> shafts are custom designed and built. Structural and mechanical parts,
> such as sheave pins, hook-block components, bridge girders, bridge and
> trolley drives, etc., are also custom designed and built as components
> or assemblies. The built-up type crane should only be used where
> commercial equipment is not available to meet the user/operational
> requirements described in this paragraph. Due to the nature of its one
> of a kind design and construction, this type of equipment is generally
> more prone to break down and should be considered as less reliable
> than commercial equipment. These units shall meet the mechanical
> design requirements provided in Paragraph 201f(2) and the following
> additional minimum requirements:

(a) Drum supporting structures should be designed so that bearings are
    mounted under compression to (1) minimize wearing of the bearings
    and (2) increase the probability of maintaining the mesh between the
    drum gear and the drive gear in the case of bearing failure. The
    structure shall be designed to preclude failure of the bearings and
    drum supports. Pillow block bearings shall have steel, or cast steel
    housings (the user of cast iron is not permitted).

(b) In descending order of preference, the drum gear when used shall be
    integrally attached, splined, bolted with close fitting body-bound
    bolts to a flange on the drum, or pressed on and keyed to either the
    periphery of the hub or shell of the drum, or attached by other
    means of equal safety.

(c) Couplings shall be located immediately next to bearings. Couplings
    between closely spaced bearings shall be of a full flexible type
    with integral gear form or grids, having metal to metal contact, and
    shall run in oil or be lubricated as recommended by the
    manufacturer. All couplings for hoists shall be pressed fit with
    keys.

> g\. [Electrical.]{.underline} Electrical design requirements are as
> follows:
>
> \(1\) Wiring and safety devices shall be in accordance with National
> Fire Protection Association (NFPA) National Electrical Code. Conduit
> and wiring shall be such that on-site work is minimized. Hard wire
> conductors such as festooned cables or articulated cable carriers,
> instead of power or feed rails, shall be considered to provide power
>
> and control to overhead cranes handling explosive or solid
> propellants, or to cranes with solid state controls.

(3) Electrical enclosures shall provide protection for the contained
    equipment against environmental conditions according to the class
    rating established by National Electrical Manufacturers Association
    (NEMA).

(4) Though not a requirement, besides electrical power overload
    protection required by the National Electrical Code, under-voltage,
    and phase reversal should be considered.

(5) All cab-operated cranes with step type control shall be equipped
    with level controls. The levers shall be of the continuous effect
    type and provided with a deadman feature that will not unduly tire
    the operator during lengthy operations.

(6) The electrical system shall be designed fail-safe to ensure that a
    failure of any component will not cause the crane to operate in a
    speed range faster than commanded. A failure that causes a speed
    different from that selected is acceptable provided no hazards are
    introduced. Failure modes that cause the bridge, trolley, or hoist
    to slow down or come to a safe stop are acceptable; those that could
    cause a hard stop, unplanned directional shifts, and/or loss of
    control are unacceptable.

(7) Provisions for grounding the hook are required for handling
    explosives, solid propellants, flammables, or any other load that
    requires a nonelectrical or static-free environment. See Paragraph
    207.

(8) For cranes used for critical lifts, an assessment shall be performed
    to determine the operational needs for remote emergency stops
    independent from the operator controlled emergency stop. Not all
    cranes used for critical lifts require a remote emergency stop.
    Remote emergency stops are required for cranes used for critical
    lifts where the crane operator's view is restricted/obstructed. When
    provided, this independent remote emergency stop operator(s) can
    clearly see the critical lift area(s). The remote emergency stop
    circuit shall be separate from and take precedence

> over the operator control circuit. The control, when activated, shall
> cause all drives to stop and the brakes to set. Hand-held remote
> emergency stop pendants should be standardized and should include
> power and circuit continuity indication. For those cranes required to
> make critical lifts and have not been modified to provide a remote
> emergency stop, handling procedures shall be developed and implemented
> to minimize the risk.

(9) For cranes used for critical lifts, dual upper limit switches are
    required. For electrical cranes, the limit switches shall meet the
    following requirements:

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(a) Initial upper limit switch electrical contacts shall be a set of
    normally closed contacts in the "raise" contractor circuit such that
    movement in the raise direction shall be precluded after the limit
    switch is encountered. Movement in the "lower" direction will not be
    inhibited.

(b) Final upper limit switch electrical contacts shall be a set of
    normally closed electrical contacts wired into the mainline circuit,
    hoist power circuit, main contractor control circuit, or hoist power
    contractor control circuit such that all crane motion or all hoist
    motion shall be precluded after the limit switch is encountered.
    These normally closed contacts may be located in the low voltage
    control circuitry.

(c) After a final upper limit switch has been activated, movement of the
    load will require action (resetting) at the final upper limit switch
    level. An inspection shall be made to determine the cause of failure
    of the initial upper limit switch. Stopping crane motion by the
    above design configuration may result in a hazardous suspended load
    condition. The crane design should include a means of detecting
    limit switch failure and allow for safe inspection and repair. For
    example, a system may be equipped with two different colored
    annunciator lights, one for each limit switch. A reset button may be
    included so that when a final upper limit switch is tripped, the
    load can be lowered immediately. The reset button should be secured
    to prevent unauthorized use.

(d) The initial upper limit switch shall be adjusted sufficiently low to
    preclude inadvertent actuation of the final upper limit switch if
    the hoist actuates the initial upper limit switch at full speed with
    no load. Similarly, the final upper limit switch shall be adjusted
    sufficiently low to ensure that the hoist will not two-block (or
    otherwise damage wire rope) if the hoist actuates the final upper
    limit switch at full speed with no load. Both limits shall be tested
    from slow speed to

> full speed to verify correction operation. It should be noted that
> this requirement effectively lowers the usable hook height of the
> hoist. The limit switch arrangement shall be considered during new
> equipment design.

(10) For cranes used for critical lifts, lower limit switches to prevent
     reverse winding of the wire rope shall be provided.

(11) Electrical cranes shall have the capability to be locked out at the
     main breaker to prevent unauthorized use.

(12) Cranes shall be designed fail-safe in the event of a power outage.

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202. TESTING

> Three types of tests are required for cranes: proof load tests, rated
> load tests, and operational tests. The proof load tests and
> operational tests shall be preformed prior to first use for new
> cranes, or for existing cranes that have had modifications or
> alterations performed to components in the load path. This applies
> only to those components directly involved with the lifting or holding
> capability of a crane that had been repaired or altered. Repairs or
> alternations to nonlifting, secondary lifting, or holding components
> such as suspension assemblies, electrical system, crane cab, etc., do
> not require a load test, although a functional check should be
> performed to determine if the repairs or alternations are acceptable.
> The rated load and operational tests shall be performed at least every
> 4 years. Cranes used frequently for critical lifts shall be load
> tested annually. Cranes used infrequently for critical lists shall be
> load tested before the critical lift if it has been more than a year
> since the last test. If a crane is upgraded (increased lifting
> capacity), a proof load test and an operational test shall be
> performed based on the upgraded rating. All load and operational tests
> shall be performed by qualified personnel according to written
> (specific or general) technical operating procedures approved by NASA
> and/or contractor safety representatives. An inspection of the crane
> and lifting components shall be performed after each load test and
> prior to the crane being released for service to ensure there is no
> damage. This inspection may include Nondestructive Evaluation (NDE) of
> components that are suspected to be cracked or otherwise affected by
> the test. The rated load test requirement may be fulfilled by a
> concurrent performed proof load test.

a.  [Proof Load Test]{.underline}. Before first use and after
    installation, all new, extensively repaired, extensively modified,
    or altered cranes shall undergo a proof load test with a dummy load
    as close as possible to, but not exceeding 1.25 times the rated
    capacity of the crane. A proof load test also should be performed
    when there is a question in design or previous testing. The load
    shall be lifted slowly and in an area where minimal damage will
    occur if the crane fails. The load rating of the crane shall be
    clearly marked to be legible from the operator's or user's position
    and shall not be more than the proof test weight divided by 1.25.

b.  [Rated Load Test.]{.underline} Each crane shall be tested at least
    once every 4 years with a dummy load equal to the crane's rated
    capacity. Crane sued frequently for critical lifts shall be load
    tested at least once per year. Cranes used infrequently for critical
    lifts shall be load tested before the critical lift if it has been
    more than a year since the last test. The acceptable tolerance for
    rated load test accuracy is +5/-0 percent unless otherwise specified
    by design.

c.  [Operational Test.]{.underline} Together with proof load and rated
    load tests, the following shall be performed with a dummy rated load
    unless otherwise specified (except as noted in Paragraph 202c(5)):

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(1) load hoisting, lowering at various speeds (maximum safety movement
    up and down as determined by the installation NASA Safety
    directorate and the responsible engineering and
    operations/maintenance organizations), and braking/holding
    mechanisms. Holding brakes shall be tested to verify stopping
    capabilities and demonstrate the ability to hold a rated load.

(2) Trolley and bridge travel (maximum safety movement in all directions
    with varying speeds as determined by the installation NASA Safety
    directorate and the responsible engineering and
    operations/maintenance organization).

(3) All limit switches, locking devices, emergency stop switches, and
    other safety devices, excluding thermal overload and circuit
    breakers. The limit switch, emergency stop, and locking device tests
    except for the final upper limit switch shall be performed with no
    load on the hook at full speed. The final upper limit switch can be
    tested by manually tripping the switch and verifying that all hoist
    motion is precluded (see Paragraph 204b(3)).

(4) Cranes used for critical lifts are required to be equipped with at
    least two means of braking (hoist), each capable of bringing a rated
    load to zero speed and holding it (see Paragraph 201f(2)(f)). The
    operational test must demonstrate each brake's ability to stop and
    hold a rated load. This can be done in one of the following ways:

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(a) Each brake's ability to hold shall be statically tested (under no
    load) with 150 percent of the rated load hoisting torque at the
    point of brake application.

(b) Alternately, each brake shall be tested for its ability to stop a
    rated load moving at full speed in the down direction. (CAUTION: It
    must be possible to quickly reenergize the out-of-circuit brake or
    provide other safety measures to perform this test safely.)

(c) Other methods as specified by the installation NASA Safety
    directorate and the responsible engineering and
    operations/maintenance organizations.

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d.  An organization may certify a crane for a specific lift (critical or
    noncritical). A load test and an operational test with a dummy load
    are required. In this case, the test weight shall be at least equal
    to the specific load that the crane is being certified to lift and
    may be greater as determined by the user and maintenance
    organization. The test weight shall not exceed 125 percent of the
    crane's rated capacity.

e.  [Test Reports and Periodic Recertification Tags]{.underline}. After
    each test, designated personnel shall prepare written, dated, and
    signed test reports including procedure reference. Inadequacies
    shall be documented and, if determined to be a hazard, corrected
    prior to further use. These reports shall be kept on file by the
    owner organization for a minimum of two test cycles and shall be
    made readily available. Following the rated load test, cranes shall
    be given a permanently affixed tag identifying the equipment and
    stating the next required rated load test date or certification
    expiration date.

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203. INSPECTION

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a.  Daily and periodic safety inspection shall be performed on all
    cranes and crane accessories. Inadequacies discovered during an
    inspection shall be documented and, if determined to be a hazard,
    corrected prior to further use. Inspections shall be made by
    qualified designated personnel according to approved technical
    operating procedures.

b.  All new, extensively repaired, or modified cranes shall be given a
    daily and a periodic inspection prior to first use. For component
    repair on cranes, only the inspections that apply to the repaired
    portion need to be performed prior to first use unless a periodic
    inspection interval expires during the downtime )see Paragraph
    203e).

c.  Cranes in regular service (used at least once a month) shall be
    inspected as required in Paragraphs 203d and 203e. Idle cranes shall
    be inspected according to Paragraph 203f.

d.  Daily Inspections. These inspection s shall be performed by the
    certified operator prior to first used each day the crane is used,
    and shall include the following:

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(1) Check functional operating and control mechanisms for maladjustments
    that could interfere with normal operations.

(2) Without disassembling, visually inspect lines, tanks, valves, drain
    pumps, gear casings, and other components of fluid systems for
    deterioration and leaks. This applies to components that can be seen
    from the ground level or for which there is safe access via crane
    inspection walkways.

(3) Without disassembling, visually inspect all functional operating and
    control mechanisms for excessive wear and contamination by excessive
    lubricants or foreign matter.

(4) Visually inspect hooks for cracks and deformities (see Chapter 5).

(5) Visually (without climbing up to bridge) inspect rope reeving for
    proper travel and drum lay, and inspect wire rope for obvious kinks,
    deformation, wire clips, and/or damage.

(6) Visually inspect hoist chains for excessive wear or distortion.

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e.  [Formal Periodic Inspections]{.underline}. These inspections shall
    be performed at varying intervals, depending on activity, severity
    of service, environment, and criticality.

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(1) [Annual Inspections.]{.underline} At least once per year, inspect
    for:

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(a) Deformed, cracked, or corroded members and welds and loose bolts or
    rivets in crane structure and runway. Various methods of
    nondestructive examination such as ultrasonics, x-ray, magnetic
    particle, dye penetrant, etc., shall be used as needed.

(b) Cracked or worn sheaves and drums.

(c) Wear or cracks in pins, bearings, shafts, gears, followers, and
    locking and clamping devices. NDE techniques should be used if
    cracks are suspected.

(d) Wear in brake and clutch system parts, linings, pawls, and ratchets
    that are readily accessible without major disassembly beyond an
    acceptable limit. Major teardown to inspect such parts should be
    based on a frequency consistent with gearbox lubrication analysis
    and other manufactures' recommended maintenance programs for these
    components.

(e) Inadequacies in load and other indicators over full range.

(f) Wear in chain drive sprockets and stretch in the chain beyond an
    acceptable limit.

(g) Gasoline, diesel, electric, or other power plants for proper
    performance or noncompliance with applicable safety requirements.

(h) Evidence of a malfunction in travel, steering, braking, and locking
    devices.

(i) Evidence of a malfunction in any safety device.

(j) Pitting or other signs of deterioration in electrical apparatus.
    Special attention shall be given to feed rails.

(k) Evidence of overheating.

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(2) [Monthly Inspections.]{.underline} At least once per month:

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(a) Inspect for wear, twist, distortion , or stretch of hoist chains.

(b) Perform a thorough inspection of all ropes paying particular
    attention to the signs of deterioration and damage outlined in
    Paragraph 204c(3).

(c) Inspect for visible deformation or cracks in hooks (see chapter 5).

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f.  [Idle and Standby Cranes]{.underline}. Cranes idle for more than 1
    month shall be inspected prior to first use according to the
    requirements of Paragraphs 203d and 203e that were not performed at
    required intervals and recorded during the standby period.

g.  [Inspection Reports]{.underline}. After each formal periodic
    inspection, qualified, authorized personnel shall be prepare
    written, dated, and signed inspection reports. These reports shall
    include procedure reference and adequacy of the crane/crane
    components. Inadequacies shall be documented and, if determined to
    be a hazard, corrected prior to further use. These reports shall be
    filed and be made readily available by the organizational element
    responsible for crane inspection.

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204. MAINTENANCE

> A preventive maintenance program shall be established based on
> manufacturers' recommendations and/or experience gained from use of
> the equipment. The program shall include procedures and a scheduling
> system for normal periodic maintenance items, adjustments,
> replacements, and repairs. The program also
>
> Shall ensure that records are kept and unsafe test and inspection
> discrepancies are documented and corrected.

a.  [Maintenance procedures]{.underline}. Before maintenance,
    adjustments, repairs, and replacements are initiated, the following
    safety precautions shall be taken:

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(1) Move crane to an area where maintenance will not interfere with
    other operations.

(2) Turn off all controls, move main or emergency switch to OPEN, and
    lock and tag switch in OPEN position unless it is necessary to have
    power on to perform the maintenance task.

(3) If other cranes are operating on the same runway as the crane being
    repaired, ensure that proximity limit switches are operating on all
    cranes or that an observer is stationed to prevent interference with
    other cranes.

(4) Cranes shall not be operated until all safety devices have been
    activated and tested/adjusted if involved in the maintenance action.

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b.  [Adjustments]{.underline}. Based upon the manufacturer's
    documentation and/or experience, adjustments shall be made to ensure
    that all crane components function properly, paying particular
    attention to:

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(1) Brakes. (Appropriate precautions should be taken by inspectors,
    repair personnel, and others who may be potentially exposed to
    airborne dust fibers from any asbestos friction materials present in
    crane braking mechanisms.)

(2) Control system.

(3) Limit switches.

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(a) The hoist initial upper limit switch shall be verified by running
    the empty hook at full speed into the limit switch. It is
    recommended that the switch be verified at slow speed prior to
    adjustment.

(b) For cranes used for critical lifts, the final upper limit switch
    shall be independently verified and adjusted as described above at
    installation and after modifications that could affect switch
    operation. The switch can be tested periodically by manually
    tripping it and verifying that all hoists motion is precluded.

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(4) Power plants.

(5) Critical operating mechanisms and safety devices.

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c.  [Repairs/Replacements]{.underline}.

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(1) For repair/replacement requirements for crane hooks with deformation
    or cracks, see Chapter 5. If repaired, crane hooks shall be proof
    load tested using the associated crane proof load value.

(2) Structural members that are cracked, bent, broken, excessively worn,
    or corroded shall be replaced or repaired. Use proper material and
    weld/repair procedures according to manufacturers' specifications
    and ANSI/AWS D14.1-82.

(3) The need to replace wire rope shall be determined by a certified or
    otherwise qualified person based on a evaluation of inspection
    results. Any of the following signs of deterioration and damage are
    sufficient reasons for questioning continued use of the rope:

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(a) Twelve randomly distributed broken wires in one rope lay or four
    broken wires in one strand in one lay.

(b) Individual outside wires with wear of 1/3 the original diameter.

(c) Kinking, crushing, bird caging, or any other damage resulting in
    distortion.

(d) Evidence of heat damage.

(e) End connectors that are cracked, deformed, or with evidence of rope
    pullout.

(f) Corrosion (internal or external) that results in reduction of rope
    diameter, or at end connectors.

(g) Reductions of nominal diameter (measured with a caliper or go/no-go
    gage) of more than:

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1.  1/64 inch for diameters of rope up to 5/16 inch.

2.  1/32 inch for diameters ¾ inch to ½ inch.

3.  3/64 inch for diameters 9/16 to ¾ inch.

4.  1/16 inch for diameters 7/8 inch through 1-1/8 inches.

5.  3/32 inch for diameters greater than 1-1/8 inches.

> \(h\) If replaced, the new rope shall be proof load tested using the
> associated crane proof load value.

205. PERSONNEL CERTIFICATION

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a.  [Program.]{.underline} Only certified (licensed) and trained
    operators shall be authorized to use/operate cranes. A training,
    examination, and licensing program shall be established or made
    available. For those NASA installations that do not have a training
    program, all crane operators shall be trained and certified by a
    recognized crane certification organization that normally performs
    this function. Certification also shall include riggers and flagmen.

b.  [Levels.]{.underline} Two levels of operator training and
    proficiency will be established. Operations where critical lifts are
    involved will require a more rigid operator certification program
    than those operations that involve more routine lifts that do not
    involve critical hardware or unique hazards.

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(1) [Noncritical Lifts.]{.underline} The certification program for
    noncritical lift operators shall include the following:

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(a) Training

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1.  Classroom training in safety and first aid/emergency procedures,
    general performance standards, requirements, pre-operational checks,
    and safety-related defects and symptoms (for initial certification
    and as needed).

2.  Hands-on training (for initial certification and as needed).

3.  An annual review of the items in Subparagraph (a) above. (This may
    be conducted informally by local supervisory personnel).

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(b) Examination

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1.  Physical examination (criteria to be determined by cognizant medical
    official using ANSI requirements).

2.  Written examination.

3.  Operational demonstration (for initial certification only).

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(c) Licensing/Operator Certification

> [1.]{.underline} An organizational element shall be designated to
> issue operator licenses/operator certification. Provisions shall be
> made to revoke licenses for negligence,
>
> violations of safety requirement, or failure to meet medical
> standards. Provisions shall be made for periodic checks of operators
> to verify they have licenses in their possession. The licenses shall
> indicate the type of crane the holder is qualified to operate.
> Alternately, the organizational element may elect to maintain a master
> list of licensed operators instead of issuing individual licenses,
> providing copies of the list are readily available to assurance and
> supervisory personnel at the work site.

2.  Renewal of all licenses shall require demonstration of proficiency.
    Licenses or certifications will expire at least every 4 years.
    Renewal procedures will be established by each licensing
    organization but as a minimum, will include items in Paragraphs
    205b(1)(a) and (b).

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(2) [Critical Lifts.]{.underline} Besides the training, examination,
    licensing, and renewal requirements for noncritical lifts, operators
    that are being certified to perform critical lifts must be trained
    in the specific hazards and special procedures associated with the
    lift. Operators also must demonstrate proficiency and operating
    finesse with the crane using a test load as appropriate for the
    initial certification or alternately be directly supervised by a
    certified operator during the first initial lifting period. The
    licenses will indicate specific cranes for which the operator is
    certified.

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206. OPERATIONS

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a.  The following practices shall be observed for crane operations:

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(1) General operating procedures describing crane operation, emergency
    steps, communication requirements, and special requirements
    including checklists and inspection requirements shall be prepared,
    approved, and followed for each crane. There must be a formal system
    for review, approval, and update to maintain valid operating
    procedures. Emergency procedure shall be developed for contingency
    actions such as power loss, brake failure, or other emergencies.
    (Also, see Paragraph 101c91)(c).)

(2) Operations shall be analyzed for hazards. The analysis shall
    consider the environment in which the operation occurs, hazards
    associated with crane maintenance, and, in general, a systems safety
    analysis of the equipment, facility, load, and interfaces as a whole
    in support of the lifting operating.

(3) Methods and procedure shall be developed for lowering a load in the
    event of crane failure or other contingencies. These should be
    demonstrated and verified if practical.

(4) A Crane shall not be loaded beyond its rated load (capacity) except
    for required testing.

(5) Cranes may be used to load test items such as slings, platforms, or
    lifting fixtures if specifically identified to do so based on a
    specified percentage of rated load and a safety analysis approved by
    the installation NASA Safety directorate and the responsible
    engineering and operations/maintenance organizations. This is to
    ensure that the crane is not damaged due to sudden unloading should
    the test article fail.

(6) Cranes shall not be used for side pulls unless specifically designed
    to do so.

(7) There shall be a system for documenting crane
    problems/discrepancies. Prior to an operation, the operator shall
    review an previously noted problems/discrepancies to determine
    possible impact on planned activity.

(8) The operator shall ensure that the crane is within inspection and
    testing intervals by examination of the periodic recertification
    tags and/or documentation.

(9) Before each lift or series of lifts, the operator shall perform a
    pre-operational check to demonstrate operational readiness. If
    controls do not operate properly, the operator is responsible for
    notifying the supervisor. Repairs and adjustments shall be made
    before operations begin.

(10) The operator shall establish safety zones before initiating
     operations. Safety zones should have appropriate barriers (rope,
     cones, etc.) established prior to lift.

(11) Before each lift or series of lifts, the operator shall
     functionally test proper operation of the upper limit switch with
     no load on the hook. Upper limit switches shall not be used as
     operating controls.

(12) Before starting to hoist, the following conditions shall be noted:
     the hoist rope shall not be kinked, multiple part ropes shall not
     be twisted around each other, and the hook shall be centered over
     the load in such a manner as to prevent swinging or side pulls.

(13) When raising loads that approach the rated capacity of the crane,
     the operator shall know the weight of the working load. The
     operator shall test the holding brakes each time a load approaching

> the rated load is handled. The brakes shall be tested by raising the
> load minimally above the surface and holding the load with the brake.
> The load should be held long enough to allow any dynamics to dampen
> out.

(14) If radio communications are to be used, crane operators and/or lift
     supervisors shall test the communication system prior to the
     operation. Operation shall stop immediately upon communication
     loss, and shall not continue until communication is restored.

(15) If hand signals are required, only standard signals shall be used
     according to Appendix C. Hand signals shall be posted in a
     conspicuous location.

(16) Crane crew emergency egress routes should be verified to be free of
     obstructions prior to hazardous operations. The availability of
     crane crew protective equipment should be verified prior to
     hazardous operations.

(17) If there is a slack rope condition, it shall be determined that the
     rope is properly seated on the drum and in the sheaves before
     starting the hoist.

(18) During hoisting, care shall be taken that there is no sudden
     acceleration or deceleration of the moving load and that the load
     does not contact any obstructions.

(19) Loads shall be secured, balanced, and controlled with proper
     slings. The use of tag lines to keep the load stabilized shall be
     required whenever load swinging is anticipated to be a viable
     hazard. Tag line personnel shall take care not to impart
     undesirable motion to the load.

(20) Person(s) shall not ride the hook or load at anytime. For personnel
     lifting requirements, see Chapter 7.

(21) Personnel shall not be located under suspended or moving loads
     unless the operation adheres to the OSHA-approved NASA Alternate
     Standard for Suspended Load Operations. (See Appendix B.)

(22) The load shall not be lowered below the point where less than two
     full wraps of rope remain on the hoist drum.

(23) A responsible person shall be in charge of the operation and shall
     instruct all personnel involved in the proper positioning, rigging,
     and moving to be done.

(24) An operator shall be at the crane controls at all times while a
     load is suspended (OSHA requirement). Due to the length of some
     NASA operations, an operator change may b e required while a load
     is suspended. This shall be accomplished via a procedure designed
     for the specific crane and operation approved by the installation
     NASA Safety directorate, ensuring that the crane controls are
     manned at all times.

(25) Hand shall be free from encumbrances while personnel are using
     crane ladders. Articles that are too large to be carried in pockets
     or belts shall be lifted and lowered by handline.

(26) Necessary clothing and personal belongings in carne cab shall be
     stored so as not to interfere with access or operations. Tools, oil
     can, waste, extra fuses and other necessary articles shall be
     stored properly, and shall not be permitted to lie loose in the cab
     or on the crane. Operators shall be familiar with the operation and
     care of the fire extinguisher provided.

(27) Crane crew discipline shall be maintained at all times during a
     crane operation. There shall be no eating, drinking, or rowdiness
     during crane operation.

(28) Outdoor hoisting operations should not commence if winds are above
     20 knots steady state of if gusts exceed 35 knots.

(29) A carbon dioxide, dry chemical, or equivalent fire extinguisher
     shall be kept in the cab or in the immediately available vicinity
     of the crane.

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207. SPECIAL CRITERIA

> a\. Special precautions shall be taken while handling explosives or
> Electro Explosive Devices (EEDs). Safety support shall be available.
> Barricades and warning signs shall be erected to control access.
> Voltage checks on crane hooks that will handle explosives or EEDs
> shall be performed to verify that the measured energy level does not
> exceed 20 decibels below the maximum safe no-fire energy level in the
> bridge wire of the associated EED. (Example: For a NASA Standard
> Initiator with a maximum safe no-fire energy level of 1 watt, the
> measured energy level shall not exceed 10 milliwatts, which
> corresponds to 100 millivolts measured across a 1 ohm resistor.) The
> crane hook shall be connected to facility ground before connecting to
> explosives or EEDs. Electrical grounding of the hook and load shall be
> accomplished prior to lifting operations while handling explosives,
> EEDs, or electrically sensitive devices/payloads. The grounding shall
> be measured/verified to be within specification by inspection
> personnel and recorded prior to the lift. If a ground connection must
> b disconnected to facilitate operations, an alternate ground should be
> connected prior to disconnecting the existing ground. The final
>
> attachment/detachment must be at least 10 feet from exposed propellant
> grain, explosives, or EEDs. The use of radio transmissions near
> explosives shall be evaluated for danger potential prior to the
> operation.

b.  Policy shall be developed and enforced for crane operation during
    electrical storms. Operations are generally permitted without
    enclosed metal or framed buildings that are properly grounded.
    Restrictions are necessary for outside operations or for those that
    cannot tolerate power failure/loss.

CHAPTER 3: MOBILE CRANES AND DERRICKS

300. GENERAL

> This chapter establishes safety standards for the design, testing,
> inspection, maintenance, and operation of mobile cranes and derricks.

301. SAFETY ASPECTS

> Generally, high quality off-the-shelf, OEM type equipment is
> acceptable for critical and noncritical lifts if it is designed,
> maintained, operated, etc., according to this standard.

a.  [Safety Design Criteria]{.underline} that should be emphasized
    during mobile crane and derrick design are contained in the
    documents listed in Paragraph 105.

b.  [Labeling/Tagging of Mobile Cranes and Derricks]{.underline}.

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(1) Mobile crane and derricks that have the specified design features,
    maintenance/inspection, and test intervals to lift critical loads
    shall be marked conspicuously so that the operator and assurance
    personnel can distinguish that the crane/derrick is qualified for
    critical lifts.

(2) A standard system of labeling shall be established and used through
    the installation.

(3) A standard tag-out system shall be established and used throughout
    the installation to indicate equipment that is not to be used due to
    inspection discrepancies, ongoing maintenance operations, etc.

(4) Certification/recertification tags are required as described in
    Paragraph 302e.

> c\. [Safety Analysis and Documentation of Mobile Cranes and Derricks
> Used for critical Lifts.]{.underline} A hazard analysis shall be
> performed on all mobile cranes and derricks used for critical lifts.
> The analysis shall, as a minimum, determine potential sources of
> danger, identify most probable failure modes, and recommend
> resolutions for those conditions found in the
> hardware-facility-environment-human relationship that could cause loss
> of life, personnel injury or loss of crane/derrick, facility, or load.
> The analysis also shall include crane/derrick description, reference
> documentation severity assessment, and assessment of specified passive
> and structural components between the hook and the holding brakes.
> Hazards that are identified shall be tracked (recorded and current
> status maintained) until final closure. Is verified. A system of risk
> acceptance is required for hazards that cannot be limited. The hazard
> analysis shall be done as part of the initial crane/derrick
> certification process, included
>
> in the equipment documentation, and updated as required to reflect any
> changes in operation and/or configuration.

d.  [Performance]{.underline}. Operational life, load capability, and
    the desired controlled characteristics with which the crane/derrick
    handles the load shall be addressed for all designs. The expected
    operational life shall be specified or detailed for system
    components. Each load-bearing component shall be designed to sustain
    the maximum imposed loads with appropriate safety factors.
    Operational equipment shall be considered in the design phase to
    ensure load and function are adequate defined and critical
    crane/derrick design features are incorporated on the delivered
    units.

e.  [Structural.]{.underline} Structural design shall be in accordance
    with industry standards for material selection, welding, allowable
    stresses, design limitations, framing, wheels, and other structural
    elements. Refer to ANSI and Power Crane and Shovel Association
    (PCSA) standards for specific design details.

f.  [Mechanical.]{.underline} The mechanical design requirements for
    mobile crane and derrick components are as follows:

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(1) They shall meet all applicable requirements of OSHA, ANSI, and PCSA.

(2) The drum gear shall be pressed on and keyed to either the periphery
    of the hub or shell of the drum, bolted with close fitting milled
    body bolts to a flange on the drum, or attached by other means of
    equal safety.

(3) Gearing shall be designed and manufactured to comply with the latest
    AGMA gear standards.

(4) Couplings shall be located immediately adjacent to bearings.
    Couplings between closely spaced bearings shall be of the full
    flexible type with internal gear form or grids, having metal-to
    metal contact, and shall run in oil or be lubricated as recommended
    by the manufacturer. All couplings for hoists shall be pressed fit
    with keys.

(5) The rated load of a hoisting rope shall not exceed the rope's
    breaking strength divided by 3.5

(6) Hooks shall meet the manufacturer's recommendations, and shall not
    be overloaded. Swiveling hooks should rotate 360 degrees on
    antifriction bearings with means for lubrication. If grease is a
    contamination concern, the either drip funnels (cups) or
    nonlubricated bearings should be provided. Latch-equipped hooks
    shall be used unless the application makes the use of a latch
    impractical or unnecessary. When required, a latch or mousing shall
    be provided to bridge the throat opening of the hook for the

> purpose of retaining slings, chains, or other similar parts under
> slack conditions.

(7) Hoists shall be provided with at least two means of braking: a
    holding brake and a control brake. The torque ratings, physical
    characteristics, and capabilities of the brakes shall be in
    accordance with industry standards.

(8) For mobile cranes and derricks used for critical lifts, two means of
    braking shall be provided, each capable of bringing a rated load to
    zero speed and holding it (with and without power). If the control
    brake and holding brake are designed to operate as a system and
    cannot independently stop and hold a rated load, then another means
    of braking is required for cranes and derricks used for critical
    lifts (e.g., emergency brake). For a telescoping boom crane, the use
    of a counterbalance valve that locks the hydraulic fluid when the
    valve is in the neutral position is an acceptable braking means. The
    brakes shall be designed so that they can be tested as required in
    Paragraph 302c(6).

(9) A positive ratchet and pawl shall be provided on all boom hoists
    drum(s).

(10) Mobile cranes and derricks with booms shall be equipped with a boom
     angle indicator to assist the operator in ensuring that the
     crane/derrick is not loaded beyond the rated load for any given
     configuration.

(11) Safe and adequate access to components to inspect, service, repair,
     or replace equipment shall be provided for during design. The
     design shall provide for visual and physical accessibility.

(12) All wire rope hoists shall be designed to have not less than two
     wraps of hoisting rope on the drum when the hook is in its extreme
     low position. Drum grooves shall be provided as recommended by PCSA
     Standards No. 4 and No. 5. The rope ends shall be anchored securely
     by a clamp or a swaged terminal in a keyhole slot, provided a
     keeper is used to prohibit the swage from moving out of the marrow
     slot. Other methods recommended by the hoist or wire rope
     manufacturer are acceptable if the rope termination anchor together
     with two wraps of rope on the drum will give an anchor system equal
     to or greater than the breaking strength of the wire rope.

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g.  [Electrical.]{.underline} Electrical design requirement are as
    follows:

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(1) Wiring and safety devices shall be in accordance with the NFPA
    National Electrical Code.

(2) Electrical enclosures shall provide protection for the contained
    equipment against environmental conditions.

(3) Though not a requirement, besides overload protection required by
    the National Electrical Code, undervoltage and phase reversal should
    be considered.

(4) The electrical system shall be designed fail-safe to ensure that a
    failure of any component will not cause the crane/derrick to operate
    in a speed range faster than commanded. A failure that would cause
    the crane/derrick to go to a slower speed is acceptable as long as
    the stop function is still available. Failure modes that could cause
    a hard stop, unplanned directional shifts, and/or loss of control
    are unacceptable.

(5) Provisions for grounding the hook are required for handling
    explosives, solid propellants, flammables, or any other load that
    requires a nonelectrical or static-free environment (see Paragraph
    307).

(6) Mobile cranes and derricks used for critical lifts do not require
    emergency stops or upper limits switches. This must be handled
    operationally. A telescoping boom crane shall be equipped with a
    two-blocking damage prevention feature.

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302. TESTING

> Three types of tests are required for mobile cranes and derricks:
> proof lad tests, rated load tests, and operational tests. The proof
> load tests and oeprational tests shall be performed prior to first
> usee for new, extensively repaired, or altered cranes and derricks.
> This applies only to those components directly involved with the
> lifting or holding capability of a crane/derrick that has been
> repaired or altered. Repairs or alternations to nonlifting, secondary
> lifting or holding components such as suspension assemblies,
> electrical system, crane cab, etc., do not require a load test,
> although a functional check should be performed to determine if the
> repairs or alterations are acceptable. The rated load and operational
> tests shall be performed at least every 4 years. Cranes and derricks
> used frequently for critical lifts shall be load tested annually.
> Crane and derricks used infrequently for critical lifts shall be load
> tested before the critical lift if it has been more than a year since
> the last test. If a crane/derrick is upgraded, a proof load test and
> an operational test shall be performed based on the upgraded rating
> All load and operational tests shall be performed by qualified
> personnel according to written (specific or general) technical
> operating procedures approved by NASA and/or contractor safety
> representatives. An inspection of the crane/derrick and lifting
> components shall be performed after each load test an prior to the
> crane/derrick being released for service to ensure there is no damage.
> This inspection shall include DE of components that are suspected to
> be cracked or otherwise affected by the test. The rated load test
> requirement may be fulfilled by a concurrently performed proof load
> test.

a.  [Proof Load Test]{.underline}. Before first use, all new,
    extensively repaired, extensively modified, or altered cranes and
    derricks shall undergo a proof load test. A proof load test also
    should be performed when there is a question in design or previous
    testing. Mobile cranes and derricks shall be tested at the minimum
    working radius (and maximum working radius for new cranes and
    derricks only) with a load as close as possible to, but not
    exceeding 1.10 times the rated load at the given radius . The load
    shall be lifted slowly and in an area where minimal damage will
    occur if the crane/derrick fails. The minimum radius/maximum load
    capacity of the crane/derrick shall be clearly marked to be legible
    from the operator's or user's position and shall not be more than
    the proof test weight divided by 1.10. For cranes/derricks with
    separate lifting systems of different ratings, the markings will
    indicate the lifting capabilities of each system (e.g., main hook,
    whip hook, and auxiliary hook). Proof load tests conducted by the
    manufacturer prior to delivery are acceptable if the necessary test
    certification papers are provided to verify the extent and
    thoroughness of the test on that specific item.

b.  [Rated Load Test]{.underline}. Each mobile crane/derrick shall be
    tested at least once every 4 years with a dummy load equal to the
    rated capacity of the crane/derrick at the minimum working radius
    according to the manufacturer's load chart. Cranes/derricks used
    frequently for critical lifts shall be load tested at least once per
    year. Cranes/derricks used infrequently for critical lifts shall be
    load tested prior to the critical lift if it has been over a year
    since the last load test. A rated load test shall be performed after
    each boom change (when boom disassembly/assembly is required) if the
    crane/derrick is to be used for critical lifts. The acceptable
    tolerance for rated load test accuracy is +5/-0 percent unless
    otherwise specified by design.

c.  [Operational Test]{.underline}. Together with proof load and rated
    load testes, the following shall be performed with a dummy rated
    load unless otherwise specified (except as noted in Paragraph
    302c(7)):

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(1) Load hoisting, lowering at various speeds with the boom at the
    minimum radius (maximum safe movement up and down as determined by
    the installation NASA Safety directorate responsible engineering and
    operations/maintenance organizations), and braking/holding
    mechanisms. Holding brakes shall be tested to verify stopping
    capabilities and demonstrate the ability to hold a rated load.

(2) Boom hoisting and lowering through full safe operating range as
    determined by the installation NASA Safety directorate and the
    responsible engineering an operations/maintenance organizations.

(3) Swinging and traveling mechanisms on mobile cranes (swinging for
    derricks) with boom at minimum radius.

(4) Boom extension and retraction mechanism on telescoping boom cranes.

(5) All limit switches, locking devices, emergency stop switches, boom
    angle indicators, and other safety devices, excluding thermal
    overload and circuit breakers. The limit switch tests shall be
    performed with no load on the hook.

(6) Cranes and derricks used for critical lifts are required to be
    equipped with at least two means of braking (hoist), each capable of
    brining a rated load to zero speed and holding it (see Paragraph
    301f(8)). The operational test must demonstrate each brake's ability
    to stop and hold a rated load. This can be done in one of the
    following ways:

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(a) Each brake's ability to hold shall be statically tested (under no
    load) with 150 percent of the rated load hoisting torque at the
    point of brake application.

(b) Alternately, each brake shall be tested for its ability to stop a
    rated load moving at full speed in the down direction, using
    power-controlled lowering. (CAUTION: It must be possible to quickly
    reenergize the out-of-circuit brake or provide other safety measures
    to perform this test safely.)

(c) Other methods as specified by the installation NASA Safety
    directorate and the responsible engineering and
    operations/maintenance organizations.

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(7) The operational test for a modified crane/derrick can be tailored to
    test only those portions of the equipment that were modified, only
    if the rated load and operational test interval has not expired.
    After boom change on a crane/derrick used for critical lifts, the
    operational test doe not have to include verification of each brake
    (Paragraph 302c(6)) if it has been less than a year since the brakes
    were tested with a load equal to or greater than the maximum
    capacity of the crane/derrick with the new boom.

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d.  An organization may certify a mobile crane/derrick for a specific
    lift (critical or noncritical). A load test and an operational test
    with a dummy load are required. In this case, test weight shall be
    at least equal to the specific load that the crane/derrick is being
    certified to lift and may be greater as determined by the user and
    maintenance organization. The test weight shall not exceed 110
    percent of the mobile crane's/derrick's rated capacity for the given
    configuration.

e.  Test Reports and Periodic Recertification Tags. After each test,
    designated personnel shall prepare written, dated, and signed test
    reports including procedure reference. Inadequacies shall be
    documented and, if determined to be a hazard, corrected prior to
    further use. These reports shall be kept on file by the owner
    organization for a minimum of 2 test cycles and shall be made
    readily available. Following the rated load test, mobile
    cranes/derricks shall be given a permanently affixed tag identifying
    the equipment and stating the next required rated load test date or
    certification expiration date.

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303. INSPECTION

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a.  Daily and periodic safety inspections shall be performed on all
    mobile cranes/derricks and accessories. Inadequacies discovered
    during an inspection shall be documented and, if determined to be a
    hazard, corrected prior to further use. Inspections shall be made by
    designated personnel according to approved technical operating
    procedures.

b.  All new, extensively repaired, or modified mobile cranes and
    derricks shall be given a daily and a periodic inspection prior to
    first use. For component repair on cranes/derricks, only the
    inspections that apply to the repaired portion need to be performed
    prior to first use unless a periodic inspection interval expires
    during the downtime (see Paragraph 303e).

c.  Mobile cranes and derricks in regular service (used at least once a
    month) shall be inspected as required in Paragraphs 303d and 303e.
    Idle cranes shall be inspected according to Paragraph 303f.

d.  [Daily Inspections.]{.underline} These inspections shall be
    performed prior to first use each day the crane/derrick is used, and
    shall include the following:

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(1) Check functional operating and control mechanisms for maladjustments
    that could interfere with normal operations.

(2) Without disassembling, visually inspect lines, tanks, valves, drain
    pumps, gear casings, and other components of fluid systems for
    deterioration and leaks. This applies to components that can be seen
    from the ground level or for which there is safe access via
    inspection walkways.

(3) Without disassembling, inspect all functional operating and control
    mechanisms for excessive wear and contamination by excessive
    lubricants or foreign matter.

(4) Inspect hooks for cracks and deformities (see Chapter 5).

(5) Inspect rope reeving for proper travel and drum lay.

(6) Inspect hoist chains for excessive wear or distortion.

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e.  [Formal Periodic Inspections]{.underline}. These inspections shall
    be performed at varying intervals, depending on activity, severity
    of service, environment, and criticality.

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(1) [Annual Inspections]{.underline}. At least once per year, inspect
    for:

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(a) Deformed, cracked or corroded members and welds and loose bolts or
    rivets in crane structure. Various methods of NDE such as
    ultrasonics, x-ray, magnetic particle, dye penetrant, etc., shall be
    used as needed.

(b) Cracked or worn sheaves and drums.

(c) Excessive wear or cracks in pins, bearings, shafts, gears,
    followers, and locking and clamping devices. NDE techniques shall be
    used if cracks are suspected.

(d) Significant inadequacies in load, wind, boom, angle, and other
    indicators over full range.

(e) Excessive wear in chain drive sprockets and stretch in the chain.

(f) Abnormal performance in power plant(s) and compliance with
    applicable safety requirements, such as locations of guards on
    belts.

(g) Evidence of malfunction in travel, steering, braking, and locking
    devices.

(h) Evidence of a malfunction in any safety device.

(i) Evidence of overheating.

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(2) Monthly Inspections. At least once per month:

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(a) Inspect for excessive wear in brake (hoist and boom) and clutch
    system parts, linings, pawls, and ratchets without major
    disassembly.

(b) Perform a thorough inspection of all ropes paying particular
    attention to the signs of deterioration and damage outlined in
    Paragraph 304c.

(c) Inspect for visible deformation or cracks in hooks (see Chapter 5).

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f.  [Idle and Standby Cranes/Derricks]{.underline}. Cranes and derricks
    idle for more than 1 month shall be inspected prior to first use
    according to the requirements of Paragraphs 303d and 303e that were
    not performed at required intervals and recorded during the standby
    period.

g.  [Inspection Reports]{.underline}. After each formal periodic
    inspection, qualified, authorized personnel shall prepare written,
    dated, and signed inspection reports. These reports shall include
    procedure reference and adequacy of the crane/crane components.
    Inadequacies shall be documented and, if determined to be a hazard,
    corrected prior to further use. These reports shall be filed and
    made readily available by the organizational element responsible for
    inspection.

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304. MAINTENANCE

> A preventive maintenance program shall be established based on
> manufacturers' recommendations and/or experience gained from use of
> the equipment. The program shall include procedures and a scheduling
> system for normal periodic maintenance items, adjustments,
> replacements, and repairs. The program shall also ensure that records
> are kept and unsafe test and inspection discrepancies are documented
> and corrected.

a.  [Maintenance procedures]{.underline}. Before maintenance,
    adjustments, repairs, and replacements are initiated, the following
    safety precautions shall be taken:

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(1) Move to an area where maintenance will not interfere with other
    operations.

(2) Cranes/derricks shall not be operated until all safety devices have
    been activated and tested/adjusted if involved in the maintenance
    action.

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b.  [Adjustments]{.underline}. Based upon the manufacturer's
    documentation and/or experience, adjustments shall be made to ensure
    that all components function properly, paying particular attention
    to:

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(1) Brakes (Appropriate precautions should be taken by inspectors,
    repair personnel, and other who may be potentially exposed to
    airborne dust fibers from any asbestos friction materials present in
    braking mechanisms.)

(2) Control system.

(3) Power plants.

(4) Critical operating mechanisms and safety devices.

(5) Operator mechanical and electrical controls.

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c.  [Repairs/Replacements]{.underline}. Repairs/replacements shall be
    promptly provided for safe operation.

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(1) For repair/replacement requirements for hooks with deformation or
    cracks, see Chapter 5. If repaired, hooks shall be proof load tested
    using the associated mobile crane/derrick minimum working radius
    proof load value.

(2) Structural members that are cracked, bent, broken, excessively worn,
    or corroded shall be replaced. Proper material and weld/repair
    procedures will be used according to ANSI/AWS D14.1-82 and
    manufacturer specifications. Procedures will be conducted by
    properly qualified personnel.

(3) The need to replace wire rope shall be determined by a certified or
    otherwise qualified person based on an evaluation of inspection
    results. Any of the following signs of deterioration and damage are
    sufficient reasons for questioning continued use of the rope:

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(a) Six randomly distributed broken wires in one rope lay or three
    broken wires in one strand in one lay.

(b) Individual outside wires with wear of 1/3 the original diameter.

(c) Kinking, crushing, bird caging, or any other damage resulting in
    distortion.

(d) Evidence of heat damage.

(e) End connectors that are cracked, deformed, or with evidence of rope
    pullout.

(f) Corrosion (internal or external) that results in reduction of rope
    diameter, or at end connectors.

(g) Reductions of nominal diameter (measured with a caliper or go/no-go
    gage) of more than:

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1.  1/64 inch for diameters of rope up to 5/16 inch.

2.  1/32 inch for diameters 3/8 inch to ½ inch.

3.  3/64 inch for diameters 9/16 inch through ¾ inch.

4.  1/16 inch for diameters 7/8 inch through 1-18 inches.

5.  3/32 inch for diameters greater than 1-1/8 inches.

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(h) If replaced, the new rope shall be proof load tested using the
    associated mobile crane/derrick minimum working radius proof load
    value.

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305. PERSONNEL CERTIFICATION

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a.  [Program.]{.underline} Only certified (licensed) and trained
    operators shall be authorized to use/operate mobile cranes and
    derricks. A training, examination, and licensing program shall be
    established or made available. For those NASA installations that do
    not have a training program, all operators shall be trained and
    certified by a recognized certification organization that normally
    performs this function. Certification also shall include riggers and
    flagmen.

b.  [Levels.]{.underline} Two levels of operator training and
    proficiency will be established. Operations where critical lifts are
    involved will require a more rigid operator certification program
    than those operations that involve more routine lifts that do not
    involve critical hardware or unique hazards.

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(1) [Noncritical Lifts.]{.underline} The certification program for
    noncritical lift operators shall include the following:

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(a) Training

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1.  Classroom training in safety and first aid/emergency procedures,
    general performance standards, requirements, pre-operational checks,
    and safety-related defects and symptoms (for initial certification
    and as needed).

2.  Hands-on training (for initial certification and as needed).

3.  An annual review of the items in Subparagraph (a) above. (This may
    be conducted informally by local supervisory personnel).

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(b) Examination

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1.  Physical examination (criteria to be determined by the cognizant
    medical official using ANSI requirements).

2.  Written examination.

3.  Operational demonstration (for initial certification only).

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(c) Licensing

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1.  An organizational element shall be designated to issue operator
    licenses. Provisions shall be made to revoke licenses for
    negligence, violations of safety requirements, or failure to meet
    medical standards. Provision shall be made for periodic checks of
    operators to verify they have licenses in their possession. The
    licenses shall indicate the type of crane/derrick the holder is
    qualified to operate. Alternately, the organizational element may
    elect to maintain a master list of licensed operators instead of
    issuing individual licenses, providing copies of the list are
    readily available to assurance and supervisory personnel at the work
    site.

2.  Renewal. Licenses or certifications will expire at least every 4
    years. Renewal procedures will be established by each licensing
    organization but as a minimum will include items in Paragraphs
    305b91)(a) and (b).

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(2) Critical Lifts. Besides the training, examination, licensing, and
    license renewal requirements for noncritical lifts, operators that
    are being certified to perform critical lifts must be trained in the
    specific hazards and special procedures associated with the lift.
    Operators must also demonstrate proficiency and operating finesse
    with the crane/derrick using a test load for the initial
    certification or alternately be immediately supervised by a
    certified operator during the first initial lifting period. The
    licenses will indicate specific cranes/derricks for which the
    operator is certified.

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306. OPERATIONS

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a.  The operator is responsible for being totally familiar with the
    information contained in the crane/derrick operating manual and load
    chart. The operator must understand the correct meaning of all notes
    and warnings and be able to calculate or determine the
    crane's/derrick's actual net capacity for every possible machine
    configuration. The following practices shall be observed for
    crane/derrick operations:

> \(1\) General operating procedures describing operation, emergency
> steps, communication requirements, and special requirement shall be
> prepared, approved, and followed for each crane/derrick. There must be
> a formal system for review, approval, and update to maintain valid
> operating procedures. Emergency procedures shall be developed for
> contingency actions such as power loss, brake failure, or other
> emergencies. (Also, see Paragraph 101c(1)(c).)

(2) Operations shall be analyzed for hazards. The analysis shall
    consider the environment in which the operation occurs, hazards
    associated with crane/derrick maintenance, and, in general, a
    systems safety analysis of the equipment, facility, load, and
    interfaces as a whole in support of the lifting operation.

(3) Appropriate load charts shall be located in the crane/derrick cab,
    if so equipped. Otherwise, the load charts shall be kept in a
    central, easily accessible place. Mobile cranes and derricks shall
    not be operated without an appropriate load chart.

(4) For critical lifts, the load shall not exceed 75 percent of the
    crane's/derrick's rated capacity for the respective radius unless
    approved, as a minimum, by the installation NASA Safety Director.
    For critical lifts greater than 75 percent of rated capacity, extra
    care shall be taken to calculate exact weight, center of gravity,
    and lift radius.

(5) Methods shall be developed and demonstrated for lowering a load in
    the event of crane/derrick failure or other contingencies. These
    shoul dbe demonstrated and verified if practical.

(6) A crane/derrick shall not be loaded beyond its rated load (capacity)
    except for required testing.

(7) Cranes/derricks may be used to load test items such as slings,
    platforms, or lifting fixtures if specifically identified to do so
    based on a specified percentage of rated load and a safety analysis
    approved by the installation NASA Safety directorate and responsible
    engineering and operations/maintenance organizations. This is to
    ensure that the crane/derrick is not damaged due to sudden unloading
    should the test article fail.

(8) Cranes/derricks shall not be side loaded or used to drag loads
    sideways unless specifically designed to do so. Side loading of the
    boom shall be limited to freely suspended loads.

(9) There shall be a system for documenting crane/derrick
    problems/discrepancies. Prior to an operation, the operator shall
    review any previously noted problems/discrepancies to determine
    possible impact on planned activity.

(10) The operator shall ensure that the crane/derrick is within
     inspection and testing intervals by examination of the periodic
     recertification tags and/or documentation.

(11) Before each lift or series of lifts, the operator shall perform a
     pre-operational check to demonstrate operational readiness. If
     controls do not operate properly, the operator is responsible for
     notifying the supervisor. Repairs and adjustments shall be made
     before operations begin.

(12) The operator and ground lead man shall establish appropriate safety
     zones before initiating operations. Safety zones should have
     appropriate barriers (rope, cones, etc.) established prior to lift.

(13) Before starting to hoist, the following conditions shall be noted:
     the hoist rope shall not be kinked, multiple part ropes shall not
     be twisted around each other, and the hook shall be centered over
     the load to prevent swinging.

(14) When raising loads that approach the rated capacity of the
     crane/derrick, the operator shall know the weight of the working
     load. The operator shall test the holding brakes each time a load
     approaching the rated load is handled. The brakes shall be tested
     by raising the load minimally above the surface and holding the
     load with the brake. The load should be held long enough to allow
     any dynamics to dampen out.

(15) If radio communications are to be used, operator and/or lift
     supervisors shall test the communication system prior to the
     operation. Operation shall stop immediately upon communication
     loss, and shall not continue until communication is restored.

(16) If hand signals are required, only standard signals shall be used
     according to Appendix C. Hand signals shall be posted in a
     conspicuous location.

(17) Crane/derrick crew emergency egress routes should be verified to be
     free of obstructions prior to hazardous operations. The
     availability of crew protection equipment should be verified prior
     to hazardous operations.

(18) If there is a slack rope condition, it shall be determined that the
     rope is properly seated on the drum and in the sheaves before
     starting the hoist.

(19) During hoisting, care shall be take that there is no sudden
     acceleration or deceleration of the moving load and that the load
     does not contact any obstructions.

(20) Load shall be secured, balanced, and kept under control with proper
     slings. The use of tag lines to keep the load stabilized may be
     required. Tag line personnel shall take care not to impart
     undesirable motion to the load.

(21) Person(s) shall not ride the hook or load at anytime.

(22) Personnel shall not be located under suspended or moving loads
     unless the operation adheres to the OSHA-approved NASA Alternate
     Standard for Suspended Load Operations. (See Appendix B).

(23) The load shall not be lowered below the point where less than two
     full wraps of rope remain on the host drum.

(24) A responsible person shall be in charge of the operation and shall
     instruct all personnel involved in the proper positioning, rigging,
     and moving to be done.

(25) An operator shall be at the crane/derrick controls at all times
     while a load is suspended (OSHA requirement). Due to the length of
     some NASA operations, an operator change may be required while a
     load is suspended. This shall be accomplished via a procedure
     designed for the specific crane/derrick and operation, approved by
     the installation NASA Safety directorate, ensuring that the crane
     controls are manned at all times.

(26) Hand shall be free from encumbrances while personnel are using
     crane/derrick ladders. Articles that are too large to be carried in
     pockets or belts shall be lifted and lowered by handline.

(27) Necessary clothing and personal belongings in cabs shall be stored
     so as not to interfere with access or operations. Tools, oil can,
     waste, extra fuses, and other necessary articles shall be store
     properly, and shall not be permitted to lie loose in the cab or on
     the crane. Operators shall be familiar with the operation and care
     of the fire extinguishers provided.

(28) Crane/derrick crew discipline shall be maintained at all times
     during an operation. There shall be no eating, drinking, or
     rowdiness during crane/derrick operation.

(29) Mobile cranes shall be level and, where necessary, outriggers shall
     be extended and/or the crane shall be blocked properly before the
     load is moved. Wood blocks used to support outriggers shall be
     strong enough to prevent crushing, free from defects, and of
     sufficient width and length to prevent shifting or toppling under
     load. For critical lifts, wood blocking is not permitted under
     outriggers unless approved by the installation NASA Safety
     directorate and the responsible engineering and operations
     organizations.

(30) On truck mounted cranes, loads shall not be lifted over the front
     area except as approved by the crane manufacturer.

(31) Outriggers shall be used when load to be handled at a particular
     radius exceeds rated load with outriggers, as specified by the
     crane manufacturer's load chart. Floats, where used, shall be
     securely attached to the outriggers.

(32) Neither the load nor the boom shall be lowered below the point
     where less than two full wraps of rope remain on the respective
     drums.

(33) For mobile cranes in transit, the following precautions shall be
     taken: boom shall be stowed/carried in line with direction of
     motion, superstructure shall be secured against rotation, except in
     negotiating turns when there is an operator in the cab or boom is
     supported on a dolly, and hook shall be lashed or otherwise
     restrained so that it cannot swing freely while in transit or
     moving.

(34) When traveling a mobile crane with a load, a person shall be
     designated responsible for determining and controlling safety and
     making decisions as to position of load, boom location, ground
     support, travel route, and speed of movement.

(35) A mobile crane with or without a load shall not be traveled with
     the boom so high that it may bounce back over the cab.

(36) When rotating cranes/derricks, sudden starts and stops shall be
     avoided. Speed shall be such that the load does not swing out
     beyond radii at which it can be controlled. A tag line shall be
     used when rotation of load is hazardous.

(37) Ropes shall not be handled on a winch head without the knowledge of
     the operator.

(38) While a winch head is being used, the operator shall be within
     convenient reach of the power unit control level.

(39) If the load must remain suspended for any considerable length of
     time, the operator shall hold the drum from rotating the lowering
     direction by activating the positive control level of the
     operator's station.

(40) Mobile cranes shall not be operated without the full amount of
     ballast or counterweight in place as specified by the manufacturer.
     The ballast or counterweight, as specified by the manufacturer,
     shall not be exceeded.

(41) Refueling with small portable containers shall be done with
     Underwriter's Laboratories or Factory Mutual Laboratories approved
     (or equivalent) safety type can equipped with an automatic closing
     cap and flame arrestor.

(42) Machines shall not be fueled with engines running. After fueling,
     wait at least 5 minutes for flammable vapors to clear before
     starting engine.

(43) A carbon dioxide, dry chemical, or equivalent fire extinguisher
     shall be kept in the cab or vicinity of the crane/derrick.

(44) Except where the electrical distribution and transmission lines
     have been deenergized and visibly grounded at the pot of work, or
     where insulating barriers, not a part of or an attachment to the
     crane, have been erected to prevent physical contact with power
     lines, mobile cranes shall be operated in accordance with the
     following:

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(a) For lines rated 50kV or below, minimum clearance between lines and
    any part of crane or load shall be 10 feet.

(b) For lines rated over 50 kV, minimum clearance between lines and any
    art of crane or load shall be 10 feet plus 0.4 inch for each 1kV
    over 50kV, or twice the length of the line insulator, but never less
    than 10 feet.

(c) The crane shall be positioned to preclude the boom or load from
    contacting or falling across the power line(s) in the event of crane
    failure.

(d) In transit, with no load and boom lowered, the clearance shall be a
    minimum of 4 feet.

(e) Clearance observers shall be provided with an acceptable means of
    giving a warning in time for operators to react to insufficient
    clearance.

(f) Crane boom tips shall have two red flags (minimum of 12 inches x 12
    inches each).

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(45) Before starting operation near electrical lines, the organization
     responsible for the lines shall be notified and provided with all
     pertinent information. The responsible organization's cooperation
     shall be requested.

(46) Any overhead wire shall be considered an energized line unless and
     until the person responsible for such line or the electrical
     utility authorities indicate that it is not an energized line.

(47) Outdoor hoisting operations should not commence if winds are above
     20 knots steady state or if gusts exceed 35 knots.

(48) Cranes/derricks left outdoors shall be secured by the operator when
     operations are complete.

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307. SPECIAL CRITERIA

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a.  Special precautions shall be taken while handling explosives or
    Electro Explosive Devices (EEDs). Safety support shall be available.
    Barricades and warning signs shall be erected to control access.
    Voltage checks on crane hooks that will handle explosives or EEDs
    shall be performed to verify that the measured energy level does not
    exceed 20 decibels below the maximum safe no-fire energy level in
    the bridge wire of the associated EED. (Example: For a NASA Standard
    Initiator with a maximum safe no-fire energy level of 1 watt, the
    measured energy level shall not exceed 10 milliwatts, which
    corresponds to 100 millivolts measured across a 1 ohm resistor.) The
    crane/derrick hook shall be connected to facility ground before
    connecting to explosives or EEDs. Electrical grounding of the hook
    and load shall be accomplished prior to lifting operations while
    handling explosives, EEDs, or electrically sensitive
    devices/payloads. The grounding shall be measured/verified to be
    within specification by inspection personnel ad recorded prior to
    the lift. If a ground connection must be disconnected to facilitate
    operations, an alternate ground should be connected prior to
    disconnecting the existing ground. The final attachment/detachment
    must be at least 10 feet from exposed propellant grain, explosives,
    or EEDs. The use of radio transmissions near explosives shall be
    evaluated for danger potential prior to the operation.

b.  Policy shall be developed and enforced for crane/derrick operation
    during electrical storms. Operations are generally permitted with
    out restriction within enclosed metal or framed buildings that are
    properly grounded. Restrictions are necessary for outside operations
    or for those that cannot tolerate power failure/loss.

CHAPTER 4: HOISTS

400. GENERAL

> This chapter establishes safety standards for the design, inspection,
> test, maintenance, and operation of hoists. These standards apply to
> electric, air-powered, and manual hoists, including those used to
> raise/lower empty personnel work platforms, surfaces, or stations.
> This does not include hoists connected to platforms used to raise or
> lower personnel For these, see Chapter 7, Special Hoist Supported
> Personnel Lifting Devices.

401. SAFETY ASPECTS

> Generally, of-the-shelf, OEM type equipment is acceptable for critical
> and noncritical lifts if it is designed, maintained, operated, etc.,
> according to this standard.

a.  [Safety Design Criteria]{.underline} that should be emphasized
    during hoist design are contained in the documents listed in
    Paragraph 105.

b.  [Labeling/Tagging of Hoists.]{.underline}

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(1) The hoist's rated capacity shall be marked on it or its load block.
    This marking shall be clearly legible from the ground floor.

(2) Hoists that have the specified design features,
    maintenance/inspection, and test intervals to lift critical loads
    shall be marked conspicuously so that the operator and assurance
    personnel can distinguish that the hoist is qualified for critical
    lifts.

(3) A standard system of labeling shall be established and used
    throughout the installation.

(4) A standard tag-out system shall be established and used throughout
    the installation to indicate equipment that is not to be used due to
    inspection discrepancies, ongoing maintenance operations, etc.

(5) Certification/recertification tags are required as described in
    Paragraph 402e.

> c\. [Safety Analysis and Documentation for Hoists used for Critical
> Lifts]{.underline}. A hazard analysis shall be performed on all hoists
> used for critical lifts. The analysis shall, as a minimum, determine
> potential sources of danger, identify most probable failure modes, and
> recommend, and recommend resolutions for those conditions found in the
> hardware-facility-environment-human relationship that could cause loss
> of life, personal injury, or loss of crane, facility, or load. The
> analysis also shall include hoist description, reference
>
> documentation, severity assessment, and assessment of certain passive
> and structural components between the hook and the holding brakes.
> Hazards that are identified shall be tracked (recorded and current
> status maintained) until final closure is verified. A system of risk
> acceptance is required for hazards that cannot be eliminated. The
> hazard analysis shall be done as part of the initial certification
> process, included in the hoist documentation, and updated as required
> to reflect any changes in operation and/or configuration.

d.  [Performance]{.underline}. Operational life, duty cycle, load
    capability, and the desired control characteristics with which the
    hoist handles the load shall be addressed for all designs. The
    expected operational life shall be specified or detailed for system
    components. Duty cycle requirements shall be based on the worst
    expected duty the unit will encounter. Each load-bearing component
    shall be specified or detailed to lift the maximum imposed loads
    resulting from zero to rated hook load with appropriate safety
    factors. Operational requirements shall be considered in the design
    phase to ensure load and function are adequately defined and
    critical hoists design features are incorporated on the delivered
    units. Environmental conditions must also be considered.

e.  [Structural.]{.underline} Structural design shall be in accordance
    with industry standards for material selection, welding, allowable
    stresses, design limitations, framing, wheels, and other structural
    elements. Refer to CMAA standards for specific design details.

f.  [Mechanical.]{.underline} The use of high quality, off-the-shelf,
    OEM type equipment is acceptable for critical and noncritical lift
    applications if it meets all user requirements and the requirements
    of this document. This high quality commercial equipment employs a
    modular type construction of the hoist unit with standard frame
    sizes and interchangeable gear boxes, drums, motors, brakes, and
    controls to achieve a wide range of capacities, lifts operating
    speeds, reeving arrangements, and controls. These interchangeable
    parts are standardized for each manufacturer's product line and the
    hoists are built to order. The mechanical design requirements for
    hoist components are as follows:

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(1) They meet all applicable requirements of OSHA, ANSI, and CMAA.

(2) Electrical and air operated hoists should be provided with at least
    two means of braking: a holding brake and a control brake. The
    torque rating, physical characteristics, and capabilities shall be
    in accordance with CMAA specifications.

(3) Powered (electric and air) hoists used for critical lifts shall have
    two means of braking, each capable of bringing a rated load to zero
    speed and holding it (with and without power). If the control brake
    and holding break are designed to operate as a system and cannot

> Independently stop and hold a rated load, then another means of
> braking is required (e.g., emergency brake). The brakes shall be
> designed so that they can be tested as required in Paragraph 402c(5).

(4) For critical lift application, speed reduction from the motor to the
    drum on the hoist should be achieved by enclosure in a gear case. If
    open gears are required, they shall be guarded with a provision for
    lubrication and inspection.

(5) All wire rope hoists shall have not less than two wraps of hoisting
    rope on the drum when the hook is in its extreme low position. Drum
    grooves, when provided, shall be as recommended by CMAA. The rope
    ends shall be anchored securely by a clamp or a swaged terminal in a
    keyhole slot, provided a keeper is used to prohibit the swag from
    moving out of the narrow slot. Other methods recommended by the
    hoist or wire rope manufacturer are acceptable if the rope
    termination anchor together with two wraps of rope on the drum will
    give an anchor system equal to or greater than the braking strength
    of the wire rope.

(6) Safe and adequate access to hoist components to inspect, service,
    repair, or replace equipment shall be provided for during design.
    The design shall provide for visual and physical accessibility.

(7) Manually operated (nonpowered), off-the-shelf OEM type hoists are
    acceptable for critical and noncritical lift applications. They
    shall comply with applicable ANSI requirements. These hoists shall
    have at least one brake as described by industry standards. No limit
    switches are required if proper over-travel restraint is provided.

(8) Air operated chain hoists can be equipped with over-travel
    protection devices instead of the hoist travel limit switches.

(9) Initial and final upper limit switches (limit control valves) shall
    be provided and tested fir air-operated hoists as described in
    Paragraph 401g(7). The final upper limit switch (limit control
    valve) shall exhaust air from the hoist, set the brakes, and require
    reset at the upper limit switch (limit control valve) level.

(10) Worm gears shall not be used as a braking means unless the lead
     angle is sufficient to prevent back driving. The braking properties
     of a worm gear tend to degrade with use; the design engineer shall
     consider this when purchasing new equipment or in existing
     installations where the hoist is subject to heavy use.

(11) In the procurement of new lifting equipment, the use of cast iron
     components in the hoist load path shall be approved, as a minimum,
     by the installation NASA Safety Director. The material properties
     of cast iron allow catastrophic failure and should not be
     considered as reliable as steel or cast steel. The engineer shall
     consider this when selecting equipment and avoid the use of load
     bearing cast iron materials where possible.

(12) Gearing shall be designed and manufactured to comply with the
     latest AGMA gear standards.

(13) Hooks shall meet the manufacturer's recommendations, and shall not
     be overloaded. Swiveling hooks should rotate 360 degrees on
     antifriction bearings with means for lubrication. If grease is a
     contamination concern, drip funnels (cups) or nonlubricated
     bearings should be provided. Latch-equipped hooks shall be used
     unless the application makes the use of a latch impractical or
     unnecessary. When required, a latch or mousing shall be provided to
     bridge the throat opening of the hook to retain slings, chains, or
     other similar parts under slack conditions.

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g.  [Electrical.]{.underline} Electrical design requirements are as
    follows:

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(1) Wiring and safety devices shall be in accordance with the NFPA
    National Electrical Code.

(2) Electrical enclosure shall provide protection for the contained
    equipment against environmental conditions.

(3) Though not a requirement, beside overload protection required by the
    National Electrical Code, undervoltage and phase reversal should be
    considered.

(4) For powered hoists used for critical lifts, an assessment shall be
    performed to determine the operational needs for remote emergency
    stops independent from the operator controlled emergency stop. Not
    all hoists used for critical lifts require a remote emergency stop.
    Remote emergency stops are required for hoists used for critical
    lifts where the operator's view is restricted/obstructed. When
    provided, this independent remote emergency stop should be located
    such that the independent remote emergency stop operator(s) can
    clearly see the critical lift area(s). The remote emergency stop
    circuit shall be separate from and take precedence over the operator
    control circuit. The control, when activated, shall cause all drives
    to stop and the brakes to set. Hand-held remote emergency stop
    pendants should be standardized an should include power and circuit
    continuity indication. For those hoist required to make critical
    lifts and have not been

> Modified to provide a remote emergency stop, handling procedures shall
> be developed and implemented to minimize the risk.

(5) Electrical control stations shall operate on 150 volts DC, 120 volts
    AC, or less. Positive detent pushbuttons or a control level shall be
    used for speed control. Controls shall return to the off position
    when the operator relieves pressure. A red, emergency stop
    pushbutton shall be provided to operate the mainline contractor,
    main circuit breaker, or pneumatic source. A dump valve is
    acceptable for the emergency stop for a pneumatic hoist.

(6) The electrical system shall be designed fail-safe to ensure that a
    failure of any component will not cause the hoist to operate in a
    speed range faster than commanded. A failure that causes a speed
    different from that selected is acceptable provided no hazards are
    introduced. Failure modes that cause the hoist to slow down or come
    to a safe stop are acceptable; those that could cause a hard stop,
    unplanned directional shifts, and/or loss of control are
    unacceptable.

(7) For hoists used for critical lists (except manual), dual upper limit
    switches are required. For electric hoists, the limit switches shall
    meet the following requirements:

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(a) Initial upper limit switch electrical contacts shall be a set of
    normally closed contacts in the "raise" contractor circuit such that
    movement in the raise direction shall be precluded after the limit
    switch is encountered. Movement in the "lower" direction will not be
    inhibited.

(b) Final upper limit switch electrical contracts shall be a set of
    normally closed electrical contacts wired into the mainline circuit,
    hoist power circuit, main contractor control circuit, or hoist power
    contractor control circuit such that all hoist motion shall be
    precluded after the limit switch is encountered. These normally
    closed contacts may be located in the low voltage circuitry.

(c) After a final upper limit switch has been activated, movement of the
    load will require action (resetting) at the final upper limit switch
    level. An inspection shall be made to determine the cause of failure
    of the initial upper limit switch. Stopping hoist motion by the
    above design configuration may result in a hazardous suspended load
    condition. The hoist design should include a means of detecting
    limit switch failure and allow for safe inspection and repair. For
    example, a system may be equipped with two different colored
    annunciator lights, one for each limit switch. A resent button may
    be included so that when a final

> upper limit switch is tripped, the load can be lowered immediately.
> The reset button should be secured to prevent unauthorized use.

(d) The initial upper limit switch shall be adjusted sufficiently low to
    preclude inadvertent actuation of the final upper limit switch if
    the hoist actuates the initial switch at full speed with no load.
    Similarly, the final upper limit shall be adjusted sufficiently low
    to ensure that the hoist will not two-block (or otherwise damage
    wire rope) if the hoist actuates the final switch at full speed with
    no load. Both limits shall be tested from slow speed to full speed
    to verify correct operation. It should be noted that this
    requirements effectively lowers the usable hook height of the hoist.
    The limit switch arrangement needs to be considered during new
    equipment design.

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402. TESTING

> Three types of tests are required on hoists: proof load tests, rated
> load tests, and operational tests. The proof load tests and
> operational tests shall be performed prior to first use for new,
> extensively repaired, or altered hoists. The rated load and
> operational tests shall be performed at least every 4 years. For
> hoists used for critical lift, these tests shall be based on frequency
> of usage. Hoists used frequently for critical lifts shall be load
> tested annually. Hoists used infrequently for critical lifts shall be
> load tested before each critical lift if it has been more than a year
> since the last test. If a hoist is upgraded, a proof load test and an
> operational tests shall be performed based on the upgraded rating. All
> load and operational tests shall be performed by qualified personnel
> according to written (specific or general) technical operating
> procedures approved by NASA and/or contractor Safety representatives.
> An inspection shall be performed after each load test and prior to the
> hoist being released for service to ensure there is no damage. If
> cracks or structural damage is suspected, suitable NDE techniques
> shall be used to determine the condition.

a.  [Proof Load Test.]{.underline} Before first use and after
    installation, all new, extensively repaired, modified, or altered
    hoists shall under go a proof load test with a dummy load as close
    as possible to, but not exceeding 125 percent of the rated load. The
    hoist rating will not be more than 80 percent of the proof load test
    weight. For platform hoists, test the hoist at 125 percent of rated
    capacity prior to hookup to the platform. With the platform
    attached, verify that the actual lift does not exceed the rated
    capacity of the hoist. The rated load of a hoist shall be clearly
    legible from the operator's or user's position. Platform hoist
    systems shall be clearly marked with the maximum load to be lifted
    by the system.

b.  [Rated Load Test.]{.underline} All hoists, except platform hoists
    shall be tested at least once every 4 years with a dummy load equal
    to hoist's rated capacity. For hoists used fro critical lifts, these
    tests shall be based on frequency of

> usage. Hoists used infrequently for critical lifts shall be load
> tested before each critical lift if it has been over a year since the
> last test. Hoists used frequently for critical lifts shall be load
> tested at least once per year. The acceptable tolerance for rated load
> test accuracy is +5/-0 percent unless otherwise specified by design.
> The rated load test can be fulfilled by a concurrently performed proof
> load test. Platform hoists do not require rated load tests.

c.  [Operational Test]{.underline}. Together with proof load and rated
    load tests, the following shall be performed with a dummy rated load
    unless otherwise specified (platform hoists shall be operationally
    tested every 4 years using the attached platform only):

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(1) Perform all hoists function in an unloaded condition.

(2) Test operation of brakes and limit, locking, and safety devices.

(3) Determine trip setting of limit switches and limiting devices by
    tests under no load conditions. Conduct tests first by hand, if
    practical, and then under the slowest speed obtainable. Test with
    increasing speeds up to the maximum speed. Locate actuating
    mechanisms so that they will trip the switches or limiting devices
    in time to stop motion without damaging the hoist.

(4) After testing in the unloaded state, apply the test load to the
    hoist to check the proper load control. Test load hoisting, lowering
    at various speeds (maximum safe movement up and down as determined
    by the installation NASA Safety directorate and the responsible
    engineering and operations/maintenance organization), and
    braking/holding mechanisms (holding brakes shall be tested to verify
    stopping capabilities and demonstrate the ability to hold a rated
    load). The load should be held long enough to allow any dynamics to
    dampen out.

(5) Powered hoists used for critical lifts are required to be equipped
    with at least two means of braking, each capable of brining a rated
    load to zero speed and holding it (see Paragraph 401f(3)). The
    operational test must demonstrate each brake's ability to stop and
    hold a rated load. This can be done in one of the following ways:

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(a) Each brake's ability to hold shall be statically tested (under no
    load) with 150 percent of the rated load hoisting torque at the
    point of brake application.

(b) Alternately, each brake shall be tested for its ability to stop a
    rated load moving at full speed in the down direction. (CAUTION: It
    must be possible to quickly reenergize the out of circuit brake or
    provide other safety measures to perform this test safely.)

(c) Other methods as specified by the installation NASA Safety
    directorate and the responsible engineering and
    operations/maintenance organization.

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(6) The operational test for a modified hoist can be tailored to test
    only those portions of the equipment that were modified, only if the
    rated load and operational test interval has not expired.

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d.  An organization may certify a hoist for a specific lift (critical or
    noncritical). A load test and an operational test with a dummy load
    are required. In this case, the test weight shall be at last equal
    to the specific load that the hoist is being certified to lift and
    may be greater as determined by the user and maintenance
    organization. The test weight shall not exceed 125 percent of the
    hoist's rated load.

e.  [Test Reports and Periodic Recertification Tags]{.underline}. After
    each test, designated personnel shall prepare written, dated, and
    signed test reports, including procedure reference. Inadequacies
    shall be documented and, if determined to be a hazard, corrected
    prior to further use. These reports shall be filed and shall be made
    readily available by the organization responsible for testing the
    hoist. Following the rated load test, all hoists shall be given a
    permanently affixed tag identifying the equipment and stating the
    next required rated load test date or certification expiration date.

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403. INSPECTION

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a.  Daily and periodic safety inspections shall be performed on all
    hoists in regular service.

b.  Prior to first use, all new or altered hoists shall be inspected to
    the requirements of both daily and periodic inspections. Inspections
    shall be performed by qualified personnel according to approved
    technical operating procedures. Inadequacies discovered during an
    inspection shall be documented, and if determined to be a hazard,
    correct3ed prior to further use. For hoists that are idle, see
    Paragraph 403e.

c.  [Daily Inspections.]{.underline} These inspections shall be
    performed each day the hoist is used and shall include the
    following.

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(1) Inspect braking mechanisms for evidence of slippage under load.

(2) Inspect load chain for wear, twists, damage links, or foreign
    matter.

(3) Visually inspect hooks for deformation, chemical damage, or cracks
    (see Chapter 5).

(4) Inspect load bearing components for damage.

(5) Inspect running rope or chain for discrepancies.

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d.  [Formal Periodic Inspections.]{.underline} These inspections shall
    be performed at varying intervals, depending on activity, severity
    of service, environment, and criticality.

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(1) [Annual Inspections]{.underline}. At least once per year:

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(a) Check for loose bolts and rivets and cracked or worn drums and
    sheaves. Various methods of NDE such as ultrasonics, x-ray, magnetic
    particle, dye penetrant, etc., shall be used as needed.

(b) Check for worn, corroded, cracked, or distorted parts such as pins,
    bearings, shafts, gears, rollers, and locking and clamping devices.
    NDE techniques shall be used if cracks are suspected.

(c) Inspect motor brake and load break for excessive wear.

(d) Inspect electrical apparatus for pitting or other signs of
    deterioration. Visually inspect for signs of overheating.

(e) Inspect hook-retaining nuts or collars, pins, welds, or rivets used
    to secure retaining members for deformations, cracks, or excessive
    corrosion. NDE techniques shall be used if cracks are suspected.

(f) Ensure that supporting structure is not deformed or cracked.

(g) Check that warning labels are legible.

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(2) [Monthly Inspections]{.underline}. At least once per month:

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(a) Inspect wire rope monthly (except those on platform systems that
    shall be inspected at least twice a year), paying particular
    attention to the following signs of deterioration and damage:

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1.  Twelve randomly distributed broken wires in one rope lay or four
    broken wires in one strand in one lay.

2.  Individual wires with 1/3 wear of original outside diameter.

3.  Kinking, crushing, bird caging, or any other damage resulting in
    distortion.

4.  Evidence of heat damage.

5.  End connectors that are cracked, deformed, or with evidence of rope
    pullout.

6.  Corrosion (internal or external) that results in reduction of rope
    diameter, or at end connectors.

7.  Reductions of nominal diameter (measured with a caliper or go/no-go
    gage) of more than:

> [a]{.underline} 1/64 inch for diameters of rope up to 5/16 inch.
>
> [b]{.underline} 1/32 inch for diameters 3/8 inch to ½ inch.
>
> [c]{.underline} 3/64 inch for diameters 9/16 inch through 3/4 inches.
>
> [d]{.underline} 1/16 inch for diameters 7/8 inch through 1-1/8 inches.
>
> [e]{.underline} 3/32 inch for rope diameters greater than 1-1/8
> inches.

(b) Inspect welded-link chain monthly by performing the following
    checks:

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1.  Raise and lower hoist while loaded. The chain should feed smoothly
    into and away from the sprockets.

2.  If chain binds, jumps, or is noisy, see that it is clean and
    lubricated. Inspect chain and mating parts for wear and distortion.

3.  Clean chain and visually examine for gouges, weld splatter,
    corrosion, and distorted links. Slacken chain and move adjacent
    links to one side; look for wear at contact points. If wear is
    observed, measure chain according to hoist manufacturer's
    instructions. If instructions are not available, select an unworn,
    unstretched portion of chain. Suspend chain vertically under tension
    and measure approximately 14 inches of links with a caliper gauge.
    Measure the same length in a work section and calculate the
    percentage of increase in length In chain exceeds the hoist
    manufacturer's recommended length or is 1.5 percent longer than he
    unused chain, replace it.

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(c) Inspect roller link chain monthly by performing steps
    [1]{.underline}, [2]{.underline}, and [3]{.underline} in Paragraph
    403d(s)(b). In addition, perform the following checks.

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1.  With hoist suspended in normal position, apply a load to eliminate
    slack in the chain. Check chain for elongation. In the absence of
    specific instructions from hoist manufacture, check chain by
    determining nominal pitch and measuring a 12-inch section that
    usually travels over chain sprocket. Using a Venire caliper check
    dimensions from the edge of one chain pin to the same edge of
    another pin; determine number of pitches per foot. If elongation
    exceed ¼-inch in 12 inches, replace chain.

2.  Check chain for twist. Replace it if twists exceeds 15 degrees in
    any 5-foot section.

3.  Check for camber. Replace chain that has a side bow exceeding ¼ inch
    in a 5-foot section.

4.  Clean chain annually in an acid-free solvent. Check for pins turned
    from their original position, rollers that do not turn freely with
    light finger pressure, joints that cannot be flexed easily by hand,
    open link plates, corrosion, gouges, and weld splatter. Remove chain
    from hoist if required for proper cleaning and inspection.

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(d) Inspect hooks monthly, except those on platform systems, or
    deformation or cracks (see Chapter 5.)

> e\. [Idle Hoists.]{.underline} Hoists idle for more than 1 month shall
> be inspected prior to first use according to the requirements of
> Paragraphs 403c and 403d that were not performed at required intervals
> and recorded during the idle period.
>
> f\. [Inspection Reports.]{.underline} After each formal periodic
> inspection, qualified, authorized personnel shall prepare written,
> dated, and signed inspection reports. These reports shall include
> procedure reference and adequacy of the hoist/hoist components.
> Inadequacies shall be documented and, if determined to be a hazard,
> corrected prior to further use. These reports shall be filed and be
> made readily available by the organization element responsible for
> hoist inspection.

404. MAINTENANCE

> A preventive maintenance program shall be established based on
> manufacturers' recommendations and/or experience gained form use of
> the equipment. The program shall include procedures and a scheduling
> system for normal periodic maintenance items, adjustments,
> replacements, and repairs. The program shall also ensure that records
> are kept and unsafe test and inspection discrepancies are documented
> and corrected.

a.  Maintenance Procedures. Before maintenance, adjustments, repairs,
    and replacements are initiated, the following safety precautions
    shall be taken:

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(1) Move hoist to designated maintenance area.

(2) Turn off all controls and main energy feed system and lockout unless
    task requires them to be on.

(3) If power has to be on, "Warning," "Out-Of-Order," or a like sign
    shall be placed in a conspicuous location or an operator shall
    remain at the pendant.

(4) Hoists shall not be operated until all safety devices have been
    activat4ed and tested/adjusted if involved in the maintenance
    action.

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b.  [Adjustments.]{.underline} Based upon the manufacturer's
    documentation and/or experience, adjustments shall be made to ensure
    that all hoist components function properly, paying particular
    attention to:

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(1) Brakes. (Appropriate precautions should be taken by inspectors,
    repair personnel, and others who may be potentially exposed to
    airborne dust fibers from any asbestos friction materials present in
    braking mechanisms.)

(2) Control system.

(3) Limit switches.

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(a) The hoist initial upper limit switch shall be verified by running
    the empty hook at full speed into the limit switch. It is
    recommended that the switch be verified at slow speed prior to
    adjustment.

(b) For hoists used for critical lifts, the final upper limit switch
    shall be independently verified and adjusted as described above at
    installation and after modifications that could affect switch
    operation. The switch can be tested periodically by manually
    tripping it and verifying that all hoist motion is precluded.

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(4) Power plants.

(5) Critical operating mechanisms and safety devices.

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c.  [Repairs and Replacements.]{.underline} Repairs or replacements
    shall be provided for safe operation. Special attention shall be
    given to:

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(1) Worn or damaged braking components such as friction discs, ratchets,
    pawls, and pawl springs.

(2) Load-supporting components that are cracked, bent, or worn.

(3) Missing or illegible warning labels.

(4) For repair/replacement requirements for hoist hooks with deformation
    or cracks, see Chapter 5. If repaired, hoist hooks shall be proof
    load tested using the associated hoist proof load value.

(5) The need to replace wire rope shall be determined by a certified or
    otherwise qualified person based on an evaluation of inspection
    results. Any of the signs of deterioration and damage outlined in
    Paragraph 403d(2)(a) are sufficient reasons for questioning
    continued use of the rope.

(6) Replacement rope or chain shall be of the same size, grade, and
    construction as original furnished by hoist manufacturer. When
    replaced, disassemble and inspect mating parts for wear, replace
    mating parts if necessary, and perform a proof load test using the
    associated hoist proof load value.

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405. PERSONNEL CERTIFICATION

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a.  [Program.]{.underline} Only certified (licensed) and trained
    operators shall be authorized to use/operate powered hoists except
    for platform hoists where procedural controls can be provided in a
    technical operating procedure. A training, examination, and
    licensing program shall be established or made available. For those
    NASA installations that do not have a training program, all hoist
    operators shall be trained and certified by a recognized hoist
    certification organization that normally performs this function.
    Certification also shall include riggers and flagmen.

b.  [Levels.]{.underline} Two levels of operator training and
    proficiency will be established. Operations where critical lifts are
    involved will require a more rigid operator certification program
    than those operations that involve more routine lifts that do not
    involve critical hardware or unique hazards.

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(1) [Noncritical Lifts.]{.underline} The certification program for
    noncritical lift operators shall include the following:

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(a) Training

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1.  Classroom training in safety and first aid/emergency procedures,
    general performance standard, requirements, pre-operational checks,
    and safety-related defects and symptoms (for initial certification
    and as needed).

2.  Hands-on training (for initial certification and as needed).

3.  An annual review of the items in Subparagraph (a) above. (This may
    be conducted informally by local supervisory personnel).

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(b) Examination

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1.  Physical examination (criteria to be determined by the cognizant
    medical official using ANSI requirements).

2.  Written examination.

3.  Operational demonstration (for initial certification only).

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(c) Licensing/Operator Certification

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1.  An organizational element shall be designated to issue operator
    licensees/operator certification. Provisions shall be made to revoke
    licenses for negligence, violations of safety requirements, or
    failure to meet medical standards. Provisions shall be made for
    periodic checks of operators to verify they have licenses in their
    possession. The licenses shall indicate the type of hoist the holder
    is qualified to operate. Alternately, the organizational element may
    elect to maintain a master list of licensed operators instead of
    issuing individual licenses, providing copies of the list are
    readily available to assurance and supervisory personnel at the work
    site.

2.  Renewal of all licenses shall require demonstration of proficiency.
    Licenses or certifications shall expire at least every 4 years.
    Renewal procedures will be established by each licensing
    organization but as a minimum, will include items in Paragraphs
    405(b)(1)(a) and (b).

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(2) Critical Lifts. Besides the training, examination, licensing, and
    renewal requirements for noncritical lifts, operators that are being
    certified to perform critical lifts must be trained in the specific
    hazards and special procedures associated with the lift. Operators
    must also demonstrate proficiency and operating finesse with the
    hoist using a test load as appropriate for the initial certification
    or alternately be immediately supervised by a certified operator
    during the firs initial lifting period. The licenses will indicate
    specific hoists for which the operator is certified.

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406. OPERATIONS

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a.  Only certified and trained operators shall be authorized to
    use/operate lifting devices, including hoist operations, except for
    platform operators where procedural controls can be provided in a
    technical operating procedure.

b.  The following practices shall be observed during all hoist
    operations:

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(1) When an "Out-of-Order" sign has been placed on the starting
    controls, the hoist operator shall not power the unit or start
    operations until required repairs, inspections, and retests have
    been made.

(2) Before starting a hoist, the operator shall be certain that all
    personnel are clear of the area. Operators shall not engage in
    practices that will divert their attention while operating a hoist.

(3) The operator shall test all controls before beginning an operation.
    If the controls do not operate properly, adjustments or repairs
    shall be made before operations begin.

(4) Hoists shall not be loaded beyond rated load except during
    authorized tests. Platform systems shall not be loaded beyond
    maximum load as designated on the platform hoist system.

(5) Hoists shall not be used for handling personnel unless specifically
    designed for such purpose (see Chapter 7).

(6) Personnel shall not be located under suspended or moving loads
    unless the operation adheres to the OSHA-approved NASA Alternate
    Standard for Suspended Load Operations. (See Appendix B.)

(7) An operator shall be at the hoist controls at all times while a load
    is suspended. Due to the length of some NASA operations, an operator
    change may be required while a load is suspended. This shall be
    accomplished via a procedure designed for the specific hoist and
    operation approved by the installation NASA Safety directorate,
    ensuring that the hoist controls are manned at all times.

(8) Before each lift or series of lifts, the operator shall functionally
    test proper operation of the upper limit switch with no load on the
    hook. Upper limit switches shall not be used as operating controls.

(9) Hoists may be used to lad test items such as slings, platforms, or
    lifting fixtures if specifically identified to do so based on a
    specified percentage or rated load and a safety analysis approved by
    the installation NASA Safety directorate and the responsible
    engineering and operations/maintenance organizations. This is to
    ensure that the crane is to damaged due to sudden unloading should
    test article fail.

(10) Installed or fixed air or electric powered hoists, excluding
     platform systems, shall be operated by designated personnel only.

(11) The operator shall ensure that the hoist is within inspection and
     periodic certification interval by examination of its tag(s) and/or
     appropriate documentation.

(12) Outdoor hoisting operations should not commence if winds are above
     20 knots steady state.

(13) Hoists shall not be used for side pulls unless specifically
     designed to do so.

(14) If radio communications are to be used, operators and/or lift
     supervisor shall test the communication system prior to the
     operation. Operation shall stop immediately upon communication
     loss, and shall not continue until communication is restored.

(15) If hand signals are required, only standard signals shall be used
     according to Appendix C. Hand signals shall be posted in a
     conspicuous location.

(16) When raising loads that approach the rated capacity of the hoist,
     the operator shall know the weight of the working load. The
     operator shall test the holding brakes each time a load approaching
     the rated load is handled. The brakes shall be tested by raising
     the load minimally above the surface and holding the load with the
     brake. The load should be held long enough to allow any dynamics to
     dampen out.

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407. SPECIAL CRITERIA

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a.  Special precautions shall be taken while handling explosives or
    Electro Explosive Devices (EEDs). Safety support shall be available.
    Barricades and warning signs shall be erected to control access.
    Voltage checks on hoist hooks that will handle explosives or EEDs
    shall be performed to verify that the measured energy level does not
    exceed 20 decibels below the maximum safe no-fire energy level in
    the bridge wire of the associated EED. (Example: For a NASA Standard
    Initiator with a maximum safe no-fire energy level of 1 watt, the
    measured energy level shall not exceed 10 milliwatts, which
    corresponds to 100 millivolts measured across a 1 ohm resistor.) The
    hoist hook shall be connected to facility ground before connecting
    to explosives or EEDs. Electrical grounding of the hook and load
    shall be accomplished prior to lift operations while handling
    explosives, EEDs, or electrically sensitive devices/payloads. The
    grounding shall be measured/verified to be with specification by
    inspection personnel and recorded prior to the lift. If a ground
    connection must be prior to disconnecting the existing Ground. The
    final attachment/detachment must be at least 10 feet from exposed
    propellant grain, explosives, or EEDs. The use of radio
    transmissions near explosives shall be evaluated for danger
    potentially prior to the operation.

b.  Policy shall be developed and enforced for hoist operation during
    electrical storms. Operations are generally permitted without
    restriction within enclosed metal or framed buildings that are
    properly grounded. Restrictions are necessary for outside operations
    or for those that cannot tolerate power failure/loss.

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CHAPTER 5: HOOKS

500. GENERAL

> This chapter establishes safety standards for the testing, inspection,
> maintenance, and operation of hooks used with lifting equipment.

501. TESTING

> Hooks shall be required to pass the tests of the equipment of which
> they are a part. Written, dated, and signed test reports shall be
> prepared together with the test reports for the equipment of which the
> hooks are a part. Inadequacies shall be documented and, if determined
> to be a hazard corrected prior to further use.

502. INSPECTIONS

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a.  Hooks shall be inspected during the daily and periodic inspections
    for the equipment of which they are a part. Hooks shall be examined
    for wear, deformation, cracks, latch damage, and improper attachment
    with particular emphasis on the following deficiencies:

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(1) Wear exceeding 10 percent (or as recommended by the manufacturer) of
    the original sectional dimension.

(2) A bend or twist exceeding 10 degrees from the plane of the unbent
    hook.

(3) An increased throat opening exceeding 15 percent 9or as recommend by
    the manufacturer.

(4) Latches that are inoperative or fail to fully close the throat
    opening because of ear or deformation.

(5) Cracks, nicks, and gouges (see Paragraph 503b).

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b.  Visual inspection of painted hooks requires consideration of the
    coating. Surface variations may indicate heavy or servere service.
    Such instances may call for stripping the paint to allow for more
    detailed analysis.

c.  Hooks shall be given a NDE using magnafluxing or other method
    immediately after all rated and load and proof load tests and prior
    to further use of the hook. A visual inspection of hooks used for
    non-critical lifts (if not attached to a crane) and sling hooks of 5
    tons or less is acceptable. All new crane hooks shall undergo a
    volumetric NDE.

d.  Written, dated, and signed inspections reports shall be prepared in
    conjunction with inspection reports for the equipment of which the
    hooks

> are a part. Inadequacies shall be documented and if determined to be a
> hazard, corrected prior to further use.

503. MAINTENANCE

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a.  Hooks with deficiencies as noted in Paragraph 502 shall be removed
    from service and replaced or repaired. Replacement shall be with
    original equipment or equal. Repair shall require approval by
    certified or otherwise qualified personnel. Minor grinding of cracks
    is to considered a repair providing an approved procedure is used.
    Hooks will be prepared by certified or otherwise qualified personnel
    only. Hooks repaired by welding should be derated to reflect the
    inherent difference in the metal introduced by this process. Hooks
    must be removed from the crane assembly prior to welding.

b.  Cracks, nicks, and gouges shall be repaired by grinding
    longitudinally, following the contour of the hook, provided that no
    dimension is reduced more than 10 percent (or as recommended by the
    manufacturer) of its original value.

c.  If repaired, hooks shall be proof load tested using the associated
    lifting device/equipment proof load value.

d.  A system shall be established for tracking/documenting the
    maintenance and repair history of hooks.

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504. OPERATIONS

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a.  Loads shall be centered in the base (bowl saddle) of the hook, to
    avoid point loading.

b.  Hooks shall not be side or back loaded.

c.  Duplex sister hooks shall be equally loaded on both sides, and the
    pin hole shall not be point loaded beyond the rated load of the hook
    except for testing.

CHAPTER 6: HYDRA-SETS

600. GENERAL

> This chapter establishes safety standards for the testing, inspection,
> and operation of Hydra-sets.

601. SAFETY ASPECTS

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a.  [Safety Design Criteria.]{.underline} Hydra-sets used for critical
    lifts shall have a 5 to 1 factor of safety based on ultimate
    strength for load bearing elements.

b.  [Labeling/Tagged of Hydra-Sets]{.underline}.

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(1) The rated load shall be plainly marked on each Hydra-set.

(2) Hydra-sets that have the necessary design features,
    maintenance/inspection, and test intervals to lift critical loads
    will be marked conspicuously so that the operator and assurance
    personnel can distinguish that the Hydra-set is qualified for
    critical lifts.

(3) A standard system of labeling shall be established and used
    throughout the installation.

(4) A standard tag-out system shall be established and used throughout
    the installation to indicate equipment that is not to be used due to
    inspection discrepancies, ongoing maintenance operations, etc.

(5) Certification/recertification tags are required as described in
    Paragraph 602d.

> c\. [Safety Analysis and Documentation of Hydra-Sets Used for Critical
> Lifts]{.underline}. A hazard analysis shall be performed on all
> Hydra-sets used for critical lifts. The analysis shall, as a minimum,
> determine potential sources of danger, identify most probable failure
> modes and recommend resolutions for those conditions found in the
> hardware-facility-environment-human relationship that could cause loss
> of life, personal injury, or loss of Hydra-set, facility, or load. The
> analysis also shall include Hydra-set description, reference
> documentation, severity assessment, and assessment of passive and
> structural components. Hazards that are identified shall be tracked
> (recorded and current status maintained) until final closure is
> verified. A system of risk acceptance is required for hazards that
> cannot be eliminated. The hazard analysis shall be done as part of the
> initial certification process, included in the Hydra-set
> documentation, and updated as required to reflect and modification
> and/or changes in operation.

602. TESTING AND INSPECTIONS

> Three types of tests are required: proof load tests, periodic load
> tests, and operational tests. The acceptable tolerance for load test
> accuracy is +5/-0 percent unless otherwise specified by design. An
> inspection shall be performed after each load test and prior to
> release for service to ensure there is no damage. If cracks are
> suspected, suitable Nondestructive Evaluation techniques should be
> used to determine their extent. Tests shall be performed by qualified
> personnel according to written (specific or general) technical
> procedures approved by NASA and/or contractor safety representatives.

a.  [Proof Load Test]{.underline}. Before initial use or after
    structural repair, test all Hydra-sets at 200 percent of rated load.
    Proof load tests shall be performed with piston rod fully extended
    to prevent instrument and seal damage.

b.  [Periodic Load Test]{.underline}. Load tests shall be performed with
    the piston rod fully extended to prevent instrument and seal damage.
    All Hydra-sets shall be tested at 125 percent of rated load at least
    every 4 years. Tests of Hydra-sets used for critical lifts shall be
    based on frequency of usage. Hydra-sets used infrequently for
    critical lifts shall be load tested before each critical lift if it
    has been over a year since the last test. Hydra-sets used frequently
    for critical lifts shall be load tested at least once per year.

c.  [Operational]{.underline} Test and Inspection. The following shall
    be performed in conjunction with proof load tests and periodic load
    tests and at least once per year:

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(1) With a test load, at least equal to 50 percent of the Hydra-set's
    rated capacity but not to exceed 100 percent, operate the unit to
    approximately the midstroke position. Using a dial indicator or
    equivalent, verify that the load does not move up or down more than
    .005 inches in 5 minutes.

(2) Inspect unit for hydraulic leaks and initial repairs when required.

(3) Inspect for structural damage and corrosion of the piston rod.

> d\. Test Reports and Periodic Recertification Tags. After each load
> test and/or inspection, written, dated, and signed reports shall be
> prepared. Inadequacies shall be documented and, if determined to be a
> hazard, corrected prior to further use. These reports shall be kept on
> file by the responsible owner organization for a minimum of two test
> cycles and shall be made readily available. Following the periodic
> load test, all Hydra-sets shall have a permanently affixed tag,
> identifying the equipment and stating the next required periodic load
> test date or the certification expiration date.

603. MAINTENANCE

> A preventive maintenance program shall be established based on
> manufactures' recommendations and/or experience gained from use of the
> equipment. The program shall include procedures and a scheduling
> system for normal periodic maintenance items, adjustments,
> replacements, and repairs. The program also shall ensure that records
> are kept and unsafe test and inspection discrepancies are documented
> and corrected.

604. OPERATOR CERTIFICATION

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a.  A training and operator certification program that specifically
    addresses the properties of Hydra-sets and operational procedures
    needed to retain positive control of the same during close mating
    operations shall be implemented. Elements of the initial training
    and certification program will include a review of the above
    procedures, hands-on training, and an operational demonstration.

b.  Licensing/operator certification will be issued every 4 years.
    Renewal will require demonstration of proficiency.

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605. OPERATIONS

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a.  When seals are replaced, an operational test and inspection shall be
    performed.

b.  Hydra-sets shall be stored in their appropriate handling containers
    when not in use.

c.  Hydra-sets shall be clearly and permanently marked with rated load
    value.

d.  Prior to use, the operator shall ensure the Hydra-set is within the
    inspection and periodic recertification intervals by examination of
    the certification tag(s) and/or documentation.

e.  Hydraulically controlled Hydra-sets are preferred over pneumatically
    controlled Hydra-sets where close mating operations or accurate
    control of distances is equired. Pneumatically controlled Hydra-sets
    shall not be used for these operations unless the following items
    are incorporated:

> \(1\) Installation of a fail-safe check valve in the Hydra-set. This
> is installed on the Hydra-set pneumatic feedline and "locks up" the
> Hydra-set in the event of a drop or loss of pneumatic control system
> pressure. A procedure shall be developed and implemented to ensure
> that the value is set at the mid-point of its range, which is
> satisfactory for most operations. However, depending on the specifics
> of the lift, it may be necessary to reset the valve using a dummy load
> as outlined in the manufacturer's recommended procedures.

(2) Installation of a fast acting safety shutoff valve downstream of the
    load regulator that is used to provide positive control of the
    Hydra-set when no motion is desired.

(3) Installation of electronic remote position indicators that warn
    operators of small movements of the hung load. However, these should
    only be installed if they will not adversely affect the operation or
    contamination control features of existing Hydra-sets.

(4) Implementation of a training and operator certification program that
    specifically addresses the unique properties of pneumatically
    controlled Hydra-sets and operational procedure needed to retain
    positive control of the same during critical lift operations.

CHAPTER 7: SPECIAL HOIST SUPPORTED PERSONNEL LIFTING DEVICES

700. GENERAL

> This chapter establishes minimum safety standards for the design,
> testing, maintenance, inspection, and operation of special hoist
> supported personnel lifting devices. These requirements are intended
> to provide for safety of personnel using this equipment and of the
> property and operations that this equipment supports. This chapter
> applies to unique devices whose operation includes the lifting and
> lowering of persons via hoist. This does not apply to platforms or
> other items that are hoisted unoccupied to a position and anchored or
> restrained to a stationary structure, before personnel occupy the
> platform. This chapter does not apply to elevators that are covered by
> ANSI A17.1, "Elevators, Dumbwaiters, Escalators, and Moving Walks."
> Also, this chapter does not apply to ground supported personnel lifts
> (e.g., manlifts, aerial devices, scissors lifts, etc., covered by ANSI
> A90 and A92 series standards) or powered platforms.

701. SAFETY ASPECT

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a.  Generally, anytime personnel must be raised or lowered with hoisting
    equipment, ANSI A17.1 should be used. Only when unique project
    requirements dictate that the elevator standard cannot be applied,
    must special equipment be procured for raising and lowering
    personnel.

b.  In some cases, standard- or custom-designed equipment can be
    obtained from manufacturers regularly engaged in the design and
    construction of personnel lifting devices. This equipment must
    comply with applicable industry and government standard such as ANSI
    and OSHA and must be tested, maintained, and inspected to their
    requirements and as required. When industry standards do not apply
    to a specific project requirement, then a system with an equivalent
    level of safety must be provided as outlined herein with appropriate
    concurrence of the applicable design, operations, and safety
    engineers.

c.  A hazard analysis and a Failure Mode and Effects Analysis (FMEA)
    shall be performed on all personnel lifting devices. The analysis
    shall, as a minimum, determine potential sources of danger and
    recommend resolutions for those conditions found in the
    hardware/facility/environment/human relationship that could cause
    injury, loss of lift, or damage to property or impact to operations
    that this equipment supports. The analysis also shall include a
    system description, reference documentation, severity assessment,
    and assessment of certain passive and structural components. Hazards
    that are identified shall be tracked (recorded and current status
    maintained) until final closure is physically verified. A system of
    risk acceptance is required for hazards that cannot be eliminated.
    The analysis shall be done as part of the initial certification
    process, included in the lifting device documentation, and

> Updated as required to reflect any changes in operation and/or
> configuration.

d.  [General design requirements]{.underline}. The design shall produce
    a personnel lifting device that will lift, lower, sustain, and
    transport personnel safely. The structure, mechanism, and material
    shall be of sufficient strength to meet operational and testing
    requirements and shall comply with applicable industry and
    government standards as a minimum and in addition, the requirements
    outlined in this chapter. Besides the requirements in Chapter 4,
    Paragraphs 401d, 401e, 401f, and 401g, the following requirements
    shall be met for all hoist supported personnel lifting devices:

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(1) It is the responsibility of design, operations, and safety engineers
    to ensure that the design, testing, operations, maintenance, and
    inspection of this equipment comply with the applicable industry and
    government standards. Moist hoist supported personnel lifting
    devices should comply with applicable industry standards. ANSI
    A120.1, A39 and A10 series, and OSHA standards establish the
    configuration, materials, design stresses, safety devices, power and
    control, test, operation, inspection, and maintenance requirements
    that should be followed.

(2) When industry standards do not cover a unique project requirement,
    then a system with an equivalent level of safety must be provided.
    This system may consist of two separate independent support systems;
    that is, two separate hoists such that the failure of one hoist, its
    reeving system, or other component will not cause the stability of
    the personnel lifting device to be lost or prohibit its movement to
    a safe location. With this configuration, alternate materials, or
    higher design stresses than permitted by industry and OSHA standards
    can be used with concurrence from the appropriate design,
    operations, and safety engineers. Another option may consist of
    lifting equipment with at least two holding brakes and additional
    factors of safety for the hoist load bearing components. All options
    shall be approved by the installation NASA Safety Directorate and
    the responsible engineering and operations/maintenance
    organizations. Operation, maintenance, and inspection requirements
    shall be developed to provide equivalent certification of equipment
    as required by industry and OSHA standards and as outlined in this
    chapter.

(3) A lockout device shall be provided on all hoist supported lifting
    devices to prevent unauthorized use.

(4) A method for safe egress of personnel or emergency lowering to the
    ground level or other safe location shall be provided. The emergency
    lowering shall be clearly marked and accessible form the ground or
    fixed structure.

(5) An emergency stop device that deenergizes the powered systems and
    stops the personnel lifting device movement shall be provided to the
    personnel controlling movement of this personnel lifting device. An
    additional emergency stop separate from normal operating controls
    should be considered for personnel at ground level or on a fixed
    structure to enhance operational safety.

(6) All directional controls shall be designed so that they
    automatically return to a neutral position when released. Neutral
    position of controls shall bring the unit to a safe stop and hold
    the unit I that position until commanded to move to another
    position.

(7) The rated capacity of the personnel lifting device shall be clearly
    marked at the entrance-way and warnings, cautions, and restrictions
    for safe operations shall be provided according to the applicable
    industry and government standards or ANSI Z35.1, "Accident
    Prevention Signs."

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702. TESTING

> Testing of personnel lifting devices shall be completed according to
> its applicable industry standard and OSHA requirements. The
> responsible design, operations, and safety engineers shall develop and
> oversee these tests for each system as required by these standards and
> as described in this chapter. The following tests shall also be
> completed (or combined with industry requirements when practical to
> avoid duplication of efforts).
>
> Three types of tests are required for personnel lifting devices: proof
> load tests, rated load tests, and operational tests. Proof load tests
> and operational tests shall be performed prior to first use for new or
> extensively repaired or altered components directly involved in the
> hoist or personnel lifting device load path. Repairs or alternations
> to nonlifting or holding components do not require a load test,
> although a functional check should be performed to determine if the
> repairs or alternations are acceptable. The rated load and operational
> tests shall be performed annually. If a personnel lifting device is
> upgraded, a proof load test and an operational test shall be performed
> based on the upgraded rating. The acceptable tolerance for load test
> accuracy is +5/-0 percent unless otherwise specified by design. All
> load and operational tests shall be performed by qualified personnel
> according to written (specific or general) technical operating
> procedures approved by NASA and/or contractor Safety representatives.
> An inspection of the personnel lifting device and its components shall
> be performed after each load test and prior to the device being
> released for service to ensure there is no damage. This inspection
> shall include NDE of components that are suspected to be cracked or
> otherwise affected by the test. The rated load test requirement may be
> fulfilled by a concurrently performed proof load test.
>
> a\. [Proof Load Test]{.underline}. Before first use, all new,
> extensively repaired, extensively modified, or altered personnel
> lifting devices shall undergo a proof load test at
>
> 1.5 times the rated load. A proof load test may also be performed when
> there is a question in design or previous testing. The load shall be
> secured to the personnel lifting device and lifted slowly and in an
> area where minimal damage will occur if the device fails. The load
> rating of the device shall ge clearly marked to be legible from the
> operator's or user's position and shall not be more than the proof
> load test weight divided by 1.5.

b.  [Rated Load Test.]{.underline} Each personnel lifting device shall
    be tested at least once every year with a load equal to the rated
    load.

c.  [Operational Test.]{.underline} Together with proof load and rated
    load tests, the following shall be performed with a dummy rated load
    unless otherwise specified:

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(1) Perform all hoist functions in an unloaded condition.

(2) Test operation of brakes and limit, locking, and safety devices.

(3) Determine trip setting of limit switches and limiting devices by
    tests under no load conditions. Conduct tests first by hand, if
    practical, and then under the slowest speed obtainable. Test with
    increasing speeds up to the maximum speed. Locate actuating
    mechanisms so that they will trip the switches or limiting devices
    in time to stop motion without damaging the hoist.

(4) After testing in the unloaded state, apply the test load to check
    for proper load control. Test load hoisting, lowering at various
    speeds (maximum safe movement up and down as determined by the
    installation NASA Safety directorate and the responsible engineering
    and operation/maintenance organizations), and braking/holding
    mechanisms (holding brakes shall be tested to verify stopping
    capabilities and demonstrate the ability to hold a rated load). The
    load should be held long enough to allow any dynamics to dampen out.

(5) For hoist supported personnel lifting devices equipped with two
    means of braking (see Paragraph 701d(2)). The operational test must
    demonstrate each brake's ability to stop and hold a rated load. This
    can be done in one of the following ways:

> \(a\) Each brake's ability to hold shall be statically tested (under
> no load) with 150 percent of the rated load hoisting torque at the
> point of brake application.

(b) Alternately, each brake shall be tested for its ability to stop a
    rated load moving at full speed in the down direction. (CAUTION: It
    must be possible to quickly reenergize the out of circuit brake or
    provide other safety measures to perform this test safely.)

(c) Other methods as specified by the installation NASA Safety
    directorate and the responsible engineering and
    operations/maintenance organizations.

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(6) The operational test for a modified hoist supported personnel
    lifting device can be tailored to test only those portions of the
    equipment that were modified, only if the rated load and operational
    test interval has not expired.

> d\. Test Reports and Periodic Recertification Tags. After each test,
> designated personnel shall prepare written, dated, and signed test
> reports including procedure reference. Inadequacies shall be
> documented and, if determined to be a hazard, corrected prior to
> further use. These reports shall be kept on file by the owner
> organization for a minimum of two test cycles and shall be made
> readily available. Following the rated load test, personnel lifts
> shall be given a permanently affixed tag identifying the equipment and
> stating the next required rated load test date or certification
> expiration date.

703. INSPECTION

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a.  Daily and periodic safety inspections are required for personnel
    lifting devices. Inspections shall be completed according to its
    applicable industry standard and OSHA requirements and shall be
    performed on all personnel lifting devices. The responsible design,
    operation, and safety engineers shall develop and oversee the
    inspections for each system as required by these standards and as
    described herein. Inspections also shall be completed (or combined
    with industry requirements where practical to avoid duplication of
    efforts). Inadequacies discovered during an inspection shall be
    documented and, if determined to be a hazard, corrected prior to
    further use. Inspections shall be made by designed personnel
    according to approved technical operating procedures.

b.  All new, extensively repaired, or modified personnel lifting devices
    shall be given a daily and a periodic inspection prior to first use.
    For component repair on personnel lifts, only the inspections that
    apply to the repaired portion need to be performed prior to first
    use unless a periodic inspection interval expires during the
    downtime (see Paragraph 703e).

c.  Personnel lifts in regular service (used at least once a month)
    shall be inspected as required in Paragraphs 703d and 703e. Idle
    personnel lifting devices shall be inspected according to Paragraph
    703f.

d.  [Daily Inspection.]{.underline} These inspections shall be performed
    prior to first use at each day the personnel lifting device is used,
    and shall include the following:

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(1) Check for defects such as cracked welds, damaged control cables,
    loose wire connections, and wheel or roller damage.

(2) Check functional operating and control mechanisms and guardrails for
    maladjustments that could interfere with normal operations.

(3) Check hose and fittings, tanks, valves, drain pumps, gear casings,
    and other components of fluid systems for deterioration and leaks.

(4) Without disassembling, inspect all functional operating and control
    mechanisms for excessive wear and contamination by excessive
    lubricants or foreign matter.

(5) Inspect hooks for cracks and deformities (see Chapter 5).

(6) Inspect rope reeving for proper travel and drum lay.

(7) Inspect hoist chains for excessive wear or distortion.

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e.  [Periodic Inspection.]{.underline} These inspections shall be
    performed at varying intervals, depending on activity, severity of
    service, environment, and criticality.

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(1) [Annual Inspections.]{.underline} Inspect for:

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(a) Deformed, cracked, or corroded members and welds and loose bolts or
    rivets in personnel lift structure. Various methods of NDE such as
    ultrasonics, x-ray, magnetic particle, dye penetrant, etc., shall be
    utilized as needed.

(b) Cracked or worn sheaves and drums.

(c) Excessive wear or cracks in pins, bearings, shafts, gears,
    followers, and locking and clamping devices. NDE techniques shall be
    used if cracks are suspected.

(d) Excessive wear in hoist brake and clutch system parts, linings,
    pawls, and ratchets.

(e) Excessive wear in chain drive sprockets and stretch in the chain.

(f) Abnormal performance in power plant(s) and compliance with
    applicable safety requirements, such as locations of guards on
    belts.

(g) Evidence of a malfunction in braking and locking devices.

(h) Evidence of a malfunction in any safety device.

(i) Pitting or other signs of deterioration in electrical apparatus.

(j) Evidence of overheating.

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(2) [Monthly Inspections]{.underline}.

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(a) Inspect for wear, twist, distortion, or stretch of hoist chains.

(b) Inspect wire rope for:

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1.  Six randomly distributed broken wires in one rope lay or three
    broken wires in one strand in one lay.

2.  Individual outside wires with wear of 1/3 the original diameter.

3.  Kinking, crushing, bird caging, or any other damage resulting in
    distortion.

4.  Evidence of heat damage.

5.  End connectors that are cracked, deformed, or with evidence of rope
    pullout.

6.  Corrosion internal or external, that results in reduction of rope
    diameter, or at end connectors.

7.  Reductions of nominal diameter (measured with a caliper or go/no-go
    gage) of more than:

> [a]{.underline} 1/64 inch for diameters of rope up to 5/16 inch.
>
> [b]{.underline} 1/32 inch for diameters 3/8 inch to ½ inch.
>
> [c]{.underline} 3/64 inch for diameters 9/16 inch through ¾ inch.
>
> [d]{.underline} 1/16 inch for diameters 7/8 inch through 1-1/8 inches.
>
> [e]{.underline} 3/32 inch for rope diameters greater than 1-1/8
> inches.

8.  Two broken wires at an end connection.

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(c) Visible deformation or cracks in hooks (see Chapter 5.)

(d) When wire ropes or chains are replaced or hooks repaired, a proof
    load test of the hook, rope, or chain shall be performed prior to
    use.

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f.  [Idle and Standby Personnel Lifting Devices.]{.underline} Personnel
    lifting devices idle for more than 1 month shall be inspected prior
    to first use according to the requirements of Paragraphs 703a and
    703b that were not performed at required intervals and recorded
    during the standby period.

g.  [Inspection Reports.]{.underline} After each formal periodic
    inspection, qualified authorized personnel shall prepare written,
    dated, and signed inspection reports, including procedure reference
    and adequacy of components. Inadequacies shall be documented and, if
    determined to be a hazard, corrected prior to further use. These
    reports shall be filed and be made readily available by the
    organizational element responsible for personnel lift inspection.

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704. MAINTENANCE

> A preventive maintenance program shall be established based on
> manufacturers' recommendations and/or experience gained from use of
> the equipment. The program shall include procedures and a scheduling
> system for normal periodic maintenance items, adjustments,
> replacements, and repairs. The program also shall ensure that records
> are kept and unsafe test and inspection discrepancies are documented
> and corrected. The need to replace wire rope or chain shall be
> determined by a certified or otherwise qualified person based on a
> evaluation of inspection results. Any of the signs of deterioration
> and damage provided in Paragraphs 703e(2)(a) and 703e(2)(b) are
> sufficient reasons for questioning continued use.

705. PERSONNEL CERTIFICATION

> Operators shall be trained and certified before operating a personnel
> lifting device. A training, examination, and licensing program shall
> be established or made available. For those NASA installations that do
> not have a training program, all personnel lifting device operators
> shall be trained and certified by a recognized certification
> organization that normally performs this function. The basic
> certification program will include the following:

a.  [Training]{.underline}.

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(1) Classroom training in safety and first aid/emergency procedures,
    general performance standards, requirements, pre-operational checks,
    and safety-related defects and symptoms (for initial certification
    and as needed).

(2) Hands-on training (for initial certification and as needed).

(3) An annual review of Items (1) and (2) above. (This may be conducted
    informally by local supervisory personnel.)

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b.  [Examination]{.underline}.

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(1) Physical examination (criteria to be determined by the cognizant
    medical official using ANSI requirements).

(2) Written examination.

(3) Operational demonstration (for initial certification only).

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c.  [Licensing]{.underline}. An organizational element shall be
    designated to issue operator licenses. Provisions shall be made to
    revoke licenses for negligence, violations of safety requirements,
    or failure to meet medical standards. Provisions shall be made for
    periodic checks of operators to verify they have licenses in their
    possession. The licenses shall indicate the type of personnel
    lifting device the holder is qualified to operate. Alternately, the
    organizational element may elect to maintain a master list of
    licensed operators instead of issuing individual licenses, providing
    copies of the list are readily available to assurance and
    supervisory personnel at the work site.

d.  [Renewal]{.underline}. Licenses or certifications will expire at
    least every 4 years. Renewal procedures will be established by each
    licensing organization, but as a minimum, will include items in
    Paragraphs 705a and b.

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706. OPERATIONS

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a.  Hoist support personnel lifting devices shall be operated according
    to applicable industry standards, government requirements, and
    manufactures' instructions. The following practices shall be
    observed when using hoist supported personnel lifting devices:

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(1) Determine that the proposed personnel lifting operation is either
    the least hazardous method or the only method available to position
    personnel so that an operation can be accomplished.

(2) Before use, the operator shall have read and understood the
    manufacturer's operating instructions and safety rules, have been
    trained and licensed according to Paragraph 705, and have read and
    understood all decals and warnings on the device.

(3) Before use, the operator shall inspect the personnel lifting device
    per the daily inspection requirements. The operator shall perform a
    pre-operational check to demonstrate operational readiness. If
    controls do not operate properly, the operator is responsible for
    notifying the supervisor. Repairs and adjustments shall be made
    before operations begin.

(4) Before the personnel lifting device is used, the operator shall
    survey the area for applicable hazards such as overhead obstructions
    and high-voltage conductors, debris, bumps and loose obstructions,
    dropoffs and holes, ditches, untamped earth fills, obstructed path
    of travel, unstable footing and other possible hazardous conditions.
    The operator shall establish appropriate safety zones before
    initiating operations.

(5) Detailed technical operating procedures describing personnel lifting
    device operation, emergency steps, communication requirements, and
    special requirements shall be prepared. There must be a formal
    system for review, approval, and update to maintain valid operating
    procedures. Emergency procedures shall be developed for contingency
    actions such as power loss, brake failure, or other emergencies.

(6) A personnel lifting device shall not be loaded beyond its rated load
    (capacity) except for required testing.

(7) The operator shall ensure that the personnel lifting device is
    within inspection and testing intervals by examination of the
    periodic recertification tags and documentation.

(8) Necessary clothing and personnel belongings shall be stored so as
    not to interfere with access or operations. Tools, oil can, waste,
    extra fuses, and other necessary articles shall be stored properly
    and shall not be permitted to lie loose during the personnel lift.
    Operators shall be familiar with the operation and care of the fire
    extinguishers provided.

(9) Prior to an operation, personnel lifting device operators shall test
    the communication system. Operation shall stop immediately upon
    communication loss, and shall not continue until communication is
    restored.

(10) Operator discipline shall be maintained at all times. There shall
     be no eating, drinking, or rowdiness, etc., during personnel
     lifting operations. Personnel shall keep all parts of the body,
     tools, and equipment inside the work platform periphery during
     raising, lowering, and traveling operations.

(11) Fall protection is required for personnel using personnel lifting
     devices. Where possible, personnel should tie off to approved
     attachment points not on the work cage. Handrails shall not be used
     as an attachment point.

> Personnel required to hold onto a moving platform shall use both
> hands. Tools and other objects shall be carried in canvas bags or by
> other methods that free both hands and do not present a snagging
> hazard. Alternate methods of tool delivery beside personnel lifting
> devices should be investigated.

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CHAPTER 8: SLINGS

800. GENERAL

> This chapter establishes safety standards for the testing, inspection,
> and operation of slings. This includes slings constructed of wire
> rope, alloy steel chain, metal mesh, natural or synthetic fiber, and
> structural slings and associated equipment such as shackles,
> turnbuckles, eyebolts, etc.

801. SAFETY ASPECTS

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a.  [Safety Design Criteria]{.underline} that should be emphasized
    during sling design are contained in the documents listed in
    Paragraph 105. Sling design shall be in accordance with industry
    standards and meet the applicable requirements of OSHA and ANSI.
    Sling design shall maintain the minimum design load safety factors
    listed in Table 8-3.

b.  [Labeling/Tagging of Slings.]{.underline}
    Certification/recertification tags are required as described in
    Paragraph 802e. A system shall be developed to identify slings used
    in critical lift applications. Completely assembled slings that have
    the necessary design features and maintenance/inspection, and test
    intervals to lift critical loads will be marked conspicuously so
    that the operator and assurance personnel can distinguish that the
    sling is qualified for critical lifts.

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802. TESTING

> The following proof load and periodic load tests apply to slings
> except as noted in Paragraph 802c. Turnbuckles shall be tested at the
> open position as a minimum. It is recommended that turnbuckles be
> tested at the open, closed, and midway positions. These tests shall be
> performed by qualified personnel according to written (specific or
> general) technical operating procedures approved by NASA and/or
> contractor Safety representatives. The acceptable tolerance for load
> test accuracy is +5/-0 percent unless otherwise specified by design.
> When slings are composed of major components that fall into more than
> one of the categories listed in Table 8-1, the components shall be
> tested individually according to applicable requirements and then as a
> system to the lowest test value (if practical). An inspection shall be
> performed after each load test and prior to release for service to
> ensure there is no damage. A periodic load test requirement can be
> fulfilled by a concurrent proof load test.
>
> a\. [Proof Load Test.]{.underline} Before first use, all new,
> extensively modified, repaired or altered slings shall undergo a proof
> load test at a specified factor of the rated load according to Table
> 8-1. Proof load tests performed by the manufacturer prior to delivery
> are acceptable, if the necessary test certification papers are
> provided to verify the extent and thoroughness of the test on the
> specific item. A proof load test also may be performed at
>
> a prescribed time when there is a question in design or previous
> testing. All components shall be tested together as a system, if
> practical.
>
> Table 8-1. Proof Load Test Factors
>
> (Based on Manufacturers' Rated Load)

  ----------------------------------- -----------------------------------
  Equipment                           Proof Load Test Factor

  Wire Rope Slings                    2.0

  Alloy Steel Chain Slings            2.0

  Metal Mesh Slings                   1.5

  Natural or Synthetic Rope Slings    1.0

  Synthetic Web Slings                2.0

  Structural Slings                   2.0\*

  Shackles, Turnbuckles, Eye Bolts,   2.0
  etc.                                

  \*Unless otherwise specified by     
  design, due to material             
  characteristics, geometry, safety   
  factors, etc., but in any case, at  
  least 125 percent of the sling's    
  rated capacity.                     
  ----------------------------------- -----------------------------------

b.  [Periodic Load Test.]{.underline} Slings shall undergo periodic load
    tests at least every 4 years at a specific load test factor of the
    design rated load as given in Table 8-2. All components shall be
    tested together as a system, if practical. For slings used for
    critical lifts, these tests shall be based on frequency of use.
    Slings used infrequently for critical lifts shall be load tested
    before each critical lift if it has been over a year since the last
    load test. Slings used frequently for critical lifts shall be load
    tested at last once per year.

Table 8-2. Periodic Load Test Factors

(Based on Manufacturers' Rated Load)

  ----------------------------------- -----------------------------------
  Equipment                           Proof Load Test Factor

  Alloy Steel Chain Slings            1.25

  Wire Rope Slings                    1.25

  Metal Mesh Slings                   1.25

  Structural Slings                   1.25

  Natural or Synthetic Rope Slings    1.00\*

  Synthetic Web Slings                1.25

  Shackles, Turnbuckles, Eye Bolts,   1.25
  etc.                                

  \*Critical lift rope slings of      
  natural or synthetic material shall 
  not be used beyond 50 percent of    
  the manufacturer's rating to        
  maintain an equivalent safety       
  factor in the load system.          
  ----------------------------------- -----------------------------------

c.  [Non-Load Test Structural Slings]{.underline}. Due to unique design
    and usage requirements, a structural sling may be designated as a
    non-load test structural sling by the installation NASA Safety
    Director and the responsible engineering and operations/maintenance
    organizations. Such slings do not require periodic load tests.

d.  [Sling Rated Load]{.underline}. Rated load for slings shall be based
    on the periodic load test weight divided by the periodic load test
    factor 9see Table 8-2). For metal mesh slings, the rated capacity
    will be noted for vertical basket and choker hitch configurations.
    For natural or synthetic rope slings, used in noncritical lifts, a
    50-percent derating for use is recommended. For natural or synthetic
    rope slings used in critical lifts, a 50- percent derating is
    required.

e.  [Test Reports and Periodic Recertification Tags.]{.underline}

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(1) Written, dated, and signed reports shall be prepared after each
    test. Inadequacies shall be documented and, if determined to be a
    hazard, corrected prior to further use. These reports shall be kept
    on file by the owner organization for a minimum of two test cycles
    and shall be made readily available.

(2) Following the load tests, all slings shall be given a permanently
    affixed tag identifying the equipment (part number) and stating the
    rated capacity based on the load test value and the next periodic
    load test due date or certification expiration date. For alloy steel
    chains, size, grade, and reach shall be stated along with the rated
    load. For natural or synthetic rope slings used for critical lifts,
    the marked rated load shall be 50 percent of the manufacturer's
    rated load. The type of material shall also be stated. All load
    bearing components shall be traceable to the most recent load test.
    This may be accomplished by clearly marking/coding or tethering all
    components of the assembly, through configuration control, or other
    procedures. (NOTE: Load bearing components not traceable to load
    test/certification will invalidate the load test/certification of
    the whole assembly.)

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803. INSPECTION

> Inspections shall be performed on all slings. Visual inspections for
> cracks, deformation, gouges, galling, kinks, crushed areas, corrosion,
> and proper configuration shall be performed each day the sling is
> used, prior to first use. An indepth inspection shall be performed
> annually or when a sling is suspected to have even a small loss of
> strength or is repaired. Inspections shall be performed by qualified
> personnel according to approved technical operating procedures.
> Inadequacies shall be documented and, if determined to be a safety
> hazard, corrected prior to further use.

a.  [Daily Inspections.]{.underline} These inspections shall be
    performed prior to first use each day the sling is used and shall
    include the following:

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(1) Check for defects such as cracks, deformation, gouges, galling,
    kinks, crushed areas, and corrosion.

(2) Check for proper configuration (the lifting assembly and associated
    hardware, as proof load tested).

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b.  [Periodic Inspections.]{.underline} The following inspections shall
    be performed at least once a year, unless otherwise specified below.
    The need to replace or repair slings shall be determined by a
    certified or otherwise qualified person based on an evaluation of
    inspection results. Any discrepancy (deterioration or damage) is
    sufficient reason for questioning continued use of the sling.

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(1) Alloy Steel Chain

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(a) Inspect each link individually to ensure every link hangs freely
    with adjoining link.

(b) Ensure that wear, corrosion, or deformities at any point on chain do
    not exceed 20 percent of original dimensions.

(c) Ensure that master links are not deformed.

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(2) Wire Rope Slings

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(a) Ensure that there are fewer than 10 randomly distributed broken
    wires in one rope lay or 5 broken wires in 1 strand in 1 lay.

(b) Ensure wear or scraping is less than 1/3 the original diameter of
    outside individual wires.

(c) Inspect for kinking, crushing, bird caging, or any other distortion
    of the rope structure.

(d) Inspect for excessive heat damage.

(e) Inspect for cracked, deformed, or worn end attachments.

(f) Inspect for significantly corroded rope or end attachments.

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(3) Metal Mesh Slings

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(a) Ensure that there are no broken welds or brazed joints along the
    sling edge.

(b) Ensure that reduction in wire diameter does not exceed 25 percent
    due to abrasion or 15 percent due to corrosion.

(c) Inspect for lack of flexibility due to distortion of the fabric.

(d) Ensure that there is no more than 25-percent reduction of the
    original cross-sectional area of metal at any point around handle
    eyes.

(e) Inspect for distortion of either handle out of plane, more than
    10-percent decrease in eye width, and more than 10-percent increase
    in the receiving handle slot depth.

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(4) Natural and Synthetic Fiber Rope Slings

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(a) Inspect for abnormal wear.

(b) Ensure that there is no powdered fiber between stands.

(c) Inspect for broken or cut fibers.

(d) Ensure that there is no rotting or acid or caustic burns.

(e) Inspect for distortion of associated hardware.

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(5) Synthetic Webbing Slings

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(a) Ensure that there are o acid or caustic burns.

(b) Inspect for melting or charring of any part of surface.

(c) Inspect for snags, punctures, tears, and cuts.

(d) Inspect for broken or worn stitches and rotting.

(e) Ensure that wear or elongation does not exceed amount recommended by
    the manufacturer.

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(6) Structural Slings

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(a) Verify overall that there is no evidence of damage, gouges in metal,
    loose bolts, rivets, connections, or deformations such as galling or
    gouges in pins, eyes, and end connections.

(b) Ensures that there are no gent, deformed, cracked, or excessively
    corroded support or main members.

(c) Without disassembly, inspect load bearing bolts for evidence of
    deterioration. Verify that assemblies are intact and that there has
    been no shifting or relative motion of parts.

(d) Inspect attachment and lifting lugs for visual deformation and
    evidence of local yielding.

(e) Ensure that there are no elongated attachment or lifting holes.

(f) Inspect around fasteners for local yielding and deformation.

(g) Remove and inspect load bearing slip pins for deformation, evidence
    of bending, abnormal defects such as galling, scoring, brinelling,
    and diameters not within design tolerances. Verify that there are no
    cracks. Dye penetrant, magnaflux, x-ray, or ultrasonics shall be
    used when required by design requirements or when cracks are
    suspected.

(h) Inspect pin bores for deformation, local yielding, scoring, galling,
    brinelling, diameters not within design tolerances. Verify that
    there are no cracks. Dye penetrant or ultrasonics shall be used when
    required by design requirements or when cracks are suspected.

(i) Inspect welds for cracks, evidence of deformation, deterioration,
    damage, or other defects by:

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1.  Visual inspection of all welds.

2.  Ultrasonics, x-ray, magnetic particle, dye penetrant, or eddy
    current as appropriate for critical welds as identified on the
    design drawings and welds where cracks are suspected.

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(j) Inspect all parts, particularly bare metal, for corrosion.
    Corrosion-protect all surfaces with strippable vinyl that are not to
    be painted, lubricated, or coated. Do not paint over uninspected
    areas, or cracks, deformation, deterioration, or other damage until
    engineering assessment has been made.

(k) All slings rejected during inspection shall be marked. An
    engineering assessment will e made to determine if the sling is
    repairable. Non-repairable slings will be destroyed as soon as
    possible to avoid unintentional use.

(l) Inspect hooks for deformations or cracks (see Chapter 5).

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c.  [Idle Slings.]{.underline} Slings that are idle will be inspected
    prior to use to fulfill the requirements in paragraph 803a and 803b
    that may have expired during the idle time.

d.  [Inspection Reports.]{.underline} Written, dated, and signed
    inspection reports shall be prepaid after each periodic inspection.
    Inadequacies shall be documented and, if determined to be a hazard,
    corrected prior to further use. These reports shall be filed and
    made readily available by the organizational element responsible for
    inspecting sling(s).

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804. MAINTENANCE

> A preventive maintenance program shall be established based on
> manufacturers' recommendations and/or experience gained from use of
> the equipment. The program shall include procedures and a scheduling
> system for normal periodic maintenance items, adjustments,
> replacements, and repairs. The program shall also ensure that records
> are kept and unsafe test and inspection discrepancies are documented
> and corrected. The need to repair or replace slings shall be
> determined by a certified or otherwise qualified person based on an
> evaluation of inspection results.

805. OPERATIONS

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a.  The following safety practices shall be followed when using slings:

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(1) Select a sling of suitable rated capacity, use proper hitch, and
    attach the sling securely to the load. For critical lifts, rope
    slings of natural or synthetic construction shall not be used beyond
    50 percent their rated load. (The minimum safety factors for
    determining rated load are provided in Table 8-3.)

(2) Avoid kinks, loops, or twists in the legs.

(3) Start lift slowly to avoid shock loading the slings.

(4) Do not pull a sling from under a load when the load is resting on
    the sling. Block the load up to remove the sling.

(5) Do not shorten a sling by any means. Knotting and wire rope clips
    are prohibited.

(6) Keep metallic slings lubricated/painted to prevent corrosion.

(7) Slings shall not be loaded over the rated load except as required
    for periodic load tests.

(8) Particular attention shall be given to preventing corrosion. Slings
    shall be stored such that they will not be damaged by moisture,
    heat, sunlight, or chemicals. Nylon shall not be used in an acid or
    phenolic environment. Polyester polypropylene, and aluminum shall
    not be used in a caustic environment.

(9) Precautions shall be taken to ensure proper sling assembly and that
    the proper configuration is maintained.

(10) The user shall ensure that the sling is within the inspection and
     periodic recertification intervals and that all load bearing
     components are traceable to the most recent load test by
     examination of the tags and/or documentation.

(11) Sling repair shall maintain the minimum design load safety factors
     based on ultimate material strength. These factors are listed in
     Table 8-3.

Table 8-3. Minimum Safety Factors for Slings

+-------------------------------------+--------------------------------+
| Equipment                           | Design Load                    |
|                                     |                                |
|                                     | Safety Factor                  |
+-------------------------------------+--------------------------------+
| Alloy Steel Chain                   | 5                              |
+-------------------------------------+--------------------------------+
| Wire Rope                           | 5                              |
+-------------------------------------+--------------------------------+
| Metal Mesh                          | 5                              |
+-------------------------------------+--------------------------------+
| Manila Rope                         | 5                              |
+-------------------------------------+--------------------------------+
| Nylon Rope                          | 9                              |
+-------------------------------------+--------------------------------+
| Nylon Web                           | 5                              |
+-------------------------------------+--------------------------------+
| Polyester Rope                      | 9                              |
+-------------------------------------+--------------------------------+
| Polypropylene Rope                  | 6                              |
+-------------------------------------+--------------------------------+
| Structural                          | 3 times yield and              |
+-------------------------------------+--------------------------------+
|                                     | 5 times ultimate               |
+-------------------------------------+--------------------------------+
| Note: Design Load Safety Factor     |                                |
| based on ultimate material          |                                |
| strength, except for structural     |                                |
| slings.                             |                                |
+-------------------------------------+--------------------------------+

APPENDIX A

[ACRONYM AND DEFINITIONS]{.underline}

ANSI: American National Standards Institute.

Brake: A device, other than a motor, used for retarding or stopping
motion by friction or power means.

Certification: That situation when the lifting device or equipment
maintenance, test, or other operational checks have been performed and
are current.

CMAA: Crane Manufacturers Association of America, Inc.

Control Braking Means: A method of controlling speed by removing energy
from the moving body or by imparting energy in the opposite direction.

Crane: A machine for lifting and lowering a load and moving it
horizontally, with the hoisting mechanism an integral part of the
machine.

Critical Weld: A weld where the single failure of which could result in
injury to personnel or damage to property or flight hardware by dropping
or losing control of the load.

Derrick: An apparatus with a mast or member held at the head by guys or
braces, with or without a boom and that uses a hoisting mechanism and
operating ropes for lifting or lowering a load.

Designated Person: Any person who has been selected or assigned (in
writing) by the responsible NASA organizational element or the using
contractor as being qualified to perform specific duties. A licensed
operator may serve as a designated person for the equipment he/she is
licensed to handle.

Design Load: The value used by the manufacturer as the maximum load that
around which the device or equipment is designed and built based on
specified design factors and limits. This is also the load referred to
as the " Manufacturer's Rated Load."

Deviation: A variance that authorizes departure from a particular safety
requirement, were the intent of the requirement is being met through
alternate means that provide an equal or greater level of safety.

Eddy Current Brake (control braking means): A method of controlling or
reducing speed by means of an electrical induction load brake.

Emergency stop (E-Stop): A manually operated switch or valve to cut off
electric power or release fluid power independently of the regular
operating controls.

Failure Mode and Effects Analysis (FMEA): A systematic, methodical
analysis performed to identify and document all identifiable failure
modes at a prescribed level and to specify the resultant effect of the
modes of failure.

Frequently: For the purpose of this document, the term "frequently" is
used to mean once or more per year.

Hazard: Any real or potential condition that can cause injury or death
to personnel, or damage to or loss of equipment or property.

Hoist: A machinery unit device used for lifting and lowering a load.

Hoist Supported Personnel Lifting Device: Lifting equipment such as a
platform, bucket or cage supported by hoist(s) that is designed, built,
tested, maintained, inspected, and certified as having sufficient
reliability for safely lifting and lowering personnel.

Holding Brake: A friction brake that is automatically applied and
prevents motion when power is off.

Hydra-set: Trade name for a closed circuit hydraulically operated
instrument installed between hook and load that allows precise control
of lifting operations and provides an indication of the applied load. It
will be used in the general sense in this standard as a means of
identifying precision load position devices.

Licensed Operator: Any person who has successfully completed the
examination for crane, hoist, or heavy equipment operator and has been
authorized to operate such equipment. (NOTE: This term includes
certified and/or authorized operator.)

Load: The actual object being raised or moved.

Nondestructive Evaluation (NDE): Test and inspection methods used to
determine the integrity of equipment that do not involve destruction of
the test object. Examples are ultrasonic, magnetic particle, eddy
current, X-ray dye penetrant, etc.

NSIS: NASA Safety Information System.

OEM: Original Equipment Manufacturer.

Operational or Working Load: A value representing the weight of the load
actually being handled plus the load attaching equipment (slings,
Hydra-set, spreader bars, etc.).

Operational Test: A test to determine if the equipment (limit switches,
emergency stop controls, brakes, etc.) is functioning properly.

OSHA: Occupational Safety and Health Administration.

Periodic Load Test: A load test performed at predetermined intervals
with load greater than the rated load, but less than the proof load.

Personnel Lift: For the purposes of this document, a working platform
that will lift, lower, sustain, and transport people.

Proof Load: The specific load or weight applied in performance of a
proof load test and is greater than the rated load.

PSCA: Power Crane and Shovel Association.

Rated Load or Safe Working Load or Rated Capacity: An assigned weight
that is the maximum load the device or equipment shall operationally
handle and maintain. This value is marked on the device indicating
maximum working capacity. This is also the load referred to as "safe
working load."

Rated Load Test: A load test performed at predetermined intervals with a
load equal to the rated load.

Remote Emergency Stop (Remote E-Stop): An emergency stop remotely
located from the regular operator controls.

Safety Factor: A ratio of ultimate strength, breaking strength, or yield
strength to maximum permissible stress. It is not "reserve strength:
that can be used to justify exceeding permissible stresses or exceeding
the design load.

Side Pull: that portion of the hoist pull acting horizontally when the
hoist lines ar not operating vertically.

Side Load: A load applied at an angle to the vertical plane of the boom.

Single Failure Point: A single item or component whose failure would
cause an undesired event such as dropping a load or loss of control.

Shall: The word "shall" indicates that the rule is mandatory and must be
followed.

Should: The word "should" indicates that the rule is a recommendation,
the advisability of which depends on the facts in each situation.

Sling: A lifting assembly and associated hardware used between the load
and hoisting device hook.

Structural Sling: A rigid or semi-rigid fixture that I used between the
load and hoisting device hook. Examples are spreader bars, equalizer
bars, lifting beams, etc.

Tagline: A line used to restrain or control undesirable motion of a
suspended load.

User-Operated Crane: A crane maintained by one group (contractor) and
operated by a different group (contractor).

Variance: Documented and approved permission to perform some act
contrary to established requirements.

Waiver: A variance that authorizes departure from a particular safety
requirement, where an increase level of risk has been accepted.

Winch: A device used for hauling or pulling in a horizontal direction by
means of a drum or barrel around which a rope or chain is wrapped or is
shortened.

Wire Rope Slings: Wire ropes made into forms, with or without fittings
for handling loads and so made as to permit the attachment of an
operating rope.

Working Load: If the device has never been down rated or uprated, this
also is the " manufacturer's rated load."

APPENDIX B

[NATIONAL AERONAUTICS AND SPACE ADMINISTRATION]{.underline}

[ALTERNATE SAFETY STANDARD FOR]{.underline}

[SUSPENDED LOAD OPERATIONS]{.underline}

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U.S. Department of Labor Assistant Secretary for

Occupational Safety and Health

Washington, D.C. 20210

Mr. George A. Rodney

Associate Administrator for

> Safety and Mission Quality

National Aeronautics and Space

> Administration

600 Independence Avenue, S.W.

Washington, D.C.

Dear Mr. Rodney:

The Occupational Safety and Health Adminstration 9OSHA) has completed
its review o the proposed alternate standard on suspended loads, as
required in 29 CFR 1960.17. With this letter, we want to inform you that
we have approved the standard. This approval is based on our
determination that the alternate standard provides equivalent protection
as would compliance with the following standards in specifically
identified operations:

-   1910.179 (n) (3) (vi) The employer shall require that the operator
    avoid carrying loads over people.

-   1910.180 (h) (3) (vi) The operator should avoid carrying loads over
    people.

-   1910.180 (h) (4) (ii) No person should be permitted to pass under a
    load on the hook.

One of the OSHA reviewers stated that this standard, ". . . appears to
be a very comprehensive approach to a finite task and requires
significant amounts of safety management from the preliminary hazard
analysis through completion of the lift.: It is essential, however, that
management ensure that this level of safety management effort continues
to effectively protect the exposed employees.

We appreciate the cooperation provided my staff in the many discussions
on this alternate standard. Your interest and support for the safety and
health of Federal employees is greatly appreciated.

Sincerely,

(Please Note: Original Letter on File with signature)

Gerard F. Scannell

Assistant Secretary

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[NATIONAL AERONAUTICS AND SPACE ADMINISTRATION]{.underline}

[ALTERNATE SAFETY STANDARD FOR]{.underline}

[SUSPENDED LOAD OPERATIONS]{.underline}

This standard applies to specifically identified operations controlled
by the National Aeronautics and Space Administration (NASA) involving
both civil service and contractor employees. The standard is an
alternate to Code of Federal Regulations 29 CFR 1910.179(n)(3)(vi), 20
CFR 1910.180(H)(3)(vi), and 29 CFR 1910.180(h)(4)(ii). NASA Safety is
responsible for its implementation and enforcement.

As an alternative standard developed pursuant to Section 1-201(d) of
Executive Order 12196 and 29 CDR 1960.17, it applies only to NASA
employees. The Occupational Safety and Health Administration (OSHA) will
inspect the working conditions of NASA employees performing these
specified operations for compliance with these alternate standard
requirements. Although OSHA can not inspect private sector employees
working in the same operation with NASA employees for compliance with
the alternate standard, it will fully consider the equivalent safeguards
specified in this standard for both NASA and contractor employees as the
basis for a de minimis violation which is recorded, but not issued.

[Suspended Load Operation Definition]{.underline}

An operation is considered a suspended load operation and subject to the
requirements of this standard if it meets all three of the following
criteria:

1.  The operation involves the use of a crane or hoist that supports the
    weight of a suspended load. (This excludes operations where the load
    is secured in a holding fixture or on substantial blocks supporting
    the entire load even though the crane/hoist hook may still be
    attached.) No distinction is made between a static load and a
    dynamic load. Rigging, i.e., slings, Hydra-sets, lifting fixtures,
    shackles, straps, when attached to the hook, is considered part of
    the load.

2.  Personnel involved in the operation have any part of the body
    directly beneath the suspended load. (This excludes operations where
    employees have their hands on the sides of a load, i.e., to guide
    the load.)

3.  In the event of a crane/hoist failure, as the load drops it could
    contact personnel working directly beneath it, with injury or death
    as a possible result. (This excludes operations where employees have
    their hands only partially under a load such that a crane or hoist
    device failure would push their hands out of the way not resulting
    in injury. This also excludes situations where the falling load
    would come to rest on hardware that is not suspended before an
    employee could be injured.)

[Requirements]{.underline}

It is recognized that cranes and hoists do not generally meet the
support requirements of a system that would allow personnel to work
beneath a suspended load. NASA's first hazard avoidance protocol is to
design hazards out of the system or operation. Accordingly, it is NASA's
intent and goal that all future systems, hardware, and equipment be
engineered, designed, installed, and operated to prevent exposing
employees to working under loads suspended from cranes and hoists. Due
to the uniqueness of NASA activities and the limitations imposed when
using present systems, hardware, equipment, and facilities, suspended
load operations may be permitted only under specifically approved and
controlled conditions. No suspended load operation shall be performed
unless all (15) of the following special requirements are met:

(1) All suspended load operations will be approved by the
    Center/facility NASA Director of Safety based upon a detailed
    engineering hazards analysis of the operation. The hazard analysis
    will be prepared by the responsible safety organization and
    coordinated through appropriate engineering and design offices. The
    analysis documentation will include the following:

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a.  [A justification why the operation cannot be conducted without
    personnel beneath the load.]{.underline} Feasible procedure/design
    options will be investigated to determine if the work can be
    accomplished without personnel working under a load suspended from a
    crane/hoist.

b.  [Details of the precautions taken to protect personnel should the
    load drop.]{.underline} Secondary support system, i.e., equipment
    designed to assume support of (catch) the load preventing injury to
    personnel should the crane/hoist fail, shall be evaluated and used
    whenever feasible. Secondary support systems will be constructed
    with a minimum safety factor of 2 to yield.

c.  [The maximum number of exposed personnel allowed.]{.underline} Steps
    shall be taken to limit the number of personnel working under a load
    suspended from a crane/hoist. Only those essential personnel
    absolutely necessary to perform the operation will be allowed to
    work in the safety controlled area.

d.  [The time of exposure.]{.underline} Steps shall be taken to ensure
    that personnel do not remain under the load any longer than
    necessary to complete the work..

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(2) Each operation will be reviewed on a case-by-case basis.

(3) Only those suspended load operations approved by the Center/facility
    NASA Director of Safety will be permitted, subject to this standard.
    A list of approved suspended load operations will be maintained by
    NASA Safety and made available to OSHA personnel upon request.

(4) The operational procedures document (e.g., Operations and
    Maintenance Instruction, Technical Operating Procedure, work
    Authorization Document) will be revised to specify the necessary
    additional requirements identified by the hazard analysis discussed
    in Paragraph (1). The procedures will be available on site for
    inspection during the operation.

(5) During a suspended load operation, if a new procedure not covered by
    the original analysis is deemed necessary due to unusual or
    unforeseen circumstances, the NASA Center/facility Safety Office
    will be consulted and must approve and document the procedure before
    operations continue. Safety will coordinate with Operations,
    Engineering, and other organizations as appropriate. If the new
    procedure is to be performed on a regular basis, a detailed hazards
    analysis and approval as outlined in Paragraph (1) are required.

(6) The crane/hoist shall be designed, tested, inspected, maintained,
    and operated in accordance with the NASA Safety Standard for Lifting
    Devices and Equipment (NSS/GO-1740.9). Test, inspection, and
    maintenance procedures will be developed and approved by qualified,
    responsible NASA engineers. Qualified specialists will perform the
    procedures and resolve noted discrepancies. NASA Quality Assurance
    will perform an independent annual inspection of all cranes/hoists
    involved in suspended load operations. The results of the annual
    inspections will be maintained and made available to OSHA personnel
    upon request.

(7) Each crane/hoist involved in suspended load operations shall undergo
    a Failure Modes and Effects Analysis 9FMEA) that shall be approved
    by the Center/Facility NASA Director of Safety. The FEMA will
    determine Single Failure Point (SFP), assessing all critical
    mechanical functional components and support systems in the drive
    trains and critical electrical components.

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a.  For those cranes/hoists identified as having no SFP whose failure
    would result in dropping the load, the total weight of the suspended
    load shall not exceed the device's rated load.

b.  For those cranes/hoists identified as having a SFP whose failure
    would result in dripping the load, use of that device for suspended
    load operations must be approved by NASA Headquarters. Complete
    documentation on the suspended load operation, including the hazards
    analysis outlined in Paragraph (1) and the FMEA described above,
    will be forwarded to NASA headquarters for evaluation. Approval will
    be given based upon detailed analysis of the potential hazards and
    rationale for acceptance. Such cases will never exceed the device's
    rated load. OSHA shall be notified when NASA Headquarters approves
    using any crane/hoist identified as having a SFP whose failure would
    result in dropping the load.

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(8) Before lifting the load involved in a suspended load operation, the
    crane/hoist will undergo a visual inspection 9without major
    disassembly) of components instrumental in assuring that the load
    will not be dropped (e.g., primary and secondary brake systems,
    hydraulics, mechanical linkages, and wire rope per NSS/GO-1740.9).
    Noted discrepancies will be resolved before the operation continues.
    This crane-lift inspection will be in addition to the inspections
    required in 1910.179 and 180(d).

(9) A trained and licensed operator (certified per NSS/GO-1740.9) shall
    remain at the crane/hoist controls while personnel are under to
    load.

(10) Safety controlled areas shall be established with appropriate
     barriers (rope, cones, etc.). All nonessential personnel shall be
     required to remain behind the barriers.

(11) Prior to the suspended load operation, a meeting with the
     crane/hoist operator(s), signal person(s), person(s) who will work
     under the load, and the person responsible for the task shall be
     held to plan and review the approved operational procedures that
     will be followed, including procedures for entering and leaving the
     safety controlled area.

(12) Communications (voice, radio, hard wired, or visual) between the
     operator(s), signal person(s), and the person(s) working under the
     load shall be maintained. Upon communication loss, operations shall
     stop immediately, personnel shall clear the hazardous area, and the
     load shall be safed. Operations shall not continue until
     communications are restored.

(13) Personnel working beneath the load shall remain in continuous sight
     of the operator(s) and/or the signal person(s).

(14) NASA shall conduct periodic reviews to ensure the continued safety
     of the procedures. As a minimum, NASA will annually evaluate the
     implementation of this procedure at each Center with operations on
     the suspended load list.

(15) A list of approved suspended load operations, list of cranes/hoists
     used for suspended load operations, and copies of the associated
     hazards analyses will be provided to the OSHA Office of Federal
     Agency Programs via NASA Headquarters for distribution to the
     appropriate regional and area OSHA offices. (NASA Headquarters, in
     conjunction with OSHA, will develop a format for transmittal of
     this information.) Quarterly updates to the documentation will be
     provided as needed.