Dear Mr. Ilango
All the Acts and Rules are mainly made for giving us guidance to us. Whatever lifting appliances, lifting tools, tackles, wire ropes, it will be having its specific life period i.e., life while in use and shell life. For Hired Vehicles RTO is having the control over it, to take the Fitness Certificate. (For Owners Vehicles it is not required as it will be maintained by the owner to keep him safe). Like that in Construction Industries, majority workforce are unskilled and to safeguard their life, the Government has made BOCW Act and enacted in parliament in 1996, which is mainly taking care of the workers involved in construction activities. The contractors may not concentrate on the safety aspect of the lifting appliances. that's the reason the Act insists the contractors to ensure that all the lifting appliances are required to be inspected by the authorised Third Party duly identified/authorised by the appropriate Government.
Whenever there is a change in the configuaration of Lifting appliances and if there is no change took place then every year, the lifting appliances must be inspected by third party and a certificate to that effect must be obtained and maintained by the contractors.
The following stuff have been reproduced from the BOCW Rules for your information I have not mentioned the Rule Nos because it may vary from state to state.
Construction and maintenance of lifting appliances
Every employer shall ensure at a construction site that-
(a) All lifting appliances, including their parts and working gear, whether fixed or movable and any plant or gear used in anchoring authoring or fixing of such appliances, are-
(i) of sound construction, sound material, and of adequate strength to serve the purpose for which these are to be used and all such appliances shall be free from patent defects; and
(ii) maintained in good repair and working condition;
(b) (i) every pulley around which the rope of any lifting appliance is carried, is of adequate diameter and sound construction in relation to such rope;
(ii) any rope which terminates at the winding drum of a lifting appliance is securely attached to such drum and at least 3 dead turns of such rope remain on such drum in every operating position of such lifting appliance;
(iv) the flange of a drum projects twice the rope diameter beyond the last layer of such rope and if such projection is not available, other measures like anti-slackness guards shall be provided to prevent such rope from coming off such drum;
(c) Every lifting appliance is provided with adequate and efficient brakes, which -
(i) are capable of preventing fall of a suspended load (including any test load) and of effectively controlling such load while it is being lowered;
(ii) act without shock;
(iii) have shoes that can be easily removed for running; and
(iv) are provided with simple and easily accessible means of adjustment:
(d) Controls of every lifting appliance,-
(i) are so situated that the driver of such appliance at his stand or seat has ample room for operating and has an unrestricted view of construction work as far as practicable, and that he remains clear of the load and ropes and that no load passes over him;
(ii) are positioned with due regard to ergonometric considerations for proper operation of such appliance;
(iii) are so located that the driver of such appliance remains above the height of the heel block during the whole operation of such appliance;
(iv) have upon them or adjacent to them clear markings to indicated their purposes and mode of operations;
(v) are provided, where necessary, with a suitable locking device to prevent accidental movement or displacement;
(vi) move, as far as practicable, in the direction of the resultant load movement; and
(vii) Wherever automatic brakes are provided, automatically come to the neutral position in case of power failure.
Test and periodical examination of lifting appliances.-
The employer shall ensure at construction site that,-
(a) all lifting appliances are tested and examined by a competent person before being taken into use for the first time or after it has undergone any alterations or repairs liable to affect its strength or stability or after erection on a construction site and also once at least in every 5 years, in the manner specified in Schedule - I;
(b) all lifting appliances are thoroughly examined by a competent person once at least in every 12 months.
Automatic safe load indicators:
(1) Every employer shall ensure at a construction site of a building or other construction work that,-
(i) every crane, if so constructed that the safe working load may be varied by raising or lowering of the jib or otherwise, is attached with an automatic indicator of safe working loads which gives a warning to the operator wherever the load exceeds the safe working load;
(ii) cut-out is provided which automatically arrests the movements of the lifting parts of every crane if the load exceeds the safe working load, wherever possible;
(2) the provisions of sub-clause (i) of sub-rule (1) apply, except where it is not possible to install an automatic safe load indicator, in which case, provision of a table showing the safe working loads at the corresponding inclinations or radius of the jib on the crane shall be considered sufficient.
Installation.-
Every employer shall ensure at a construction site that,-
(a) fixed lifting appliances are installed:
(i) by competent persons;
(ii) in a manner that such appliances cannot be displaced by the load, vibration or other influences;
(iii) in a manner that the operator of such appliances is not exposed to danger from loads, ropes or drums; and
(iv) in a manner that the operator can either see over the zone of operation or communicate with all loading and unloading points by signal, or other communication system; points by signal or other communication system;
(b) adequate clearance is provided between parts or loads of lifting appliances and
(i) the fixed objects such as walls and posts; or
(ii) electrical conductors;
(c) the lifting appliances, when exposed to wind loading are given sufficient additional strength, stability and rigidity to withstand such loading safely;
(d) No structural alterations or repairs are made on any part of the lifting appliances that effect the safety of such appliances without obtaining the opinion of the competent person to this effect.
Winches
Every employer shall ensure at a construction site that, -
(a) (i) winches are not used if control levers operate with excessive friction or play;
(ii) double gear winches are not used unless a positive means of locking the gear shift is provided;
(iii) there is no load other than the fall and the hook assembly on the winch while changing gears on a two gear winch;
(iv) adequate protection is provided to winch operator against abnormal weather;
(v) temporary seats or shelters for winch operators which may pose hazard to the operator or any workers are not allowed to be used;
(vi) control levers are secured in the neutral position and, whenever possible, the power is shut off whenever winches are left unattended;
(b) in use of every steam winch-
(i) measures are taken to prevent escaping steam from construction site or other workplace or from otherwise hindering or injuring any worker;
(ii) extension control levers which tend to fall of their own weight are counterbalanced;
(iii) Operators are not permitted to use the winch control extension levers except for short handles on wheel type controls and that such levers are of adequate strength, secure and fastened with metal connections at the fulcrum and at the permanent control lever;
(c) in use of every electric winch, no worker is permitted to transfer, alter or adjust electric control circuits in case of any defect in such winch;
(d) electric winches are not used for building work where-
(i) the electro-magnetic brake is unable to hold the load; or one or more control points, either hoisting or lowering, are not operating properly.
Buckets
Every employer shall ensure at a site that tip-up buckets are equipped with a device that effectively prevents accidental tipping.
Identification and marking of safe working load.-
Every employer shall ensure at a construction site that,-
(a) every lifting appliance and loose gear is clearly marked for its safe working load land identification by stamping or other suitable means;
(i) every derrick (other than derrick crane) is clearly marked for its safe working load when such derrick is used either in single purchase with a lower block or in union purchases in all possible block positions;
(ii) the lowest angle to the horizontal, to which the derrick may be used, is legibly marked;
(b) every lifting appliance having more than one working load is fitted with effective means to enable the operator to determine safe working load at each point under all conditions of use;
(c) means to ascertain the safe working load for lifting gears under such conditions in which such gears may by used are provided to enable a worker using such gears and such means shall consist of-
(i) marking the safe working load in plain figures or letters upon the sling or upon a tablet or ring of durable material attached securely thereto in case of chain slings; and
(ii) either the means specified in sub-clause (i) or notices so exhibited as can be easily read by any concerned building worker stating the safe working load for the various sizes of the wire rope slings used in case of wire rope slings.
Loading of lifting appliances and lifting gears.-
Every employer shall ensure at a construction site that,-
(a) no lifting appliance, lifting gear or wire rope is used in an unsafe way and in such a manner as to involve risk to life of workers, and that they are not loaded beyond their safe working load except for testing purposes under the direction of a competent person in the manner as specified in Schedule I;
(b) no lifting appliance, lifting gear or any other material handling appliance is used, if,-
(i) the Inspector having jurisdiction is not satisfied with reference to a certificate of test or examination or to an authenticated record maintained as provided under these rules; and
(ii) in the view of such Inspector, the lifting appliance, lifting gear or any other material handling appliance is not safe for use in site and
(iii) no pulley block is used in site unless the safe working load and its identification are clearly marked on such block.
Operator’s cab or cabin.-
Every employer shall ensure at a construction site that,-
(a) the operator of every lifting machine in outdoor service is provided with a cab or cabin which-
(i) is made of fire resistant material;
(ii) has a suitable seat, a foot rest and protection from vibration;
(iii) affords the operator an adequate view of the area of operation;
(iv) affords the necessary access to working parts in cab;
(v) affords the operator an adequate protection against the weather;
(vi) is adequately ventilated; and
(vii) is provided with a suitable fire extinguisher.
Operation of lifting appliances.-
Every employer shall ensure at a construction site that-
(a) every crane driver or lifting operator possess adequate skill and training in the operation of the particular lifting appliance;
(b) no person under 18 age is in control of any lifting appliance, scaffold winch, or to give signals to the operator;
(c) precaution is taken by the trained operator to prevent lifting appliance from being set in motion;
(d) the operation of lifting appliance is governed by signals, in conformity with the relevant national standards;
(e) the lifting appliance operator’s attention is not distracted while he is working;
(f) no crane, hoist, winch or other lifting appliance or any part of such crane, hoist, winch or other lifting appliance is , except for testing purposes, loaded beyond the safe working load;
(g) during the hoisting operations effective precaution is taken to prevent any person from standing or passing under the load in such operations;
(h) operator does not leave lifting appliance unattended while power is on or load is suspended to such appliance;
(i) no person rides on a suspended load or any lifting appliance;
(j) every part of a load in course of being hoisted or lowered is adequately suspended and supported to prevent danger;
(k) every receptacle used for hoisting bricks, tiles, slates or other material is suitable enclosed as to prevent the fall of any such materials;
(l) the hoisting platform is enclosed when loose materials or loaded wheel-barrows are placed directly on such platform or lowering, such materials or wheel barrows;
(m) no material is raised, lowered or slowed with any lifting appliance in such a way as to cause sudden jerks to such appliance;
(n) in hoisting a barrow, any wheel of such barrow is not used as a means of support unless adequate steps are taken to prevent the axle of such wheel from slipping out of its bearings;
(o) long objects like planks or girders are provided with a tag line to prevent any possibility of danger while raising or lowering such objects;
(p) during the process of landing of material, a building worker is not permitted to lean out into empty space for finding out the loading and unloading of such material;
(q) the hoisting of loads at places where there is regular flow or traffic is carried out in an enclosed space, or in case such hoisting is impracticable in enclosed space, measures are taken to hold up or divert the traffic during the time of such hoisting;
(r) adequate steps are taken to prevent a load, in the course of being hoisted or lowered from coming into contact with any object to avoid any displacement of such load;
(s) appliances are provided and used for guiding heavy loads when raising or lowering heavy loads to avoid crushing of hands of building workers during such raising or lowering of loads.
Hoists.-
Every employer shall ensure at a construction site that,-
(a) hoist towers are designed according to relevant national standards;
(b) hoist shafts are provided with rigid panels or other adequate fencing-
(i) at the ground level on all sides of such shafts; and
(ii) at al other levels on all sides of the access to such shafts;
(c) the walls of hoist shafts, except at approaches, extend to at least 2M above the floor or platform of access to such shafts;
(d) approaches to a hoist are provided with gates which are-
(i) gridded to maintain visibility;
(ii) at least of 2M height; and
(iii) equipment with a device which requires such gate to be closed before the platform of such hoist can leave the landing and prevents the gate from being opened unless such platform is at the landing;
(e) approaches to a hoist are adequately lit;
(f) the guides of hoist platforms offer sufficient resistance to bending and bucking, in the case of jamming, by providing a safety catch;
(g) overhead beams and their supports are capable of holding the total maximum live and dead loads that such beams and supports will be required to carry, with a safety factor of at least 5;
(h) a clear space is provided--
(i) above the highest stopping place of a cage or platform to allow sufficient unobstructed travel of such cage or platform in case of over winding; and
(ii) below the lowest stopping place of such cage or platform;
(i) adequate covering is provided above the top of hoist shafts to prevent materials from falling into such shafts;
(j) outdoor hoist towers are erected on adequately firm foundations and are securely braced, guyed and anchored;
(k) a ladder way extends from the bottom to the top of every outdoor hoist tower in case no other ladder way exists within easy reach and such ladder way comply with the relevant national standards;
(l) the rated capacity of a hoisting engine is at least 1.5 times the maximum load that such engine will be required to move;
(m) all gearing on a hoisting engine is securely enclosed;
(n) steam piping of a hoisting engine is adequately protected against accidental contact of such piping with a building worker;
(o) electrical equipment of a hoisting engine is effectively earthed;
(p) a hoist is provided with suitable devices to stop a hoisting engine as soon as the platform of such hoist reaches its highest stopping place;
(q) a hoisting engine is protected by a suitable cover against weather and falling objects;
(r) a hoisting engine set up in a public thoroughfare is completely enclosed;
(s) all exhaust steam pipes discharge steam in such a manner that the steam so discharged does not scald any person or obstruct the operator’s view;
(t) the motion of a hoist is not reversed without first bringing it to rest to avoid any harm from such reverse motion;
(u) a hoist, not designed for the conveyance of persons, is not set in motion from the platform of such hoist;
(v) pawls and ratchet-wheels of a hoist, requiring disengagement of such pawls from such ratchet wheels, before the platform of such hoist is lowered, are not used;
(w) a platform of a hoist is capable of supporting such maximum load, that such platform may carry, with a safety factor of at least 3;
(x) a platform of a hoist is equipped with suitable safety gear which can hold such platform with its maximum load in case its hoisting rope breaks;
(y) on platform of a hoist, the wheelbarrows or truck are efficiently blocked in a safe position;
(z) a cage of a hoist or a platform, where workers are required to enter into such cage or to go on such platform at landing level, is provided with a locking arrangement to prevent such cage or platform from moving during the time a worker enters or leaves such cage or platform;
(za) the sides of a platform of a hoist which, are not used for loading or unloading, are provided with toe-board and enclosures of a wire mesh or any other suitable means to prevent the fall of any part of a load from such platform;
(zb) a platform of a hoist, which has any probability of falling and part of load from it, is provided with an adequate covering with such fall;
(zc) the counter-weights of a hoist consisting of an assemblage of several parts are so constructed that such parts are rigidly connected together;
(zd) the counter-weights of a hoist run between guides;
(ze) at every level of work the workers are provided with adequate platforms for performing such work;
(zf) a legible notice in Kannada / English as well as in a local language is displayed at –
(ii) a conspicuous place of the platforms of a hoist and that such notice states the maximum carrying capacity of such hoist in kg;
(iii) a conspicuous place on the hoisting engine and that such notice states maximum lifting capacity of such hoist in kg;
(iv) a conspicuous place on a hoist carrying goods and other materials and such notice states that such hoist is not meant for carriage of persons.
Fencing of and means of access to lifting appliances.-
Every employer shall ensure at a construction site that,-
(a) safe means of access is provided to every part of a lifting appliance;
(b) the operator’s platform on every crane or tip driven by mechanical power is securely fenced and is provided with safe means of access and where access to such platform is by a ladder,-
(i) the sides of such ladder extend to a reasonable height beyond such platforms or some other suitable handhold is provided in lieu thereof to prevent any falling of persons from such platforms;
(ii) the handling place on such platform is maintained free from obstruction and slipping; and
(iii) in case the height of such ladder exceeds 06M, the resting platforms are provided on such ladder at every 06M of its height and where the distance between the last platform so provided and the top end of such ladder is more than 02M then on such top end.
Construction and maintenance of lifting gear.-
Every employer shall ensure at a construction site that,-
(a) every lifting gear is -
(i) of good design and construction, sound material and adequate strength to perform the work for which it is used;
(ii) free from patent defects; and
(iii) properly maintained in good repair and working order;
(b) components of the loose gear, at the time of its use, are renewed if one of its dimensions at any point has decreased by 10% or more by user;
(c) a chain is withdrawn from use when it is stretched and increased in length which exceeds 5% of its length or when a link of such chain is deformed or is otherwise damaged or raised scarves of defective welds appeared on it;
(d) rings, hooks, swivels and end links attached to a chain are of the same material as that of such chain;
(e) the voltage of electric supply to any magnetic lifting device does not fluctuate by more than + 10% or – 10%.