REV_Gammon_COPbooklet_English_24Jan2017

LORRY CRANE

Guidance

Issue 1
2015 - 02

INTRODUCTION:

The purpose of this manual is to guide Gammon employees CONTENTS:
and sub-contractors on how to operate lorry cranes safely
and to highlight the risks involved when carrying out lifting Definitions 3
operations. Risks 4
Lifting Capacity De-rating Charts 5
USING THIS MANUAL: Three Major Hazards 8
Lorry Crane Operator Safety 9
1. READ through this manual and go through it with Lorry Crane Inspections 10
your work team. Outriggers 11
Outrigger Pads 12
2. LOOK at the images to help improve When to Use a Lifting Plan 13
understanding. When a Lifting Plan is NOT Needed 14
Procurement Control 15
3. UNDERSTAND. Test workers’ understanding of Incident Reports 16
the content by asking them questions. Hold Notes 18
demonstrations if necessary.

4. SUGGESTIONS. Ask workers if they have any
additional suggestions on how to work safely
when operating lorry cranes.

Remember:
5. LOOKOUTFOREACHOTHER.Remindworkers

to stop and correct unsafe acts.
6. REPORT any unsafe acts or conditions to

a supervisor.
7. ZERO HARM must always be the goal!

2

DEFINITIONS:

Installation and construction work:

This includes a range of activities and operations such as:
• Concreting
• Constructing curtain walls
• Installing steelwork
• Installing escalators
• Lifting materials into a building
• Lowering materials into a basement

or excavation

Loading and unloading:

This is the simple operation of using the lorry’s crane
to lift materials or objects off the ground and onto the
lorry bed OR from the lorry bed to the ground.

Off Loading

Loading

Lifting materials onto a building.

3

RISKS: Poor or sloped ground
conditions.
Incidents or injuries from: Resting outriggers on the
wrong support.
• Performing lifting operations
without knowing the exact
weight of the load to be lifted.

• Not following Safe
Working Loads.

• Using the wrong positioning
of the lorry crane while
performing lifting operations.

• The lorry crane becoming
unbalanced once a load has
been offloaded from its bed.

• Not having the correct safety
precautions in place such as
barricades or fatal zones.

• Driving lorry cranes too close
to overhead powerlines.

Loading or unloading objects below ground level.

4

LIFTING CAPACITY DE-RATING CHARTS:

Use the following de-rating charts to help position your lorry crane De-rating chart not followed
correctly to maximise its lifting capacity according to where the
crane is mounted and if it has a tail outrigger or not. It’s important Front mounted lorry crane
to take note of the yellow and red zones where the lifting with 4 outriggers:
capacity is greatly reduced and could lead to the lorry crane
becoming unstable.

FRONT MOUNTED LORRY CRANES:

40% of rated load 100% of rated load
70% of rated load

R-20m

Strongest at: Rear and both sides 20° 20°
Weakest at: Front side R-12m

• 40% of rated load 5
• 70% of rated load
• 100% of rated load

LIFTING CAPACITY DE-RATING CHARTS:

40% of rated load 70% of rated load How to calculate when de-rating Safe
Working Loads (SWL).
20°
The following must be done to calculate how
6 much of the total load can be lifted when lifting in
the weaker yellow and red zones.

R-20m Example 1:
20° • If a lorry crane's SWL is 7.16 tons and you

need to lift an object that is 4 tons, BUT
you’re lifting in a zone that can only handle

40% (red zone) of the total SWL:
7.16 x 0.4(40%) = 2.86

• This means that a MAXIMUM safe working
load of 2.86 tons can be lifted in that zone,
so the lift can NOT take place because the
load weighs 4 tons.

Front mounted lorry crane Example 2:
with 2 front outriggers: • If a lorry crane's SWL is 7.16 tons and you

Strongest at: Rear and both sides need to lift an object that is 4.5 tons, BUT
Weakest at: Front sides you’re lifting in a zone that can only handle
• 40% of rated load
• 70% of rated load 70% (yellow zone) of the total SWL:
7.16 x 0.7(70%) = 5.01

• This means that a MAXIMUM safe working
load of 5.01 tons can be lifted in that zone, so
the lift CAN take place because the load only
weighs 4.5 tons.

LIFTING CAPACITY DE-RATING CHARTS:

REAR MOUNTED LORRY CRANES: 100% of rated load

40% of rated load 70% of rated load 70% of rated load

Rear mounted lorry crane with Rear mounted lorry crane with Rear mounted lorry crane with
2 rear outriggers: 4 outriggers: 5 outriggers:

R-20m R-20m R-20m

R-12m R-7m 10° 10°

Strongest at: Within range of 12m Strongest at: Within range of 7m R-7m
Weakest at: Outside range of 12m Weakest at: Outside range of 7m
Strongest at: Rear side
• 40% of rated load • 70% of rated load Weakest at: Front and both sides
• 70% of rated load • 100% of rated load • 70% of rated load
• 100% of rated load

7

THREE MAJOR HAZARDS

These are the three major hazards that affect a lorry crane's lifting capacity and
need to always be kept in mind.

1 Working Radius: 2 Counter Weight: 3 Ground Conditions:

Always keep the de-rating charts in mind Lifting loads off a lorry crane's bed can Ground conditions that are too wet,
when carrying out lifting operations. mean that the weight the object offered sloped or uneven can cause lorry
Remember, rotating or extending the to the lorry crane's stability is now being cranes to sink, slide and topple over.
movement arm can place the load in shifted to just its crane. This can have Depending on how bad the ground
a zone where the loading capacity is obvious implications of causing the crane conditions are they can be resolved by
decreased causing the lorry crane to lorry to topple over; however this can moving the lorry crane to a safer location
become unstable. also be avoided. or by using aggregate/hardcore and
outrigger pads.
Rotate and extend the movement arm By having two loads on the lorry crane's
within the safe range of the de-rating bed that weigh more or less the same Make sure ground conditions are properly
chart. amount and whereby only one of them inspected, especially after heavy rainfall.
needs to be offloaded, you can ensure
that the lorry crane remains stable.

! Risk of instability

Stable

8

LORRY CRANE OPERATOR SAFETY:

• Never stand on a lorry crane's bed Outriggers must be
during operations. fully extended.

• Operate the lorry’s crane remotely Stand in a
during operations if possible. safe location.

• Stay clear of a lorry crane's load
and never stand underneath it.

Lorry Crane Safety:

• ALWAYS follow the appropriate Lifting
Capacity De-rating Chart for each
specific lorry crane.

• Move the lorry crane to the correct
position where it’s at its strongest to
carry out operations.

• Check ground conditions are safe
and lay down hardcore/aggregate
if necessary.

• Barricades and fatal zones
must be constructed according
to Gammon standards.

Place barricades or fatal zones around Only the signaller
lorry cranes and lifting operations. can stand within
the red barriers.
Remember to always: PROVE IT SAFE!
9

LORRY CRANE INSPECTIONS:

Lorry crane inspections must be done according to the operation being
done, how old the lorry is and if it belongs to a supplier.

Installation and construction operations:

• Perform a Critical Parts Inspection (CPI)
on the lorry crane.

• Obtain a valid Plant Permit.

Loading and unloading operations:

Lorry crane newer than 15 years:
• CPI is not required.

Lorry crane older than 15 years/age or
is unknown:
• CPI is required.

• Obtain a valid Plant Permit.

Fatal zone.

Lorry crane is a supplier’s: Designated lifting
• Complete a lorry crane pre-use checklist. supervisor.
• Check all statutory forms.

(Form 1, 3, 5, 6 and 7).
• Fully extend outriggers on approved pads.
• A Gammon Designated Lifting Supervisor

with a DRA must be present.
• Fatal zones are placed according to

Gammon standards.

Outriggers fully
extended.

10

OUTRIGGERS:

Outriggers are used to stabilise the lorry crane while operations Fully extended outriggers.
are being carried out. Use outrigger pads.

Outrigger markings:
All lorry cranes must have markings to indicate when outriggers are fully extended.
Inspectors must check the extension markings before they can issue a Critical Parts
Inspections (CPI) report.

If all outriggers can’t be fully extended:
This could happen if there are site/space restrictions or if there is only space on
one side for outriggers to fully extend.

Requirements:
• Adjust the Automatic Safe Load Indicator (ASLI) RPE certification via the

Factories and Industrial Undertakings (Lifting Appliances and Lifting Gear)
Regulations [FIU(LALG)R] – F3 and F5 at reduced extension.
• Get a signed Lorry Crane Lifting Plan.
• Do a CPI and a get valid Plant Permit.

Remember the effect tail outriggers have on the de-rating charts.

70% of rated load 100% of rated load

40% of rated load 70% of rated load

2 rear outriggers 4 outriggers 5 outriggers

11

OUTRIGGER PADS:

Outrigger pads are placed under outrigger floats to increase the surface area and distribute the
weight of lorry crane loads, increasing stability.

• Outrigger pads must comply with Gammon standards.
• The maximum number of outrigger pads to be used under an outrigger float is two.
• Where necessary, use steel plates to place outrigger floats on to spread the load’s weight more evenly.

500mm

500mm

38 - 50mm Timber packs used to support and stabilise
Outrigger pads must be at least 3 times the size of outriggers must be tightly packed and not
the outrigger float. For example, 500mm x 500mm and be more than 2 layers high.
have a thickness of between 38 - 50mm.

12

WHEN TO USE A LIFTING PLAN:

A lifting plan MUST be used when one or more of the All lifting plans, operation hold
following conditions are observed: points, method statements and risk
assessments must be approved by
Lifting Operation: Ground Conditions: Plant Department and Area Manager.
• Installation and construction. • Sand is loose.
• Clay is soft or firm. LPILFATNI N G
Tandem Lifting: • After heavy rain/if site has a high
Tandem lifting occurs when two Poor ground conditions.
separate lorry cranes lift a single object. groundwater level.
This is not encouraged and should only • Lorry crane is on a slope/adjacent 13
be used as a last resort.
to a slope.
This requires: • Lorry crane is adjacent to a braced
• Lifting plan
• Method statement excavation/basement/paved area
• Risk assessment with subsurface ducts.
• Must be agreed on and signed off by

the Plant Department.

Use of a Fly Jib: Fly jib
A fly jib is used to extend the reach of a
crane and fits on the end of the
crane’s boom.

This requires:
• Lifting plan
• Method statement
• Risk assessment
• Must be agreed on and signed off by

the Plant Department.

WHEN A LIFTING PLAN IS NOT NEEDED:

A lifting plan is NOT REQUIRED when the following
conditions are observed:

Off Loading

Loading

Lifting Operation: Outrigger Extension: Ground Conditions:
Simple loading and unloading Rigger is able to fully extend. • Sand is dense or solid.
• Clay is stiff.
of goods. • Ground is hard.
• Lorry crane is on firm,

flat and level ground.

● Statutory forms must also be in place.

14

PROCUREMENT CONTROL:

1. Gammon-owned or hired crane lorries can only be obtained from:
• Well tune;
• Sze Wai;
• Ah D; or
• Strategic partners/subcontractors who have done a Gammon Critical Parts Inspections (CPI)

2. Supplier lorry cranes can only be used for delivering goods and materials to site.

Lorry Crane Type Gammon Owned/ Supplier Lorry Crane
Hired/Strategic Partners

Fit for: All usage. Loading and unloading only.

CPI: Mandatory. Not required.
Lifting plan:
Supervision: Mandatory in some cases. Not required but
Statutory Forms: complete Lorry Crane
pre-use checklist.

Yes, by a Gammon Designated Lifting Supervisor
and a DRA must be done before.

Required. Required.

15

INCIDENT REPORTS:

High Potential Incident Report 1 Weight of S.W.L (F.3) = 7.16 tons Key Findings:
the load DeratingC4a0p%acity • The pipe exceeded the
A lorry crane was being used to lift a pipe and 3.3 tons S.W.L (de1r0aTteodn) = 2.86 tons
lower it into an excavation. As the pipe was lorry crane's Safe
being lowered the lorry crane became unstable Working Load after
and started to lean causing an outrigger to lift off de-rating.
the ground. The operator luckily noticed
and stopped the operation immediately.

70% of rated load
100% of rated load
40% of rated load

Controls:
• Always follow the Lifting Capacity De-rating Chart.
• Position the lorry crane correctly to maximise its lifting load capability.

16

INCIDENT REPORTS: Controls:
• Always inspect conditions properly – especially after rain.
High Potential Incident Report 2 • Fully extend outriggers.

A lorry crane was going to be used for casting • Restrict lorry crane safe working loads to 70% of the safe
concrete by lifting a concrete skip. The lorry's working load in Form 3.
outriggers were placed on outrigger mats and
hardcore/aggregate was thrown on the ground
underneath it. Once the load was lifted the lorry's
back-right outrigger and outrigger mat sunk into
the ground causing the lorry crane to become
unstable and tilt in the direction of the load.

Key Findings:
• Poor ground conditions.
• Outrigger not fully extended.

Poor ground conditions.

Inspect ground conditions. Fully extend outriggers.
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NOTES:

18

NOTES:

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