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Dock Workers (Safety, Health & Welfare) Regulations, 1990










Lifting Appliances and Gear,

40. Construction and maintenance of lifting appliances

(1) General.

All lifting appliance, including all parts and working gear thereof, whether fixed or moveable, and any plant or gear used in anchoring of fixing such appliance, shall be:

(a) of good construction, sound material, adequate strength for the purpose for which it is used and free from patent defect; and

(b) maintained in good repair and working order.

(2) Drums.

(a) Every drum or pulley round which the rope of any lifting appliances is carried, shall be of adequate diameter and construction In relation to the rope used.

(b) Any rope which terminates at the winding drum of a lifting appliances shall be securely attached to the drum and at least three dead turns of the rope shall remain on the drum in every operating position of the lifting appliance.

(c) The flange of the drum should project twice the rope diameter beyond the last layer and if this height is not available, other measures such as anti-slackness guards shall be provided to prevent the rope from coming off the drum.

(3) Brakes.

Every lifting appliances shall be provided with an efficient brake or brakes which shall-

(a) be capable of preventing fall of a suspended lead (Including any test load applied in accordance with these regulations) and of effectively controlling a load while it is being lowered;

(b) act without shock;

(c) have shoes that can be easily removed for relining; and

(d) be provided with simple and easily accessible means of adjustment:

Provided that this regulation shall not apply to steam winch which, can be so operated that the winch is as safe as it would be if a brake or brakes were provided in accordance with this regulation.

(4) Controls.

Controls of lifting appliance shall,-

(a) be so situated that the driver at his stand or seat has ample room for operating and has an unrestricted view of dock work, as far as practicable, and remains clear of the load and ropes, and that no load passes over him;

(b) be positioned with due regard to ergonometric considerations for easy operation;

(c) be so located that the driver does not have to remain in the bright of the heel block;

(d) have upon them or adjacent to them clear markings to Indicate their purpose and mode of operation;

(e) be provided, where necessary, with a suitable locking device to prevent accidental movement or displacement;

(f) as far as practicable, move in the direction of the resultant load movement; and

(g) automatically come to a neutral position in case of power failure wherever automatic brakes are provided.

41. Test and periodical examination of lifting appliances.-

(1) Before being taken into use for the first time or after It has undergone any alternations or repairs liable to affect its strength or stability and also once at least in every five years, all lifting appliances including all parts and gears thereof, whether fixed or moveable, shall be tested and examined by a competent person in the manner set out In Schedule I.

(2) All lifting appliances shall be thoroughly examined by a competent person once at least In every 12 months. Where the competent person making this examination forms the opinion that the lifting appliance cannot continue to function safely, he shall forthwith give notice in writing of his opinion to the owner of the lifting appliance or in case of lifting appliance carried on board a ship not registered in India, to the Master or officer-in-charge of the ship.

(3) Thorough examination for the purpose of this regulation shall mean a visual examination, supplemented if necessary by other means such as hammer test, carried out as carefully as the conditions permit, in order to arrive at a reliable conclusion as to the safety of the parts examined; and if necessary for this purpose, parts of the lifting appliance and gear, shall be dismantled.

42. Automatic safe load indicators.-

(1) Every crane, if so constructed that the safe working load may be varied by raising or lowering of the jib or otherwise, shall have attached to it an automatic indicator of safe working loads which shall also give a warning to the operator wherever the safe working load is exceeded.

(2) Cut-out shall be provided which automatically arrests the movement of the lifting parts of the crane in the event of the load exceeding the safe working load wherever possible.

(3)The provisions of sub-regulation (1) shall not apply where it is not possible to instal an automatic safe load indicator, in which case, provision on the crane of a table showing the safe working loads at the corresponding inclinations or radii of the jib shall be considered sufficient compliance.

43. Rigging of ship's derricks.-

(l) Every ship shall carry the current and relevant rigging plans and any other relevant information necessary for the safe rigging of its derricks and necessary gear.

(2) All such rigging plans shall be certified by a competent person.

44. Securing of derrick foot.-

Appropriate measures shall be taken to prevent the foot of a derrick being lifted out of its socket or supports.

45. Winches.-

(1) General

(a) Winches shall not be used if control levers to operate with excessive friction or excessive play.

(b) Double gear winches shall not be used unless a positive means of locking the gear shift is provided.

(c) When changing gears on a two gear winch, there shall be no load other than the fall and the cargo hock assembly on the winch.

(d) Adequate protection shall be provided to winch operator against the weather, where necessary.

(e) Temporary seats and shelters for winch operators which create a hazard to the winch operator or other dock workers shall not be allowed to be used.

(f) When winchs are left unattended, control levers shall be secured in the neutral position and whenever possible, the power shall be shut off.

(2) Steam winches

In every steam winch used in dock work,-

(a) measures shall be taken to prevent escaping steam, from obscuring any part of the decks or other work places or from otherwise hindering or injuring any dock worker;

(b) extension control levers which tend to fall of their own weight shall be counter-balanced;

(c) except for short handles on wheel type controls, winch operations shall not be permitted to use the winch control extension levers unless they are provided by either the ship or the employer and such levers shall be of adequate strength and secure and fastened with metal connections at the fulcrum and at the permanent control lever.

(3) Electric winches

(a) In case of any defect, dock workers shall not be permitted to transfer with or adjust electric control circuits.

(b) Electric wireless shall be used for dock work in case where,-

(i) the electro-magnetic brake is unable to hold the load; and

(ii) one or more control points, either hoisting or lowering is not operating properly.

46. construction and maintenance of loose gears.-

(1) Every loose gear shall be

(a) of good design and construction, sound material and adequate strength for the purpose for which it is used and free from patent defects and,

(b) properly maintained in good repair and working order.

(2) Components of the loose gear shall be renewed if one of the dimensions at any point has decreased by 10 per cent. or more by user.

(3) (a) Chains shall be withdrawn from use when stretched and increased in length exceeds five per cent, or when a link of the chain deformed or otherwise damaged or raised scarfs of defective welds appeared.

(b) Rings hooks, swivels and end links attached to chains shall be of the same material as that of the chains.

(4) The voltage of electric supply to any magnetic lifting device shall not fluctuate by more than + 10 per cent.

47. Test and periodical examination of loose gears.-

(1) All loose gears shall be initially tested for the manufacturer by a competent person, in a manner set-out in Schedule-I before taking into use or after undergoing any substantial alternations or renders to any part liable to affect its safety and shall subsequently be retested for the owner of the gear, at least in every five years.

(2) All loose gears shall be thoroughly examined once at least in every twelve months by a competent person. In addition chains shall be thoroughly examined once at least every month by a responsible person.

48. Ropes.-

(1) No rope shall be used for dock work unless:-

(a) it is of suitable quality and free from patent defect, and

(b) in the case of wire rope, it has been tested and examined by a competent person in the manner set out in Schedule I.

(2) Every wire rope of lifting appliance or loose gear used in dock work shall be inspected by a responsible person once at least in every three months, provided that after any wire has broken in such rope, it shall be inspected once at least in every month.

(3) No wire rope shall be used in dock work if in any length of eight diameters the total number of visible broken wires exceed 10 per cent. of the total number of wires or the rope shows sign of excessive wear, corrosion or other defects which in the opinion of the person who inspects it or Inspector, renders it as unfit for use.

(4) Eye splices and loops for the attachment of hooks, rings and other such parts to wire ropes shall be made with suitable thimble.

(5) A thimble or loop splice made in any wire rope shall conform to the following standard,-

(a) wire rope or rope sling shall have at least three tucks with full strand of rope and two tucks with one-half of the wires cut out of each strand and strands in all cases shall be tucked against the lay of the rope;

(b) protruding ends of strands in any salice on wire rope and rope slings shall be covered or treated so as to leave no sharp points;

(c) fibre rope or rope sling shall have at least four tucks tail of such tuck being whipped in a suitable manner; and

(d) synthetic fibre rope or rope sling shall have at least four tucks with full strand followed by further tuck with one-half filaments cut-out of each strand and final tuck with one-half of the remaining filaments, cut-out from trends. The portion of the splices containing the tucks with the reduced number of filaments shall be securely covered with suitable tape or other materials: Provided that this sub-regulation shall not operate to prevent the use of another form of splice which can be shown to be as efficient as that laid down in this regulation.

49. Heat treatment of loose gears.-

(1) All chains other than briddle chains attached to derricks on mass and all rings, hooks, shackles and swivels used in hoisting or lowering shall, unless they have been subjected to such treatment as an Inspector may, subject to confirmation by the Chief Inspector approve, be effectively annealed under supervision of a competent person and at the following intervals:

(a) 12.5 milimetre and smaller chains, rings, hooks, shackles and swivels in general use, once at least in every six months; and

(b) all other chains, rings, hooks, shackles and swivels in general use, once at least in every twelve months:

Provided that in the case of such gear used solely on cranes and other hoisting appliances worked by hand twelve months shall be submitted for six months in sub-clause (a) and two years for twelve months in sub-clause (b):

Provided further that where an Inspector is of the opinion that owing, to the size, design material or frequency of use of any such gear or class of such gear, the requirements of this regulation as to annealing is not necessary for the protection of dock workers, he may by certificate in writing (which he may at his discretion revoke) and subject to confirmation by the Chief Inspector exempt such gear or class of gear from such requirement subject to such conditions as may be specified in such certificate.

(2) Sub-regulation (1) shall not apply to;

(i) pitched chains, working on sprocket of sprocketed wheels;

(ii) rings, hooks and swivels permanently attached to pirched chain, pulley blocks or weighing machines; and

(iii) hooks and swivels having ball bearings or other case hardened parts.

(3) All chains and loose gears made from high tensile steel or alloy steel be plainly marked with an approved mark indicating that they are so made. No chain or loose gear made from high tensile steel or alloy steel shall be subject to any form of heat treatment except where necessary for the purpose of repair and under the direction of a competent person.

(4) If the past history of wrought iron gear is not known or if it is suspected that the gear has been heat treated at incorrect temperature, it shall be normalised before using the same for dock work.

50. Certificate to be issued after actual testing, examination, etc.-

A competent person shall issue a certificate for the purpose of regulation 41, 47, 48 or 49 only after actual testing or, as the case may be, examination of the apparatus specified in the said regulation.

51. Register of periodical test and examination and certificates thereof.-

(1) A register in Form II shall be maintained and particulars of test and examination of lifting appliances and loose gears and heat treatment, as required by regulations 41, 47 and 49 shall be entered in it,

(2) Certificates shall be obtained from competent person and attached to the register in Form II, in respect of the following, in the forms shown against each:

(a) initial and periodical test and examination under regulations 41 and 47, for-

(i) winches, derricks and their accessory gear in Form III.

(ii) cranes or hoists and their accessory gear in Form IV;

(b) test, examination and re-examination of loose gears under regulation 47 in Form V;

(c) test and examination of wire ropes under regulation 48 in Form VI;

(d) heat treatment and examination of loose gears under sub-regulation (1) of regulation 49, in Form VII;

(e) annual thorough examination of the loose gears under sub-regulation (2) of regulation 47 in Form VIII, unless required particulars have been entered in the register in Form II.

(3) The register and the certificates attached to the register shall be,-

(a) kept on board the ship in case of ship's lifting appliances, loose gears and wire ropes;

(b) kept at premises of the owner in respect of other lifting appliances, loose gear and wire ropes;

(c) produced on demand before an Inspector; and

(d) retained for at least five years after the date of the last entry.

(4) No lifting appliance and loose gear in respect of which an entry is required to be made and certificates of test and examination are required to be attached in the register in Form II, shall be used for dock work unless and until the required entry has been made in the register and the required certificates have been so attached.

52. Marking of safe working load.-

(1) Every lifting appliance and every item of loose gear shall be clearly marked with its safe working load and identification mark by stamping or where this is impracticable, by other suitable means.

(2) (a) Every ship's derrick (other than derrick crane) shall be clearly marked with its safe working load when the derrick is used,-

(i) in single purchase,

(ii) with a lower cargo block, and

(iii) in union purchases in all possible block positions;

(b) The lowest angle to the horizontal, that the derrick may be used, shall also be legibly marked.

(3) Every lifting appliance (other than ship's derricks) having more than one safe working load shall be fitted with effective means enabling the operator to determine the safe working load under each condition of use.

(4) Means shall be provided to enable any dock worker using loose gears to ascertain the safe working load for such loose gears under such conditions as it may be used and such means shall consists,-

(a) as regards chain slings, of marking the safe working load in plain figures or letter: upon the sling or upon a tablet or ring of durable material attached securely thereto; and

(b) as regards wire rope slings, either the means specified in CL (a) above or a notice or notices so exhibited as can be easily read by any concerned, dock worker stating the safe working load for the various sizes of the wire rope slings used.

(5) No lifting appliance or loose gear shall be used unless marked in accordance with the provisions of this regulation.

53. Loading of lifting appliances and loose gears.-

(1) No lifting appliance, loose gear and wire rope shall be used in an unsafe way and in such a manner as to involve risk to life of dock workers, and, in particular, shall be loaded beyond its safe working load or loads, except for testing purposes as given in Schedule I and under the direction of a competent person.

(2) No lifting appliance and loose gears or any other cargo handling appliances shall be used, if-

(a) the Inspector is not satisfied by reference to a certificate of test or examination or to an authenticated record maintained as provided under the regulations; and

(b) in the view of the Inspector, the lifting appliance, loose gear or any other cargo handling appliance is not safe for use in dock work.

54. Pulley blocks.-

No pulley blocks shall be used in dock work unless the safe working load and its identification marks are clearly stamped upon it.

55. Vacuum and magnetic lifting device.-

(1) No vacuum or any other lifting device where the load is held by adhesive power only, be used while workers are performing operations in the holds.

(2) Any magnetic lifting device used in connection with dock work shall be provided with an alternative supply of power, such as batteries, that come into operation immediately in the event of failure of the main power supply:

Provided that the provisions under this sub-regulation shall not apply to magnetic lifting device that is being used to load or unload scrap metal or to other cargo handling operations of such a nature that there is no dock worker within the swinging zone of the load.

56. Knotting of chains and wire ropes.-

No claim or wire rope shall be used in dock work with a knot in it.