MFRH Erection & Commissioning Method.pdf

MATERIAL HOIST

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Method Statement
Erection and Commissioning of
Multi-Function Rope Hoist
DI-02-09-00.05.02.2022

2. Page 2 of 24
1. Introduction
1.1 Objective:
It has been noticed that planned activities, clear scope of work and
responsibilities produces better results and then doing activities in unplanned
way and haphazardly.
Erection of tower hoist at site needs execution of safe work practices, planned
activities and skilled team to carry out job successfully. This document will serve
as a guideline for erection and commissioning team and customer both in order
to complete erection and commissioning work seamlessly and within planned
scheduled time.

1.2 Technical Specifications
Technical specification of Tower Hoist
TECHNICAL
DATA
TH 1.0 TON TH 1.0 TON TH 1.5 TON
Maximum
Lifting Height
Up to 125 Meters Above 125 Meters Up to 125 Meters
Maximum Pay
Load
700 kg for Rectangular
or TBT Bucket
500 kg for Rebar Carrier
700 kg for Rectangular or
TBT Bucket
500 kg for Rebar Carrier
1200 kg for Rectangular
or TBT Bucket
500 kg for Rebar Carrier
Wire Rope Size 12 mm 12 mm 12 mm
Drive Power
(Electrical
Brake Motor)
10 HP 12.5 HP 12.5 HP
Lifting Speed
(Meter/minute)
30 30 30
Tower
Structure
1. Single Mast High
Tensile Angle
50x50x6mm
2. All joining Angle
40x40x5mm
1. Single Mast High
Tensile Angle
50x50x6mm
2. All joining Angle
40x40x5mm
1. Single Mast High
Tensile Angle
50x50x6mm
2. All joining Angle
40x40x5mm

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1.3 Scope of work activities
Customers Scope: Unloading of hoist material, its storage and proper stacking,
shifting of material at erection site, protection of material from theft, damage,
fire and due to any other reasons, arrangement of unskilled labours, material
handling equipment like hydra, mini crane, gas cutters and welding equipment,
grinder etc. will be in customer’s scope .
Esquires Scope: Job will be carried out under supervision of our trained and
skilled staff with the support of unskilled labours provided by customer.
Hand Tools like Spanner/Pliers/on line tester/ Multi-meter and any special tool
required for job will be arranged by Esquire team.
Before commencement of job, esquire team will prepare an erection schedule
and share with customer after review of planned activities and this has to be
signed by customer/representative/responsible/authorized person.
1.4 Safety at work place
Safety at work place is a collective responsibility and we follow our work safety
culture very strictly at all job sites.
All the team working at job site should be safety trained by safety team at site,
should wear safety PPE, and carry “Safety Induced” sticker on their helmet, this
sticker should have signature of Site Safety officer/in-charge.
No worker allowed to work at job site until authorized and approved by Safety
Officer/site in-charge.

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1.5 Erection and Commissioning process flow chart :










































Foundation / Anchoring For
Tower mast base frame
Bottom Mast and Bottom
Required No of Center mast
Top mast and Top pulley
Channel Platform Assembly
Wall Tie-inns
Foundation / Anchoring For
Winch assembly

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1.6 Preparing Erection Schedule.
Day wise planned activities will be recorded in below mentioned format and method
of execution should be discussed and mutually agreed between customer and
esquire erection team, if required name of person should also be mentioned.
Electrical Connections
Trial of Hoist
Load Test
Wire rope Assembly

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This document to be prepared and signed by customer and esquire team both
before commencement of erection work.
Erection Schedule of Tower Hoist

Customer Name: Site:
Day Planned
Date
Activity
planned
Customers
Scope
Esquires
Scope
Signatures
Customer/Esquire
1
2
3
4
5

1.7 Daily monitoring of planned activities.
Daily monitoring of planned activities will be done by esquire team and daily
report on this will be sent at the end of day by esquire team, deviations,
rescheduling of activities and any support required will also be mentioned in
daily report in order to resolve any of the issues hindering work progress.

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2. Job Site planning
2.1 Marking job site area.

Figure-01
2.2 Unloading of material

Unloading material must be kept within 10 meters maximum of foundation area.
The loading/unloading may consist of:
• A trained loading/unloading operator (i.e. forklift/crane operator).
• Riggers & Helpers assigned to assist the crane operator

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2.3 Storage of hoist material
It is the responsibility of the asset Engineer or the contractor to store equipment in
such a manner as to avoid mechanical damage, corrosion, chemical exposure, etc.
clean the components, mend surface treatment damage and to preserve the
functional surfaces according to storage period,
 lubricate the machine according to the lubrication schedule, prevent the lubricants
from leaking out of gears especially
 place the components on suitable beds, prevent them from being dirtied up by mud,
prevent them from damage,
 store the components in such a way that no water rests inside these (watch out for ice
appearing in hollows),
 pay special attention to electrical equipment. Treat contacts and movable parts with
suitable aids. Prevent water and dirt from entering the plugs and sockets. It is
recommended to put charges absorbing humidity (silica gel) inside switchboards.
 lock the switchboards properly,
 Store clean, checked and preserved the connecting materials in a covered storehouse.

2.4 Stacking of Tower hoist material
There should be proper stacking of tower hoist materials.
Stacking of tower hoist parts should be such that it becomes easy for labours at
site to know about tower hoist parts.
Stacking should be such that fasteners of winch should be near winch, fasteners
of mast assembly should be near mast, etc. This ultimately helps to do erection
and installation easily and smoothly.

2.5 Protection of material
Covering by Tarpaulins

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2.6 Shifting of material from storage area to erection location
By Forklift, By Hydra, By Tower Crane, By Manual trolley pallet

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3. Erection
3.1 General guidelines.
Completion of planned erection activities needs proper understanding of process
and procedures involved and team involved in carrying out job should be trained
enough to execute job successfully.
Unskilled manpower hired for the job should be in lines with construction labour
rules as applicable.
Labours should properly safety inducted as per site safety rules and regulation.
PPEs required for these workers should be supplied by labour
contractors/customer.
Storage/stacking of material should be near and as possible closed to work place,
in order to save time on shifting of material.
It is always suggested to not to change unskilled workers as until job
completion.

3.2 Foundation preparation and fixing of foundation frame:
Prepare a foundation concrete slab as per drawing.Figure-02, Figure-04
Base Frame Leveling: Place tower mast base frame and winch base frame
adequately and level with level bottle by adding packing under the base frame.
Requirement: Drilling Tools, Forklift, Man Power

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Figure-04
Figure-02
Foundation detail of 1 ton tower
Figure-03
1 Ton tower mast base frame
No. Of 6 Holes
provided for
anchor bolt

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Foundation detail of winch base frame


Figure-05
Winch base frame

 Consider thoroughly position of the tower hoist in relation to the building before
preparing the foundation. Pay attention especially to the distance between the hoist
and the building, possibility to create the mast and landing tying points along the
whole height of the hoist lift. Ground pressure must be ensured. Pay attention to
made-up ground, frozen ground, drainage etc. Not keeping the above-mentioned in
mind may cause the substantial material damage or make erection impossible in a
particular place. Ensure that Drum Centre is in alignment with Centre Line of Bottom
Pulley.(Ref.Figure-06)


No. Of 6 Holes
provided for
anchor bolt
Pulley center and drum center
should be in one plane
Wire rope
Tower
Winch

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3.3 Fixing Bottom Mast and Bottom pulley:
Place bottom mast on tower mast base frame. Plum with water tube leveler and
plum bob. Assemble bottom mast on Base frame by M12X120 grade 8.8 Bolt. Also
fix the bottom pulley by using M12x120 Grade 8.8 bolt in such a way that it would
be above ground level and perpendicular to the winch. (Figure-07)
Requirement: Fasteners (Bolt - M12X120 Grade 8.8 (Bottom mast), M12x120 Grade
8.8 (Bottom Pulley) , Washer-M12 , Nut -M12, Spring Washer M12) , Fix/Ring
Spanner(17X19)




Figure-07
Bottom mast and Bottom pulley fitting
Figure-08
Center mast fitting

Figure-06
Tower and Winch

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3.4 Fixing Center mast:
 After the bottom piece is fixed, place the first section of the tower on top of it and
fasten it. Care should be taken to maintain the PLUMB of the tower. It should be
ensured that proper alignment is maintained and there should be no GAP between
matching tower structures. Continue this process till required height is obtained.
(Figure-08)
Requirement: Fasteners (Bolt - M12X130 Grade 8.8 (Bottom mast), M12x130
Grade 8.8 (Bottom Pulley) , Washer-M12 , Nut -M12, Spring Washer M12) ,
Fix/Ring Spanner(17X19)

 Requirement: Tower Crane, Man Power, Spanners

3.5 Fixing of wall tie –inns:

 TIE IN is having mechanical arrangement to mount on Column. TIE IN is used for Mast,
to hold tightly with column. Assemble first Tie-in at 6 meter.

(Figure-09)

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 Requirement : Fasteners(Wedge anchor fasteners Bolt - M16X150 , FT bolt M12X75,
M16X75 ,Washer-M12, M16, Spring washerM12, M16, Nut-M12,M16 , Regular Nut Eye
Bolt M16X200 Forged, Spanner(24X27) , V-hook , Spanner(17X19)








3.6 Fixing Top mast and Twin Top Pulley :

Place the top section with pulley on the tower structure at the desired height with the hook
side facing towards inside of the pit. (Figure-10)
Figure-09
Wall Tie-inns

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Acceptable Tolerance for Erection of Total height of Masts are min. 5 mm to max. 8 mm.
Requirement: Tower Crane, Man Power, Spanners


Figure-10
Fixing Top mast and Top Pulley
Figure-11
Fixing of platform

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3.7 Fixing of platform:
 Dismantle the “Top Rollers” and “Bottom Locking Flats” assembled with the platform,
and place it against the tower structure such that the bottom rollers touch the tower
structure. Now replace the dismantled “Top Rollers” and the “Bottom Locking Flats” to
the platform, such that the tower is engaged between the “Top rollers” and the
“Bottom Rollers”. (Figure-11)

3.8 Wire rope assembly:
 Locate the winch as shown in Image-01. Keep the winch as far away as possible from
the pit and never less than 4.5 Meter.
 Release the brake of the “Winch Assembly”. Pull the wire rope out and pass it through
the “Bottom Pulley” of the tower followed by “Top Pulley” of the tower, pulley of
“Platform” , bolt it with the Thimble by use of u clamps hook provided at the top Twin
Pulley of the tower structure in sequence.

3.9 Bucket Assembly:
 Place Rectangular Bucket on Platform. To fasten the Bucket & platform by use of Hex
Bolt M12x35, Taper Washer M12,Spring Washer M12, Plain Washer M12, Hex Nut.
M12, Spanner (17X19).
 For Tilting Bucket : Place Bucket Locking Lever Assembly & Guide Channel with
Cleats on Platform and Fasten with Taper Washer M12, Spring Washer M12, Plain
washer M12, Hex. Bolt M12x35, Hex Nut M12.

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 Place Tilting Bucket On both Guide Channel. Lock the Tilting Bucket with Platform by
use of MS WELDED CHAIN 3/8" and Hex Bolt M8 x 30, Plain washer M8, Spring Washer
M8, HEx nut M8.


3.10 Electrical Connections:
 Electrical equipment includes the switchboards, all electric components, fixed and
moving wiring (for power supply, control, hoist control and for providing the safety
functions), power supply for electric appliances and register of operation.(Refer
electrical diagram attached below )

3.11 Fixing Top limit switches/Bottom limit switch :
 On top of mast and near ground there are limit switches provided, which can switch off
motor’s power, in case operator does not push the stop Button in Remote Pendent.
3.12 Fixing Rebar carrier :
 On platform mount Rebar carrier by using fasteners. Holes are provide in both side of
channel platform for left and right rebar arrangement.(Figure-12)
 Requirement : Fasteners Hex bolt High Tensile grade 8.8 M12X90, ,Washer-M12 ,
Spring washer M12, Hex Nut Grade 8-M12 , Spanner(17X19)

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Figure-12
Channel Platform and Rebar Bracket fitting

Figure-13
Channel Platform and Rebar Housing fitting

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 Fasten Rebar Housing on Rebar Bracker Fitting by use of Hex Head Bolt High Tensile
Grade 8.8 M10x40, Plain washer M10, Spring Washer M10, Hex Nut Geade 8 M10,
Taper Washer M10.
 Place “CENTER PLATFORM REBAR ASSEMBLY” on Rebar Housing by use of Hex Bolt
HT HEX BOLT M24X130 HIGH TENSILE 10.9 as Mention.

Figure-14
Rebar Housing and Center Platform Rebar Assembly fitting
 Assemble “SIDE PLATFORM REBAR ASM MFH100” by use of Hex Head Bolt M12X90
High Tensile Grade 8.8, Plain washer M12, Spring Washer M12, Hex Nut Grade 8 M12
with Check Nut on Upper Side as mention in Below Image.

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 Assemble other “SIDE PLATFORM REBAR ASM MFH100”.

 Lock Rebar Assembly by use of “REBAR HANDLE” as shown in Below image During the
travel from Ground to Desire Floor.

 When Platform Reach the Desire Floor when require to Unload the Rebar Pull Rebar
assembly after Unlock the Rebar Handle.

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4 Commissioning of Hoist
Commissioning of hoist involves thorough inspection of functioning of all the
components of Tower hoist, setting limit switches and Winch
 Make sure that all lubricating parts should be lubricated properly.
 Ensure that top and bottom Limit Switches are actuated by the cam mounted on the
Channel Platform.
 Check the working of Limit Switch by manually operating the lever and check continuity
of connection using Multi Meter. Consult circuit diagram for identifying use of NO / NC
Contacts on Limit Switch.
 Connect Power to Panel, Press and start the motor, and immediately stop it.
 Check the direction of rotation, if reversed, inter change any two phases.
 Ensure that bottom and top limit switches are disconnecting motor power supply when
the Platform reaches the limit.
 Make sure that electric motor does not create noise and overheat.
 Lubricate all the spots in following table before installation. Lubrication must be done
periodic (once per week). Must clean dusty parts before lubrication.

5 Trial Run
Hoist has to go under trial run for full erected height after successful commissioning.
During trial run hoist should travel 10 cycles in NO LOAD and 10 cycles in FULL LOAD
conditions.
Trial run should be carried out by Esquire team and during trial run except erection
team members no workers/passengers are allowed to travel.

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6 Training of operator
Once after erection and commissioning of hoist is over operator has to be trained by
esquire on below mentioned points

 Maintaining log book (Log book has be provided by customer)
 Safe-operation of hoist.
 Load identification
 Emergency Stop Button.
 Do’s and don’ts.
 Daily /weekly scheduled maintenance and cleaning.
 Contact number of person in case any technical support required.

7 Testing, Inspection and Certification of Hoist by Competent Person/ Authorities
After hoist is erected and trial run and having a trained operator at place hoist has
to be inspected, and certified by authorized competent person by govt authorized
agencies.
Calling competent person at scheduled time and certification fees etc should be paid by
customer.

8 Load Test
8.1 Overload Test
Hoist should be loaded with additional 10% of its maximum load capacity in
presence of competent person and lifted to maximum 3Mtrs height.
No person should remain present near hoist during load test. Put additional tyres
/ shock absorbers at the bottom of platform during overload test.


During load test nearby area at hoist should be kept free from movement and
entry should be restricted to “Authorized Persons Only” in that area.

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9 Handover of Hoist and signing off commissioning report.
Once successful completion load tests in presence of competent person, commissioning
report to be signed by customer and copy of report to be returned to Esquire team for
records and registering equipment under warranty in records.

10 Assistance and helpline:
During erection and commissioning or even after completion of commissioning
customer may approach on below mentioned contact numbers in escalation order
1. Mr…… Designation:
Email id Contact No.
2. Mr….. Designation:
Email id Contact No.
3. Mr…. Designation:
Email id Contact No.