|
Document No. |
RMZ-MS-ELEV-001 |
|
Revision |
Rev 01 |
|
Date |
18 April 2026 |
|
Prepared by |
RaMsProZone Technical Team |
|
Approved by |
Project Manager / HSE Manager |
|
Classification |
Controlled Document |
|
Compliance |
ISO 9001 | ISO 45001 | OSHA | IOSH | EN 81-20/50 |
1. SCOPE
This Method Statement uploaded by RAMSPROZONE outlines the complete installation procedure for a
passenger/goods lift (elevator) system from initial site preparation through to
final handover. It applies to all personnel involved in lift installation
activities and must be read in conjunction with the relevant project-specific
Risk Assessment.
This document complies with internationally recognised standards
including:
·
ISO 9001:2015 – Quality Management Systems
·
ISO 45001:2018 – Occupational Health & Safety
Management Systems
·
EN 81-20:2014 / EN 81-50:2014 – Safety Rules for Lifts
·
OSHA 29 CFR 1926 (USA) – Construction Industry Safety
Standards
·
IOSH Managing Safely Framework
·
Local statutory regulations and building codes as
applicable
2. REFERENCES
The following documents form an integral part of this Method Statement:
·
EN 81-20:2014 – Safety rules for the construction and
installation of lifts
·
EN 81-50:2014 – Examination and testing of lift
components
·
ISO 9001:2015 – Quality Management Systems requirements
·
ISO 45001:2018 – OH&S Management Systems
·
OSHA 29 CFR 1910.147 – Control of Hazardous Energy
(Lockout/Tagout)
·
OSHA 29 CFR 1926.552 – Material Hoists, Personnel Hoists
and Elevators
·
IEC 60364 – Electrical Installations of Buildings
·
BS 7671 / NEC 70 – Wiring Regulations
·
Manufacturer's Installation Manuals and Shop Drawings
·
Project-specific Risk Assessment and HSE Plan
·
Permit to Work Procedures
3. EQUIPMENT & TOOLS
The following equipment and tools shall be available on site prior to
commencement of work:
|
EQUIPMENT / TOOL |
SPECIFICATION |
QTY |
|
Construction Hoist
/ Chain Block |
Min. 2T capacity
rated SWL |
1 |
|
Plumb Bobs / Laser
Level |
Precision
alignment grade |
2 |
|
Template Boards |
Project specific |
2 sets |
|
Spirit Level (1m) |
EN 13927 certified |
2 |
|
Scaffolding /
Working Platform |
EN 12811 compliant |
1 set |
|
Torque Wrenches |
Calibrated, 0-300
Nm |
2 |
|
Electric Drill /
Impact Driver |
110V/220V double
insulated |
2 |
|
Angle Grinder |
4.5-inch, guarded |
1 |
|
Multimeter /
Insulation Tester |
CAT III rated |
1 each |
|
Oscilloscope /
Drive Analyzer |
Commissioning
grade |
1 |
|
Personal
Protective Equipment |
Full set per EN
397 / ANSI Z89 |
Per person |
|
Fall Arrest System |
EN 363 / ANSI Z359
compliant |
Per person |
|
Fire Extinguisher |
CO2 type, 2kg min. |
2 |
|
First Aid Kit |
BS 8599-1 / ANSI
Z308 |
1 |
4. ROLES & RESPONSIBILITIES
|
ROLE |
RESPONSIBILITIES |
QUALIFICATIONS |
|
Project Manager |
Overall
accountability for safe execution, resource planning, client liaison |
Degree in
Engineering / PMP Certified |
|
HSE Manager |
Enforcing safety
protocols, conducting toolbox talks, incident investigation |
NEBOSH / IOSH /
OSHA 30-hr certified |
|
Lift Installation
Supervisor |
Technical
supervision of all installation activities, quality checks |
5+ yrs lift
experience, manufacturer certified |
|
Lift Mechanic
(Lead) |
Execution of
mechanical installation tasks, alignment, assembly |
Manufacturer
trained, competency card holder |
|
Electrician
(Licensed) |
Electrical wiring,
panel connections, commissioning support |
Licensed
Electrician, IEE / NEC qualified |
|
Rigger / Crane
Operator |
Material handling,
hoist operation, rigging activities |
LEEA / OPITO
certified rigger |
|
Quality Inspector |
ITP compliance,
NCR management, final inspection sign-off |
QMS auditor, ISO
9001 trained |
5. GENERAL REQUIREMENTS
5.1 Health, Safety & Environment (HSE)
·
A valid Permit to Work (PTW) must be obtained before
commencement of any activity.
·
A Task-Specific Risk Assessment must be reviewed and
signed by all operatives.
·
Toolbox Talks (TBT) to be conducted daily before works
commence.
·
All personnel to wear mandatory PPE: hard hat, safety
shoes, high-vis vest, safety glasses, and gloves.
·
Working at height requires full body harness, lanyard,
and approved anchorage points per EN 363 / ANSI Z359.
·
LOTO (Lockout/Tagout) procedures per OSHA 1910.147 to be
strictly followed for electrical isolation.
·
Housekeeping to be maintained throughout; all debris
removed daily.
·
No lone working permitted inside shaft or pit.
5.2 Quality Management
·
All materials to be verified against approved submittals
and manufacturer's documentation.
·
Inspection and Test Plans (ITP) to be followed at each
stage of installation.
·
Non-Conformance Reports (NCRs) to be raised immediately
for any deviations.
·
All measuring equipment to carry valid calibration
certificates.
·
Progressive sign-off by Supervisor and QA Inspector at
each key stage.
6. PLUMBING
The plumbing phase establishes the datum references for the entire lift
installation. Accuracy at this stage is critical.
·
Verify shaft dimensions match approved drawings (width,
depth, height).
·
Establish and mark the centreline of the car and
counterweight (CWT) on the pit floor using a theodolite or precision laser.
·
Install plumb lines from top to bottom of shaft. Minimum
2 plumb lines for car guides and 2 for CWT guides.
·
Verify plumb bob clearances meet EN 81-20 requirements.
·
Record all measurements on the Plumbing Inspection Record
Form.
·
Obtain supervisor sign-off before proceeding to guide
rail installation.
NOTE: Minimum guide rail
plumb tolerance: ±0.5 mm per metre as per EN 81-20 Annex G.
7. INSTALLATION OF HOIST & HOIST TEST
·
Install temporary construction hoist (chain block or
electric hoist) at top of shaft or machine room.
·
Hoist anchorage to be designed and approved by a
competent structural engineer.
·
Rated SWL (Safe Working Load) of hoist must exceed
maximum single lift weight by minimum factor of 1.5.
·
Conduct static load test at 110% SWL and dynamic load
test per LEEA 050 / ASME B30 requirements.
·
Issue Hoist Test Certificate before commencing material
lifting operations.
·
Display SWL placard on hoist at all times.
·
Hoist operator must be LEEA certified.
8. FIRST GUIDE RAIL & 2ND LEVEL GUIDE RAIL
·
Using established plumb lines, position first car guide
rail in pit, aligning to template.
·
Fix bottom guide rail bracket using approved fixings per
manufacturer specification.
·
Torque all fixing bolts to manufacturer's specified
values using calibrated torque wrench. Record values.
·
Install fish plates at rail joints; align joint gap to
< 0.5mm per EN 81-20.
·
Progress upwards installing rail brackets at maximum
centres specified in approved drawings.
·
Repeat process for CWT guide rails maintaining parallel
alignment throughout.
·
Check rail alignment using straight edge and feeler
gauges at every joint.
·
Complete second level and proceed upwards, re-positioning
templates as required (refer Section 14).
9. PIT INSTALLATION
·
Pit must be clean, dry, and well-lit before works
commence.
·
Install pit buffer supports for car and CWT buffers,
aligning to centreline marks.
·
Fix car buffer base plate to pit floor; grout if
required. Verify level.
·
Install CWT buffers per manufacturer's clearance
specifications.
·
Install pit ladder (fixed steel) per EN 81-20
requirements – rungs at 300mm centres, minimum 150mm toe clearance.
·
Install pit lighting (min. 50 lux) and 13A/16A pit socket
outlet.
·
Install pit stop switch and pit inspection control
station per EN 81-20.
·
Verify pit depth and overhead clearances match approved
layout drawings.
10. SLING INSTALLATION
·
Assemble car sling (frame) on ground floor or in pit as
per manufacturer assembly instructions.
·
Identify and verify all sling components against
manufacturer's parts list.
·
Attach car safety gear (safety gear / catching device) to
lower sling member.
·
Verify safety gear jaws move freely and align with car
guide rails.
·
Lift assembled sling into shaft using construction hoist.
Ensure tag lines used for control.
·
Hang sling from construction hoist and position over
guide rails.
·
Attach sling guide shoes to guide rails; do not tighten
fully at this stage.
11. INSTALLATION OF CAR FLOOR
·
Install car floor (platform) onto sling cross-member
using approved fastenings.
·
Verify floor panel alignment and level. Tolerance: ±1mm.
·
Fit rubber isolation pads between floor and sling per
manufacturer specification.
·
Torque all floor fixing bolts to specification.
·
Temporarily secure a working platform / protective roof
over car floor (refer Section 13).
12. INSTALLATION OF TEMPORARY OVER SPEED GOVERNOR
·
A temporary overspeed governor is MANDATORY for all
construction hoist phases.
·
Install temporary OSG on top of car sling or designated
bracket per manufacturer instructions.
·
Route temporary governor rope vertically through shaft to
pit, attaching to pit tension device.
·
Test OSG operation by manually triggering – verify safety
gear engages guide rails positively.
·
Issue Temporary OSG Test Certificate. Record in Quality
Dossier.
NOTE: The temporary OSG
must be inspected daily during construction hoist operation. Replace with
permanent OSG at roping stage – refer Section 21.
13. INSTALLATION OF WORKING PLATFORM / PROTECTIVE ROOF
·
Assemble car roof (protective roof) components on car
floor as per manufacturer's drawings.
·
The protective roof must cover the full plan area of the
car with a minimum overhang.
·
Roof structure to withstand minimum 200 kg/m² live load
as per EN 81-20.
·
Install handrails around all four sides of the working
platform at 1.1m height.
·
Install safety chains/gates at access points.
·
Connect working platform inspection panel and emergency
stop per EN 81-20.
·
Inspect and sign-off protective roof before any person
works from the roof.
14. ATTACHING THE HOIST TO SLING / SAFETY PEDAL
·
Attach construction hoist chain/rope to designated
lifting lug on top of sling.
·
Verify shackles are moused and rated correctly for the
SWL.
·
Install safety pedal / dead man's pedal on working
platform inspection station per manufacturer requirements.
·
Test safety pedal function: release pedal must
immediately stop hoist movement.
·
Demonstrate and record safety pedal test in the
construction hoist commissioning record.
15. CAR GUIDE INSTALLATION (INTERMEDIATE FLOORS) &
REPOSITIONING TEMPLATES
·
Working from the protective roof, continue car and CWT
guide rail installation at each floor level.
·
Re-position template boards at each landing using the
established plumb lines as datum.
·
Maintain strict guide rail alignment at all joints;
record joint gap measurements on ITP.
·
Install guide rail brackets at centres per approved
drawings; torque to specification.
·
Staged installation: complete guides for a minimum of two
floors above current platform position before advancing.
·
Carry out progressive alignment checks every 3 metres of
guide rail.
16. INSTALLATION OF TOP MOST CAR GUIDE / CWT PLUMB LINES
·
Install final (topmost) car guide rail bracket in the
overhead.
·
Verify overall plumb of car guide rail assembly from pit
to overhead. Maximum deviation per EN 81-20: see Table of Tolerances in project
documents.
·
Drop CWT plumb lines from CWT guide rail positions at top
of shaft to pit.
·
Verify CWT plumb lines clear of car sling and rope
fastenings at all levels.
·
Lock off plumb lines and record final positions on
as-built drawings.
17. CWT GUIDE INSTALLATION
·
Install CWT guide rails following the same procedure as
car guides (Sections 8 and 15).
·
CWT guides must be parallel to car guides within
manufacturer's specified tolerance.
·
Ensure sufficient clearance between car and CWT at all
levels per EN 81-20 Section 5.
·
Install CWT guide shoes on CWT frame; adjust clearance to
manufacturer's specification.
18. LANDING ENTRANCES & LANDING DOORS
·
Install landing entrance door frames at each floor,
aligning to sill datums. Verify plumb and level.
·
Fix sill support brackets; install landing sill at
correct height relative to finished floor level.
·
Hang landing door panels on upper door track. Adjust top
hangers for smooth operation.
·
Install door bottom guides; adjust to prevent door sway.
·
Install inter-lock mechanism on each landing door. Test:
door must not open without car present.
·
Adjust all door locks to manufacturer's tolerance. Record
gap measurements.
·
Test each landing door per EN 81-20 Section 7.4 –
mechanical strength and inter-lock test.
·
Install landing door restrictors per EN 81-20 where
required for reduced side clearance.
19. MACHINE INSTALLATION & MACHINE ROOM WIRING
·
Position traction machine on machine room beam/frame as
per approved layout drawing.
·
Level machine to ±0.5mm using shims and precision level.
·
Bolt machine to beam using specified fastenings;
anti-vibration mounts as specified.
·
Install controller panel in machine room; ensure adequate
working clearance per EN 81-20.
·
All machine room wiring to be completed by a licensed
electrician.
·
Wire power supply to controller per approved wiring
diagrams (IEC 60364 / BS 7671 compliant).
·
Install main supply isolation switch adjacent to machine
room entry.
·
Label all circuits per approved cable schedule.
·
Insulation
resistance test all circuits before energising: minimum 1 MΩ at 500V DC.
20. INSTALLATION OF TRAVELLING CABLE
·
Identify and uncoil travelling cable; verify
specification matches approved design.
·
Attach one end of travelling cable to car sling bracket
at mid-travel position.
·
Route cable through shaft to machine room controller.
·
Secure cable with approved clips at 600mm maximum centres
on car and shaft walls.
·
Ensure adequate free loop at mid-travel to prevent
tension or snagging.
·
Terminate travelling cable at controller and car junction
box per wiring diagrams.
·
Insulation test travelling cable; record results on ITP.
21. INITIAL COMMISSIONING TO RUN THE MACHINE
·
Verify all mechanical, electrical, and safety device
installations are complete before initial run.
·
Energise controller with car at lowest landing; observe
for faults or abnormal noise.
·
Carry out initial inspection run in Inspection Mode (low
speed, ≤0.63
m/s) per EN 81-20.
·
Verify all limit switches, final limit switches, and
safety circuits operate correctly.
·
Record initial commissioning data: motor current,
voltage, drive parameters.
NOTE: No passengers or
unauthorised personnel in shaft during initial commissioning phase.
22. ROPING & PERMANENT OVER SPEED GOVERNOR
·
Remove temporary OSG and rope after permanent roping is
confirmed complete.
·
Rope lift per manufacturer's roping diagram. Use only
approved ropes per EN 81-20 Section 9.
·
Verify rope diameter, grade, and construction match
specification.
·
Equalise rope tensions using calibrated tension gauge.
Maximum deviation: 5% between ropes.
·
Install permanent overspeed governor (OSG) in machine
room on designated mounting.
·
Route permanent governor rope through shaft to pit
tension device.
·
Set OSG trigger speed per EN 81-20 / manufacturer's
specification.
·
Conduct OSG trip test: verify safety gear engages at
correct speed. Record test results.
23. CAR & CAR DOOR INSTALLATION
·
Assemble car walls, ceiling, and front return panels per
manufacturer's sequence.
·
Verify car internal dimensions match specification.
·
Install car door track, hanger, and door panels.
·
Adjust car door opening speed, closing speed, and closing
force per EN 81-20 Section 7.5.
·
Install door motor, operator arm, and door operator
control board.
·
Wire door operator per wiring diagram; test full
open/close cycle.
·
Test reopening device (light curtain / door edge): door
must reopen on obstruction detection.
·
Measure door closing force: must not exceed 150N per EN
81-20.
24. CAR, SHAFT & PIT ELECTRIFICATION
·
Complete all car top wiring: limit switches, car roof
socket, car top inspection station.
·
Install shaft lighting at maximum 2.5m centres; minimum
50 lux at floor level.
·
Connect pit lighting, pit socket, pit inspection station,
and pit stop switch.
·
Complete travelling cable terminations at car junction
box.
·
Insulation
resistance test all circuits: minimum 1 MΩ per circuit.
·
Earth
continuity test: all metalwork < 0.1 Ω to earth.
·
Record all test results on Electrical Test Record Form.
25. COMMISSIONING FOR SERVICE DRIVE
·
Configure drive parameters: acceleration ramp,
deceleration ramp, nominal speed.
·
Carry out floor levelling commissioning: adjust floor
level accuracy to ≤
±5mm per EN 81-20.
·
Test all door safety functions at every landing.
·
Verify overload device operates correctly.
·
Test manual lowering operation in event of power failure.
·
Carry out rescue operation test per EN 81-20.
26. SIGNALISATION & CAR DECORATION
·
Install landing push button stations and display
indicators at each floor.
·
Install car operating panel (COP): buttons, indicators,
intercom, alarm bell.
·
Wire and test all signalisation devices.
·
Install car interior finishes: mirrors, handrails, floor
finish, ceiling panels.
·
Verify car interior lighting level: minimum 100 lux at
floor per EN 81-20.
·
Test emergency lighting: must illuminate for minimum 1
hour on battery backup.
·
Test intercom/alarm system: verify two-way communication
to emergency response point.
27. BALANCING OF CAR & COUNTERWEIGHT
·
Calculate car + 40-50% rated load for CWT balance (per EN
81-20 recommendation).
·
Add or remove CWT filler weights to achieve specified
balance percentage.
·
Verify balance by measuring motor current at 50% rated
load travelling up and down.
·
Current difference between up and down runs must be
within ±5%.
·
Record final balance weights and motor current readings
on Balance Record Form.
28. COMMISSIONING FOR NORMAL SPEED
·
Increase drive speed progressively from inspection speed
to full contract speed.
·
Verify all safety devices operate correctly at full
speed.
·
Carry out car deceleration accuracy check: floor level
within ±5mm across all landings.
·
Perform rated load ride quality test: measure
acceleration, deceleration, jerk to EN 12016/ISO 18738.
·
Carry out overspeed test: trigger OSG and verify safety
gear engagement.
·
Carry out buffer test per EN 81-20 Annex D.
·
Complete all EN 81-20 Annex A inspection checklist items.
29. QUALITY INSPECTION & HANDOVER
The following documents must be completed and submitted at handover:
|
DOCUMENT |
REFERENCE |
STATUS |
|
Plumbing Inspection Record |
ITP-PLB-01 |
Required |
|
Hoist Test Certificate |
ITP-HT-01 |
Required |
|
Temporary OSG Test Certificate |
ITP-OSG-01 |
Required |
|
Electrical Test Records (Insulation/Earth) |
ITP-ELEC-01 |
Required |
|
Permanent OSG Trip Test Record |
ITP-OSG-02 |
Required |
|
Balance Record Form |
ITP-BAL-01 |
Required |
|
EN 81-20 Annex A Inspection Checklist |
QF-EN81-001 |
Required |
|
Commissioning Data Record |
ITP-COM-01 |
Required |
|
Non-Conformance Register |
QF-NCR-01 |
Required |
|
As-Built Drawings |
Project Specific |
Required |
|
Operation & Maintenance Manual |
Manufacturer Provided |
Required |
|
Client Acceptance / Handover Certificate |
QF-HAC-01 |
Required |
DOCUMENT APPROVAL & SIGN-OFF
|
ROLE |
NAME & SIGNATURE |
DATE |
|
Prepared by:
Installation Supervisor |
|
|
|
Reviewed by: HSE
Manager |
|
|
|
Approved by:
Project Manager |
|
|
0 Comments