Project Scoping, Design, and Hazard Planning

Why Planning Comes Before Building

In the elevator trade, no mechanic picks up a wire or opens a hydraulic line before a complete project package exists on paper. Rushing into physical work without a design rationale, a system schematic, and a written hazard analysis is a leading cause of rework, code violations, and serious injury. This lesson walks you through each piece of that planning package so you can produce one that would satisfy a journeyman, an inspector, and — most importantly — keep everyone on the job site safe.

Selecting the Right Drive Type

Your first decision is whether the job calls for a hydraulic, traction, or specialty (freight) system. Each has defined limits that ASME A17.1 addresses in its general requirements, and selecting the wrong type creates code violations before installation even begins.

Hydraulic systems use a piston and cylinder driven by hydraulic fluid under pressure from an electric pump unit. They are most common in low-rise applications — typically up to about six floors — because the piston length and fluid pressure required become impractical at greater heights. Hydraulic systems have a relatively low machine-room height requirement, and their pump units can be located away from the hoistway. A critical hazard with hydraulic systems is fluid: hydraulic oil is flammable, can cause chemical skin and eye burns, and a line failure can create a slip hazard and an environmental spill requiring containment.

Traction systems use steel hoist ropes running over a grooved sheave driven by an electric motor. The weight of the car is counterbalanced by a counterweight, which significantly reduces motor energy demand. Traction systems are standard for mid- and high-rise buildings and for applications requiring higher speeds. The overhead machine room (or, in machine-room-less designs, the machine located in the hoistway or adjacent space) must be sized and ventilated to code.

Freight elevators may use either drive type but are designed and rated for heavy, uniformly distributed loads rather than passenger use. Class designations (Class A, B, C1, C2, C3) define what types of loads — including industrial trucks — the elevator is designed to carry. ASME A17.1 contains specific requirements for freight elevator capacity, loading, and door types.

Your design rationale must state which drive type you selected, why it fits the scenario's building height, speed requirements, and capacity, and cite the relevant general requirements of ASME A17.1.

Drawing the System Schematic

A wiring and system schematic is a map of how every major electrical and mechanical element connects. A complete schematic for this project must include:

• Power supply — main disconnect, feeder conductors, branch circuit overcurrent protection
• Control panel — controller cabinet, logic elements, terminal strips
• Door operator circuit — car door, hoistway door interlocks, door motor
• Safety-device string — the series circuit that must remain closed for the elevator to run, including the buffer electrical contact, overspeed governor switch, car and counterweight safeties, pit stop switch, and any stop switches in the pit and machine room
• Hoistway lighting — required at defined intervals throughout the hoistway and at the pit

Begin with a hand sketch on graph paper. Use standard ladder-diagram or schematic symbols consistently. Label every component. Then transfer the design to CAD or schematic software, which makes peer review and correction far easier. During peer review, your partner should check specifically for missing safety-device contacts, unlabeled wires, and any branch that bypasses the safety string.

Building a Bill of Materials

A bill of materials (BOM) lists every component needed for the build phase before you order or touch a part. Each line should include a plain-English description, the function of the part, approximate quantity, and any specification notes (voltage rating, ampacity, type). A complete BOM prevents mid-build delays and ensures the JHA covers all equipment involved.

Writing the Job Hazard Analysis

A Job Hazard Analysis (JHA) — sometimes called a Job Safety Analysis (JSA) — is a structured document that identifies hazards step by step and pairs each one with specific controls. In the elevator trade, you must address at minimum:

1. Electrical hazard — shock and arc flash from energized circuits. Control: follow LOTO (Lockout/Tagout) procedures per applicable OSHA requirements; verify zero energy with a tested meter before touching conductors; wear appropriate voltage-rated PPE.

2. Fall hazard — working at the top of the car, in an open hoistway, or on a ladder. Control: use a full-body harness anchored to a rated anchor point; install hoistway barriers and warning lines at floor openings.

3. Struck-by hazard — tools or materials dropped from above, counterweight movement. Control: hard hats required in hoistway; tool tethers; communicate before moving any load.

4. Hydraulic fluid hazard — pressurized fluid injection injury, burns, slip. Control: relieve system pressure before opening any fitting; contain spills immediately; wear chemical-splash goggles and appropriate gloves.

5. Confined space hazard — the pit is a permit-required confined space. Control: atmospheric testing before entry; attendant stationed outside; entry permit completed and posted.

6. Housekeeping hazard — debris, cords, and fluid spills create trip and fire risks. Control: clean work area continuously; secure cords; dispose of oily rags in approved containers.

Each JHA entry must name the hazard, describe the control, and identify the PPE required. Your instructor must sign off on the completed JHA before the team moves to any hands-on phase.