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1
Contents
Introduction
Roles and responsibilities
Wire ropes
Slings, belt slings, round slings,
Bow Shackles
Rigging Hitches & Slinging Methods
Basic Knots
Chain blocks
Pull lifts
Tirfors, eye bolts, plate clamps, turnbuckles, hooks,
lifting beams
Lifting Appliances
Procedure for lifting operations
2
INTRODUCTION
A. Mission
3
B. Problem Analysis
4
C. Expectation
To analyze all lifts
Ground Preparations
Using proper lifting tackles
Interpretations of capacity charts
Operators and signalmen must
maintain continuous and undivided
communication
5
D. Objectives
Upon completion of the lesson, participants will
be able to:
6
Roles and Responsibilities (Cont.)
Rigging Superintendent
Ensuring that the lifting equipment and gear
selected to work, has been inspected, certified
and is maintained according to procedure
Ensuring that only
qualified and competent
riggers/slingers/banks-men
are assigned to any lifting
operations
7
Roles and Responsibilities (Cont.)
Appointed Competent Person (Lifting
Equipment) Third Party
Appointed Competent Person (Lifting
Gear) Third Party
Responsible for ensuring that the testing,
examination and certification of lifting
Equipment / Gear is carried out in
accordance with the Requirement
8
Roles and Responsibilities (Cont.)
Line Supervisors
9
Roles and Responsibilities (Cont.)
Riggers and Slingers
10
Roles and Responsibilities (Cont.)
Banks-men
11
Wire Ropes
12
Single Layer Rope
13
Wires in a Stranded Rope
14
Stranded Ropes
Single layer Two layers Three layers
Rotates Rotational Resistant Low Rotation
15
Rotation-resistant rope
(Illustration is 35LS - Low rotation rope)
16
Rope Dimensions
17
Measurement of Rope Diameter
(New rope)
2 measurements at right angles at two
positions spaced approximately one metre
apart.
(Measurements taken over strand crowns)
Average of the four measurements is the
rope diameter.
18
Sheave Groove Profile
Wrong Wrong
19
WHIP LASH:
A damaged or overstrained rope may break and cause serious
injury to anyone in its path.
20
Slings
21
WIRE ROPE SLINGS
Inspection
Safe working load stamping. Soft Eye
Identification mark.
Correct colour code (if applicable).
Broken wires (Randomly distributed wire breaks are not to
exceed 5% in any length of 10 diameters. Localised breaks are
not to exceed 3 in a close group or in any one strand within a
length of 6 diameters).
Ensure rope end of the looped parts does not terminate inside
ferrule.
Excessive wear (max 10% loss of nominal diameter)
Kinks.
Exposure of core.
Flattening of rope (especially in the eye).
Stretch by reduction in diameter or circumference.
Corrosion.
Heat damage, look for evidence of discoloration, loss of
lubricant, pitting and the presence of weld blobs.
Action Soft Eye Endless
If any of the above faults are present refer to a competent
person for through examination.
Maintenance
Keep ropes clean and free from grit.
Lubricate at regular intervals.
Slings should be suspended from storage rack if not in use.
Grommet
22
CARE AND USE OF WIRE ROPES.
Corrosion
Kinking.
Broken and fraying strands.
Corrosion Kinking
23
Wire Rope Capacities
24
The stresses in the legs of the sling increases as the
angle between them increases. Using the human
body and two buckets filled with water it will not be
difficult to demonstrate the effects of lifting a load at
narrow and wide angles. The arms represent the
sling and lift angle.
25
SKETCH A SHOWS THE ARMS VERTICAL AND A
REASONABLY EASY LIFTING CONDITION.
SLING
26
SKETCH B SHOWS THE ARMS STRETCHED BEYOND ITS LIMIT WITH THE
LOAD. THE BODY AND SLINGS ARE NOT DESIGNED TO TAKE UN-NECESSARY
STRAINS.
SLING
27
28
Caution Slung Angles are Critical
29
Chain Slings
Only Grade 8 or better ALLOY Chain can be used for
overhead lifting purposes! All chain is not rated the same!
Chain must have a capacity tag attached to it.
Chains will withstand more rough handling and abuse, but a
chain with the same rated lifting capacity of wire rope will be
much larger in diameter and heavier in weight.
Chains must be inspected daily before use and as often as
necessary during use to assure safety.
It is the riggers responsibility to do the inspections!
30
Chain Slings
31
SPECIFIC REQUIREMENTS FOR THE
WEBBING SLING (FLAT & ROUND)
All webbing sling shall;
Be stored away from direct sunlight to minimize
the effect of UV deterioration.
Be stored on a non-corrodible rack, away from
any source of heat.
Not be used in knotted or twisted condition.
Never be repaired. A damaged webbing sling or
sling with damaged cover shall be discarded
and taken out of service.
32
BELT SLINGS
Identification
Safe working load marking.
Identification mark.
Colour inspection code (if used).
Condition of stitching.
Tears or abrasions
Burning of outer surface.
Excessive wear. Belt Sling with Eyes
If any of the above faults are present refer to a
competent person for through examination.
Maintenance
Keep surface clean and free from grit.
Re-apply colour code if necessary.
Sling should be suspended in storage when not in use.
33
Flat Webbing and Round Synthetic
Slings
Types of synthetic slings and fittings
34
Flat Webbing and Round Synthetic
Slings
INSPECTION
35
Flat Webbing and Round Synthetic
Slings
LOOK FOR:
36
Flat Webbing and Round Synthetic
Slings
Damage to the label or stitching.
Damage to the eyes or any terminal
attachments or end fittings.
Where the sling is covered by a sleeve, the
sleeve must cover the sling for the full length
from eye to eye.
37
Flat Webbing and Round Synthetic
Slings
DISCARD A SYNTHETIC SLING IF:
38
Flat Webbing and Round Synthetic
Slings
A polypropylene sling comes into contact with an organic solvent
such as, paint, coal tar or paint stripper
There are any visible cuts on the sling.
NB: A nylon sling will lose more than 10% of its strength
when it is wet.
39
Flat Webbing and Round Synthetic
Slings
40
Flat Webbing and Round Synthetic
Slings
41
Flat Webbing and Round Synthetic
Slings
(g) The use of hooks that are too narrow (h) Burn damage to sleave and (i) Surface wear evident by furry surface
load-bearing yarn
has damaged the eye of the sling
42
ROUNDSLINGS
Identification Typical Round sling colour coding
(Basic Configuration)
A further category of man-made fiber slings is the round sling. WLL Tonnes Colour
This is manufactured from an endless polyester yarn and
1.0 Violet
covered with a protective polyester sleeve stitched as illustrated. 2.0 Green
3.0 Yellow
4.0 Grey
Maintenance 5.0 Red
Safe working load markings. 6.0 Brown
Identity number. 8.0 Blue
10.0 Orange
Colour inspection code.
Broken load bearing internal yarn.
Cuts and abrasions to external cover. Endless Round Sling
Cuts in stitching.
Discoloration (due to chemical attack).
Burn marks on outer surface.
Knots.
Action
If any of the above faults are present refer to a competent
person for thorough examination.
Maintenance
Keep clean and free form grit.
Re-apply colour code if necessary
Sling should be suspended in storage when not in use.
Round Sling with eyes
43
SLING INSPECTION
while inspecting the sling;
44
COLOR CODING
The project operates a system where by all
Lifting Equipment is color coded with a unique
color, at monthly intervals, after inspection where
applicable.
45
Thumb Rules
46
Bow Shackles
47
SHACKLES
Three types of shackles are commonly used for rigging
applications. They are the anchor (bow type), chain shackle (D-
shackle) and wide-body type shackle.
48
Screw Pin Anchor Shackle Bolt Type Anchor Shackle
49
Wide Body Shackles
Greatly improve wear-ability of wire
rope slings and can be used to connect
high strength Synthetic Round Slings
or Wire Rope Slings by improving the
D/d ratio. The sling bearing area
increases by a minimum of 58 %
which increases sling strength by a
minimum of 15 %. Pins are smaller
than equally rated quenched and
tempered shackle pins and for
instance a 75 Tonne wide body
shackle can be utilized where a 55
Tonne normal quenched and
tempered shackle is intended to fit.
50
Normal Shackle
Reduced Sling Bearing Area in Shackle Bow
51
A simple Formula is used to calculate the
Factor of D/d
0.5
Factor = 1 -
D/d
52
This means if a 25 mm Diameter Sling is
used over a 30 mm Pin the Equation will
be:
0 .5 0.5
1- = 1- = 1 0.416 = 0,584
30 / 25 1.2
53
54
Rigging Hitches & Slinging Methods
55
IDENTIFICATION OF RIGGING HITCHES
56
PRECAUTION WHEN USING
LIFTING GEAR
CURVATURE:
58
Slinging Hazards
59
60
SOFT EYE
Not to be hammered
down
61
DOUBLE CHOKER
OR
A PAIR OF CHOKER HITCHES
62
DOUBLE BASKET
OR
PAIR BASKET HITCHES
63
64
SAFE WORKING LOAD (SWL)
A calculated, design approved and
certified maximum load, normally
specified in Kilograms (kgs) or Tones,
up to which, an item of Lifting
Equipment is safe to operate.
65
CENTER OF GRAVITY
The center of gravity of an object is that point at which the object will balance.
The entire weight may be considered as concentrated at this point.
Any suspended object (load) will center itself directly under the hook.
66
UNSTABLE
Load is not above Load will shift until
Center of Gravity Center of Gravity is
below the Hook
67
UNSTABLE
Load is not above Center of Gravity
68
69
Rules to Follow When Slinging and
Handling a Load
Move
Raise
Lower
slowly
70
Basic Knots
71
ROUND TURN AND
TWO HALF HITCHES
Used to secure a rope to a column or post. Easily tied and does not jam.
Will stand heavy strain without slipping.
BOWLINE
A favorite knot with riggers and one of the best
known and widely used of all knots.
It is easily constructed and used wherever a
hitch is required that will not slip, jam or fail.
REEF KNOT
Also known as the square knot. Used to join two rope or
lines of the same size. Holds firmly and is easily united.
72
Chain Blocks,
Pull lifts,
Tirfors, eye bolts, plate clamps,
turnbuckles, hooks, lifting
beams
73
USING CHAIN BLOCKS
Ensure that the SWL of Head Lifting
the chain block is
adequate for the load to
be lifted.
Attach the head fitting
to a suitable anchorage
Pull the operating chain
to determine the
hoisting and lowering Load Chain
Hand wheel
Pawl Lever
75
PULL LIFT OPERATION:
HOISTING OR PULLING:
76
LOWERING:
To lower the load, turn the lever
to the down position.
Operate the handle backwards
and forwards to lower the load.
When the load is securely in
position, operate the handle to
slacken the chain.
Turn the lever to the neutral
position and turn the hand
wheel to give sufficient length
of chain to be able to release
the slings and / ore shackles.
77
Examine a
chain before
using it.
Look for
stretched
links, wear,
distortion
and any
other sign of
weakness.
78
HAND OPERATED WINCH / TIRFOR
Identification
A hand operated, lever controlled friction drive mechanism for lifting,
lowering and pulling a load.
Identification
Safe working load stamping.
Identity number.
Colour inspection code (if used).
Check for free operation of operation, reversing and rope release lever.
Check that correct shear pins are fitted, and pin condition is satisfactory.
Inspect complete machine for cracks, indentations or distortion.
Wear in operation jaws
Corrosion.
Inspect wire rope and hooks.
Correct rope.
Damage to casing.
79
Identification
This is a multi purpose tool made to pull and
pay-off wire rope.
A special wire rope is fitted through the
machine and cannot be removed whilst
there is a load on the winch.
When the operating handles are actuated by
hand, the rope is either pulled or paid-out
through the machine.
These machines are available in a range of
Sizes to suit different working conditions.
Using the hand-operated winch 2. Push the release handle into the notched position to
1. Uncoil the special wire rope, used with the machine, in a straight open the jaws inside the machine.
line to prevent loops which might untwist the stands or form kinks 3. Insert the tapered end of the wire ripe into the
under tension. machine at the hole in position A
Notched Release
position handle
A
80
4. Push the rope through the machine until it emerges at 5. Anchor the machine using the correct slings.
exit B. Fit them to the hook attached to the machine.
B
Hoisting or Pulling
Fit the operating handle on to the actuating lever and work the handle
to and fro.
6. Pull the wire rope through the machine until the
This action pulls the rope through the machine and automatically
desired length is reached and the rope
locks it in position when the operating handle is released.
becomes tight on the load.
7. Lift the release handle out of the notched
position and allow it to return to the operating
position under its spring pressure. The rope is
now firmly held in jaws fitted inside the
machine.
Actuating lever
81
Lowering or slackening off
Lowering lever
Fit the operating handle to the lowering
lever and work the handle to and fro.
this action pulls the rope back through the
machine and when the handle ceases to
move automatically locks the rope in
position.
82
COLLAR EYE BOLT
83
EYE BOLT WITH LINK
84
DYNAMO EYE BOLT
85
PLATE CLAMPS
Identification
There are various types of plate clamps in use, the following three being the most common:
Inspection
Safe working load stamping.
Identity number.
Plate thickness marking
Colour inspection code (if used).
Free working of assembly.
Condition of teeth
Wear at all bearing points and on pins.
Cracks, nicks and gouges.
Inspect weld (if used).
Security of all pins.
Deformation. Universal Vertical Horizontal
Corrosion.
Condition of springs
Action
If any of the above faults are present refer to a competent person for thorough
examination.
Maintenance
Keep clean and free from grit.
Lubricate moving parts if necessary.
Re-apply colour code if necessary.
86
PLATE CLAMPS
Plate clamps are available in two basis designs, i.e horizontal plate clamps (sued in pairs and usually suspended by a two leg sling from
a lifting beam) for handling plates in the horizontal position. (These clamps can also lift from horizontal to vertical and vice versa, but
Pre-use Examination
Before using any plate clamps, the following checks should be made:
87
Lock the jaw in the closed position and ensure the jaws have a firm bite on the plate.
Always
i) Check that the plate is clean and free from mill scale, dirt, Oil and grease.
ii) Double check that the jaws are locked.
iii) Use an adequate number of clamps to balance the load.
iv) Lift slowly to allow the jaws to obtain a good grip.
Never
Attach clamps to the side of the plate
88
Never
Fast lower onto the floor as this could cause the clamp to open and release the
plate.
Lift horizontally with a vertical clamp.
Lift more than one plate at a time.
Use large capacity clamps to lift light loads.
When using horizontal plate clamps, do not exceed the sling angles indicated
below and do not lift more than one plate at a time unless the clamps are suitable,
i.e. sheet bundle clamps
Never
Use endless slings with clamp pairs as this practice
can drastically overload the clamps.
89
COMMON TURNBUCKLE
Turnbuckles (Rigging Screws) can be obtained with various types and combinations of end
fittings, the most popular being the Jaw and Eye type.
90
When using a turnbuckle in an application where vibration is present, (most areas in an engineering
environment), it is extremely important to lock the end fittings to the frame or body to prevent them from
unscrewing and possible releasing the load. The most popular and preferred method is to wire the eye or jaw
to the body (see fig. 1). As an alternative (for open body type only) a split pin through the end of the screwed
shank is acceptable (see fig 2). The split pin has to be removed to facilitate adjustment. Should lock nuts be
used, care must be taken not to over tighten them as this can put undue stress on the threaded shank (see fig
3)
WARNING
When turnbuckles are to be left under load for any length of time, eg temporary hangers for
pope work, etc they should be visually checked on a daily basis to ensure they are still secure.
91
PRE-USE EXAMINATION
Prior to using a turnbuckle in a lifting situation, visually examine it and ensure that:
i) The SWL is adequate for the load.
ii) The colour code is current and the turnbuckle has a plant number / I.D. mark.
iii) The threads are free from wear, stretch and impact damage.
iv) The eyes/hooks are not worn or stretched.
v) The clevis pin and pin holes are free from distortion/wear.
vi) The threads are suitable lubricated.
Particular care must be taken when using Closed Body type screws. It may be necessary
CORRECT
to dismantle to dismantle the turnbuckle, measure the length of the UNSAFE
threaded shanks,
reassemble and use measurement to ensure the above unsafe case is avoided.
92
SWIVEL HOOKS WITH SAFETY
CATCHES
These allow the load
to be moved round
without twisting and
possibly endangering
slings, wire ropes and
chains. The safety
catch ensures that the
rope or chain does not
slip off the hook.
93
CARE OF HOOKS:
Fit a shackle between the
lifting hook and the eye
bolt to prevent the point
of the hook being
strained.
The shackle will swivel to
allow the sling and hook
to make a correct lift as
illustrated along side and
below.
95
WEIGHT OF SPREADER BEAM AND
LIFTING BEAMS
96
LIFTING APPLIANCES
97
LIFTING APPLIANCES
98
Rough Terrain
(RT) All Terrain (AT)
Crawler
99
Crane Selection
Weights, Dimensions and Lift Radii expected
100
Site Review and Crane Setup
Character of the Ground and Soil
Conditions.
Working Area
101
RESPONSIBILITIES
102
THE PROCEDURE FOR SETTING UP
AND WORKING WITH A CRANE
Set up the crane as close as possible to the load , set the outriggers
and block out securely ensuring that the crane is as level as
possible. You can use a level or the main block to level the crane.
Barricade the area making sure that no other personnel other than
the rigging crew are within the barricade.
Prepare the load for lifting making sure all equipment used is of
sufficient size and Safe Working Load including crane radius and
boom length
Rig the load once everything has been checked float the load
making sure it is balanced this assists the crane to check his
brakes and stability
When all the checks have been completed continue with the lift
following all safety procedures only one person giving the signals,
using tag lines to control the load if required.
Once the load has been placed into its final position remove all the
equipment and barricades.
103
WHEN WORKING WITH CRANES YOU MUST
BARRICADE THE WORKING AREA
BARRIER .
TAPE
Z
A
W
CONES
E
.
D
Z
.
A
W
E
D
. .
WARNING Z
A
SIGNS
W
E
D
104
Crane Mats
105
Isolate Working Area
106
CRANE HOOKS
Most cranes are fitted with C type hooks to prevent snagging on protrusions such
as handrails, etc., and in certain cases also have safety catch to prevent the eye of
the lifting sling being accidentally displaced in the figure. Large cranes however tend
to be fitted with ramshorn type hooks which could have an effect on the sling design.
Soft
Eye Hard
Soft Eye
Eye
107
IDENTIFICATION OF TYPES OF CRANE &
THEIR PARTS
108
Poor Ground Conditions are a Factor in
Many Accidents
109
Poor Ground Conditions are a Factor in
Many Accidents
110
Failure to Level the Crane is a
Common Accident Cause
What can happen
when you swing
over the side!
111
LEVELING THE CRANE
The line
Should lie dead in the centre of the boom in all
positions, end, side and corner.
WRONG RIGHT
Accurate Calculations are available from the specific, applicable Crane Manufacturers
114
Failure to Level the Crane is a
Common Accident Cause
The machine must be level Remember capacity chart ratings are
based on ideal conditions:
Standing on firm, level surface
CALM wind
No side loads or outswing of load
Good visibility
Machine in A-1 condition and equipped
as when leaving the factory.
DONT FORGET:
115
Many Crane Accidents are Caused by
Poor Blocking Under Floats
116
Many Crane Accidents are Caused by
Poor Blocking Under Floats
WARNING:
Only cranes with approved free on wheels ratings can be used without outriggers set.
117
Set Outriggers Correctly
118
Set Outriggers Correctly
OUTRIGGERS:
119
Set Outriggers Correctly
WARNING
120
Set Outriggers Correctly
HYDRAULIC OUTRIGGERS:
When setting hydraulic outriggers make sure that the
outriggers are set evenly otherwise severe twisting of the
cranes chassis frame will result.
121
Exceeding the Rated Capacity of any
Crane is Dangerous
Overloads can damage the machine and such damage causes
failure and accidents.
Whoops!
122
Spreads out the load so the supporting surface can support it
124
Setting Up and Parking
125
WRONG
126
WRONG
127
Know Conditions and Use
Precautions
128
Ensure Handbook
and Chart are with
Crane
129
130
Required Clearance for Operations near
High Voltage Power Lines
To 50 KV 10 ft. 3.05 M
132
Mechanical
Advantage
Correct
Wrong
133
MECHANICAL ADVANTAGE
134
Wedge Socket
135
Two Block Cutout
136
Know The Radius Of The Load
Watch for boom drawdown as the
crane takes the load. This increases
the radius and can result in the load
drifting away from the crane.
137
Always Ensure
that the Hook
has got a
Safety Catch
138
Never let the
Boom touch a
Structure
139
It
Might
Cause
the Boom
to
Collapse
Or Damage
140
Use Taglines
141
Always Stand Clear
of Suspended Loads
142
IDENTIFICATION OF CRANE HAND SIGNAL
143
The Users Responsibilities
Crane
Operator
Rigger
144
Protecting Rigging From
Damage or Environment
Rigging components are expensive to buy and to replace!
Use them properly and store them properly!
Keep wire rope slings lubricated and all rigging stored out of
the weather.
Treat the rigging as though your life depended on it!
Because it does if it fails!
Dont use makeshift rigging or attempt to repair any rigging
components.
Knots tied in rigging reduces the strength by 50% or more!
145
Lifting Operations Procedure
(Cont.)
Lifting operation planning:
Planning shall basically contain and consider the following
steps:
Weight of the load
Method of lifting
Working radius
Communication system
Ground stability
Existing services (AG / UG)
Height restriction
Competent resources
Over head power line
Selection of equipment
146
Lifting Operations Procedure
(Cont.)
Ground stability
When planning a lift, consideration must be
given to the ground conditions.
Outriggers
Sound timber packing or metal plates shall be
positioned under each outrigger pad / Crawler to
distribute the load.
These should be a
minimum of 3 times
the area dimension
of the outrigger pad.
147
Lifting Operations Procedure
(Cont.)
Outriggers must be fully extended on both
sides when performing a lifting operation.
Outrigger pads are not to be permanently
attached to outriggers
A sign warning of the danger of
overhead power lines shall be mounted
in each crane.
148
Lifting Operations Procedure
(Cont.)
Lifting Equipment
The lifting equipment operator shall not begin the machine
movement, until the banks-man is within his range of vision, or
in radio contact, and the signal is given and understood.
Where several individuals are involved, the crane operator shall
obey the signal of the
banks men ONLY.
The only exception shall
be in the case of an emergency,
when the crane operator can
receive the Emergency Stop
Signal from anyone
149
Lifting Operations Procedure
(Cont.)
Restrictions to crane operations
The most common restriction to lifting operations is bad
weather, specifically high wind.
However, No lifts will be permitted at wind speeds
exceeding 30 Knots or 35 Miles per hour.
When working in close proximity to overhead electric
lines or cables, the crane shall not be positioned closer
to the plumb of the nearest line or cable than a distance
equal to the length of the crane Jib fitted, plus 6 meters
measured along the ground.
150
Lifting Operations Procedure
(Cont.)
Communication
151
Lifting Operations Procedure
Color Code System
(Cont.)
The Color Code System shall be developed and implemented for all
Lifting Gear used within the Project such as for slings, shackles, rope
wire, belts.
The color shall indicate to the user and the inspector, that an examination
has been performed within the prescribed period.
A new color shall be introduced on regular basis as per the Project Color
Coding System and each color shall be current for a specified period
Information boards showing the current
color coding shall be posted at prominent
locations at each work site where it is
anticipated lifting operations will take
place.
152
Lifting Operations Procedure
(Cont.)
153
CRANE OPERATION ANALYSIS
"our plan for a safe job"
EMERGENCY INFORMATION
What is the wind direction?
Reviewed emergency alarms/phone numbers Yes
Escape route(s):
Location of eyebath/shower station:
154
RIGGING PLAN
155
RIGGING COMPONENTS
List each component
Slings
Sling 1
Sling 2
Sling 3
Sling 4
Shackles
Size Capacity
Shackle 1
Shackle 2
Shackle 3
Shackle 4
Other Devices:
Description Capacity
156