Basic Rigging

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BASIC RIGGING

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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

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INTRODUCTION A. Mission

This course on Lifting Equipment, Rigging, and Slinging is designed to identify and detail the mandatory requirements for the safe utilization of all lifting equipment operating on the Project. The course will also provide a clear understanding of Lifting tackles, Rigging and Slinging practice, Safe Working Loads, Different types of Cranes and Crane Signals.

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B. Problem Analysis

Everyday, Routine Crane Operations – • cause most of our accident due to lack of adequate planning.

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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

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D. ObjectivesUpon completion of the lesson, participants will

be able to:

• List the four major causes of crane accidents.

• Describe the pre-planning that is required before putting a crane in use.

• State the main precautions that apply to working with cranes.

• Explain at least three ways to eliminate hazards that may lead to injury when using cranes or slings to handle materials.

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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

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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

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Roles and Responsibilities (Cont.)Line Supervisors

– Ensuring the adequate supervision of personnel, carrying out, or involved in, lifting operations

– Ensuring that work method statements, task risk assessments, Lifting Plan /Rigging Study have been carried out

– Ensuring that areas around the lifts are suitably barricaded and warning signs posted

– Ensuring that the Load weight, shape and radius of lift are suitable for selected lifting equipment and gear

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Riggers and Slingers

– Identifying any defects in lifting gear– Conforming the weight, center of gravity and

characteristics of a load prior to lifting

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•Banks-men

– Preventing all unauthorized personnel from entering the restricted area around the lifting operation

– Ensuring that taglines are attached and used on all loads

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Wire Ropes

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Single Layer Rope

• One layer of outer

strands (usually 6 or 8)

laid helically over a

centre core of fibre or

steel

• Illustration - rope with

independent wire rope

core (IWRC)

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Wires in a Stranded Rope

Core wiresInner wire

Outer wire Centre wire

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Stranded Ropes

Single layer Two layers Three layers

Rotational Resistant Low RotationRotates

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Rotation-resistant rope(Illustration is 35LS - Low rotation rope)

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Rope Dimensions

Actual (measured) diameter22.2 mm

Nominal diameter (d)22 mm

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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.

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Sheave Groove Profile

Wrong Wrong

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WHIP LASH:A damaged or overstrained rope may break and cause serious

injury to anyone in its path.

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Slings

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WIRE ROPE SLINGSInspection• Safe working load stamping.• 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.

ActionIf 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.

Soft Eye

Soft Eye Endless

Grommet

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CARE AND USE OF WIRE ROPES.

Examine all wire ropes for damage before use. Faults which may render a rope unserviceable include;

Kinking

Badly worn strands•Corrosion•Kinking.•Broken and fraying strands.

Broken and fraying

strands

Corrosion

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Wire Rope Capacities

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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.

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SKETCH “A” SHOWS THE ARMS VERTICAL AND A REASONABLY EASY LIFTING CONDITION.

SLING

A

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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

B

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On two leg sling work always be aware of the changing SWL factor with the changing angles of the slings.

Caution — Slung Angles are Critical

Slings should always be used as near vertical as possible.In general if L is greater than S then the slinging is OK

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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!

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Chain Slings

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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.

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BELT SLINGSIdentification• Safe working load marking.• Identification mark.• Colour inspection code (if used).• Condition of stitching.• Tears or abrasions• Burning of outer surface.• Excessive wear.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.

Belt Sling with Eyes

Endless Belt Sling

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Flat Webbing and Round Synthetic Slings

Types of synthetic slings and fittings

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• INSPECTION

• Synthetic slings must be inspected before each use.

• They must also be inspected by a competent person at least once every 3 months. If a sling is subject to severe conditions the inspections should be more frequent.

• Send slings for a proof load test at least every 12 months.


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• LOOK FOR:

• Any external wear such as abrasion or cuts and contusions.• Internal wear which is often indicated by a thickening of the sling

or the presence of grit and dirt.• Damage to the protective coating of the sling.• Damage caused by high temperatures, sunlight or chemicals

(indicated by discolouration).


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• 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.


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• DISCARD A SYNTHETIC SLING IF:

• It is considered that it has lost more than 10% of its original breaking strength. (Send the sling to the manufacturer for regular testing.)

• The label has been removed or destroyed.

• There is any damage to the sleeve or protective coating.

• A nylon sling comes into contact with acid.

• A polyester sling comes into contact with alkaline substances.


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• 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.

After 6 months exposure to sunlight send a sling in for

testing.


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(b) Some damage to load-bearing fibres(c) Badly damage sleeve

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(d) Load-bearing fibres have been cut (e) Cut load-bearing fibres (f) Broken load-bearing yarn

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(g) The use of hooks that are too narrow has damaged the eye of the sling

(h) Burn damage to sleave and load-bearing yarn

(i) Surface wear evident by furry surface

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ROUNDSLINGSIdentificationA further category of man-made fiber slings is the round sling. This is manufactured from an endless polyester yarn and covered with a protective polyester sleeve stitched as illustrated.

Maintenance• Safe working load markings.• Identity number.• Colour inspection code.• Broken load bearing internal yarn.• Cuts and abrasions to external cover.• 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.

Typical Round sling colour coding (Basic Configuration)

WLL Tonnes Colour

1.0 Violet2.0 Green3.0 Yellow4.0 Grey5.0 Red6.0 Brown8.0 Blue10.0 Orange

Endless Round Sling

Round Sling with eyes

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SLING INSPECTIONwhile inspecting the sling;

• Sling should be laid out in good light and examined over its entire length for:

1. Damage caused by sharp edges (cuts)2. Damage caused by abrasion (burning or scuffing)3. Impact damage.4. Contamination by chemicals.5. ID tag with SWL marked ID number and length.6. Certification.

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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.

• Red color is reserved especially for items scrapped or not to be used. We have to comply with the project color coding system every 3 months or depending upon the project requirement.

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Thumb Rules

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Bow Shackles

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SHACKLESThree types of shackles are commonly used for rigging

applications. They are the anchor (bow type), chain shackle (D-shackle) and wide-body type shackle.

Many more different type shackles are available in the market-place which should not be considered for rigging use.

Three suppliers of shackles are well known in the construction industry with Crosby and Green Pin being the leaders and most widely utilized. Le Beon shackles can occasionally be

found as well.

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Screw Pin Anchor Shackle Bolt Type Anchor Shackle

Screw Pin Chain Shackle Bolt Type Chain Shackle

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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.

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Normal ShackleReduced Sling Bearing Area in Shackle Bow

Wide Body ShackleIncreased Sling Bearing Area up to 58 %.

Increases usable sling strength up to 15 %

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A simple Formula is used to calculate the Factor of D/d

Factor = 1 -dD /

5.0

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This means if a 25 mm Diameter Sling is used over a 30 mm Pin the Equation will

be:

25/30

5.0

2.1

5.01 - = 1- = 1 – 0.416 = 0,584

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Rigging Hitches & Slinging Methods

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IDENTIFICATION OF RIGGING HITCHES

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CURVATURE:

Sharp bends in a wire rope sling reduce its strength and cause crushing.Fit a wire rope sling so that the minimum radius around which it is bent is atleast 3 times the diameter of the rope.Packing may be inserted to increase the radius of the bend.

PRECAUTION WHEN USING LIFTING GEAR

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Slinging Hazards

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Slinging Hazards

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SOFT EYENot to be hammered

down

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DOUBLE CHOKER OR

A PAIR OF CHOKER HITCHES

Not to be hammered down.

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DOUBLE BASKETOR

PAIR BASKET HITCHES

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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.

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CENTER OF GRAVITYThe 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.

STABLE Hook is directly above Center of Gravity

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UNSTABLELoad is not aboveCenter of Gravity

Load will shift until Center of Gravity is

below the Hook

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UNSTABLELoad is not above Center of Gravity

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Rules to Follow When Slinging and Handling a Load

RaiseMove

Lower slowly

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Basic Knots

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ROUND TURN ANDTWO HALF HITCHES

Used to secure a rope to a column or post. Easily tied and does not jam. Will stand heavy strain without slipping.

BOWLINEA 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 KNOTAlso known as the square knot. Used to join two rope or lines of the same size. Holds firmly and is easily united.

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Chain Blocks, Pull lifts,Tirfors, eye bolts, plate clamps, turnbuckles, hooks, lifting beams

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USING CHAIN BLOCKS

Ensure that the SWL of the chain block is adequate for the load to be lifted.Attach the head fitting to a suitable anchoragePull the operating chain to determine the hoisting and lowering sides of the chain.Attach the load to the hook using correct slings and / or shackles.Pull down the relevant side of the operating chain to hoist or lower the load.

Operating Chain

Hook

Safety catch

Load Chain

Head Lifting

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USING PULL LIFTS

Attach the head fitting to a suitable anchorage taking into account the load to be lifted, lowered or pulled.

Hook with Safety catch

Step Line

Head fitting

Pawl Lever

Hand wheel

Operating Lever

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PULL LIFT OPERATION:

HOISTING OR PULLING:

1. Turn the lever to the neutral position.

2. Turn the hand wheel to adjust the chain to the required length.

3. Attach the load to the bottom hook, using appropriate slings and / or shackles.

4. Turn the lever to the up position.5. Turn the hand wheel to take up the

slackness in the chain.6. Operate the handle backwards and

forwards to lift or pull the load.

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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.

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Examine a chain before using it.Look for stretched links, wear, distortion and any other sign of weakness.

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HAND OPERATED WINCH / TIRFORIdentificationA 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.

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IdentificationThis 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.

Using the hand-operated winch1. Uncoil the special wire rope, used with the machine, in a straight

line to prevent loops which might untwist the stands or form kinks under tension.

2. Push the release handle into the notched position to open the jaws inside the machine.

3. Insert the tapered end of the wire ripe into the machine at the hole in position A

These machines are available in a range of Sizes to suit different working conditions.

Notched position

Release handle

A

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4. Push the rope through the machine until it emerges at exit B.

B

5. Anchor the machine using the correct slings. Fit them to the hook attached to the machine.

6. Pull the wire rope through the machine until the desired length is reached and the rope 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.

Hoisting or PullingFit the operating handle on to the actuating lever and work the handle to and fro.

This action pulls the rope through the machine and automatically locks it in position when the operating handle is released.

Actuating lever

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Lowering or slackening offFit 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.

Releasing the wire ropefrom the machine1. Fit the operating handle on to the lowering lever

and work the handle to and fro until all the tension is taken off the rope.

2. Remove the anchoring slings.

Push the release handle to the notched position to open the jaws inside the machine

3. Pull the rope back through the machine.

The jaws in the machine automatically lock the rope in position. It is therefore impossible to release the wire rope form the winch whilst there is any strain (load) on it.

Lowering lever

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COLLAR EYE BOLT

This bolt has a small This bolt has a small eye; a large collar eye; a large collar with a machined with a machined under face which is under face which is relieved to allow a relieved to allow a radius between collar radius between collar and shank and to and shank and to provide a thread run provide a thread run out.out.

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EYE BOLT WITH LINK

This bolt is used This bolt is used for normal lifting for normal lifting purposes and has purposes and has a link forged in a link forged in the eye.the eye.

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DYNAMO EYE BOLT

This is designed for This is designed for vertical lifting only.vertical lifting only.

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PLATE CLAMPSIdentificationThere 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.• Corrosion.• Condition of springs

ActionIf 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.

Universal Vertical Horizontal

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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

should NOT be used to transport plates horizontally).

SelectionThe first consideration when selecting the clamp is how the plate is to be transported and stacked, ie horizontal or vertically.

The second consideration is the weight of the plate to be handled which will determine the SWL of the clamps.

The third consideration is the plate thickness which will determine the correct model of clamp with the appropriate jaw opening.

Pre-use ExaminationBefore using any plate clamps, the following checks should be made:

•The SWL is adequate for the load.

•The colour coding (where applicable) is current and the clamp has a plant number / ID mark.

PLATE CLAMPS

Horizontal Clamps Universal (Vertical) Clamps

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Lock the jaw in the closed position and ensure the jaws have a firm bite on the plate.

Alwaysi) 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.

NeverAttach clamps to the side of the plate

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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.

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SelectionThe first consideration when selecting turnbuckles

is the SWL which is determined by the thread diameter.

The second consideration is the adjustability (commonly known as “Take-up”) of the turnbuckle. The take-up often varies with different patterns.

Turnbuckles (Rigging Screws) can be obtained with various types and combinations of end fittings, the most popular being the “Jaw and Eye” type.

COMMON TURNBUCKLE

Eye Jaw Stub Hook

(Has Reduced capacity)

Jaw & Eye combination

Jaw & Jaw combination

Hook & Hook combination

Hook & Eye combination

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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)

PreferredFig - 1

AcceptableFig - 2

Caution RequiredFig- 3

Lock wire will hold

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.

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PRE-USE EXAMINATIONPrior 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.

SafetyTurnbuckles must always have the threaded shank protruding into the body to ensure

that the load is borne over the correct length of the threaded shank.

Particular care must be taken when using “Closed Body” type screws. It may be necessary

to dismantle to dismantle the turnbuckle, measure the length of the threaded shanks,

reassemble and use measurement to ensure the above “unsafe” case is avoided.

Check for cracks & bends

Check for thread damage & bent rods

CORRECT UNSAFE

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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.

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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.

Note: Collar eye bolts are not designed to take hooks.

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CARE OF EYE BOLTS:

Always tighten eye bolts to the correct position, but do not over strain them. Fit a shackle so that the minimum strain is imposed when the lift is made unless an eye bolt with link is used.

Ensure the collar is hard down on the material and the eye in the right direction for the lift.

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WEIGHT OF SPREADER BEAM AND LIFTING BEAMS

Weight of spreader beams can be calculated from weight tables of the steel section, from which they are made, or obtained from the manufacturer’s specification.

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LIFTING APPLIANCES

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LIFTING APPLIANCES

• CRANES (Tower, Mobile, Crawler.)

• Identification

• Hand signals

• Safety Procedures

• Inspection

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Rough Terrain (RT) All Terrain (AT)

Crawler

Truck Crane (TC)

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Crane Selection

Weights, Dimensions and Lift Radii expected

Type of Lifting to be done

The Crane Position, where the Load is to be lifted from, Access, Erection and Dismantling restraints

Site Conditions

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Site Review and Crane Setup

Character of the Ground and Soil Conditions.

Access and Stability

Working Area

Presence and Location of any Underground Hazards

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RESPONSIBILITIES

• Be familiar with the lifting capabilities of the crane.• Check the lifting equipment being used is in good condition,

certified for use, correctly color coded, and is of sufficient capacity to carry out the lift.

• Ensure taglines are attached to loads which are likely to swing.• Be aware of any obstruction within the crane radius and working

area.• Check that the area around the load to be lifted is clear and that

the load is attached to the floor, transportation cradle or adjacent equipment.

• Ensure that the escape route is identified.

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THE PROCEDURE FOR SETTING UPAND 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 lengthRig the load once everything has been checked float the load making sure it is balanced this assists the crane to check his brakes and stabilityWhen 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.

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BARRIER TAPE

ZAWED

ZAWED

ZAWED

WARNING SIGNS

.

.

..

CONES

WHEN WORKING WITH CRANES YOU MUST BARRICADE THE WORKING AREA

.

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Crane Mats

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Isolate Working Area

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CRANE HOOKSMost 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

Soft Eye Hard

Eye

‘C’ Hook Ramshorn Hooks

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IDENTIFICATION OF TYPES OF CRANE & THEIR PARTS

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Poor Ground Conditions are a Factor in Many Accidents

Never attempt to make a liftfrom soft or unstable ground

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Poor Ground Conditions are a Factor in Many Accidents

Over 50% of all crane accidents are the result of mistakes made

and rushed sloppy work done when the crane was being put

together, readied and placed to make its lifts.

REMEMBER: Failure to follow just one safety

precaution can cause that accident, to men or machine.

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Failure to Level the Crane is a Common Accident Cause

Just a little side tilt when lifting a load over the

rear can become dangerous when swung

over the side.

What can happen when you swing over the side!

Load radius increases when swung over the

side.

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LEVELING THE CRANEThe line

Should lie dead in the centre of the boom in all

positions, end, side and corner.

WRONG RIGHT

Leveling With the Load Line

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Check That Cranes are Level

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Boom Length and Radius Capacity Lost

When out of Level

1° 2° 3°Short Boom, Minimum Radius 20 % 20 % 30 %

Short Boom, Maximum Radius 8 % 15 % 20 %

Long Boom, Minimum Radius 30 % 41 % 50 %

Long Boom, Maximum radius 5 % 10 % 15 %

Possible Capacity Loss Due to being out of Level

Accurate Calculations are available from the specific, applicable Crane Manufacturers

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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.

When such conditions cannot be attained, loads being handled must be reduced to

compensate.

DON’T FORGET:

If a tipping condition is suddenly sensed — start lowering the load and retract or

elevate the boom to bring the load in. Never lower the boom and aggravate the

condition.

Failure to Level the Crane is a Common Accident Cause

The machine must be level

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Many Crane Accidents are Caused by Poor Blocking Under Floats

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Many Crane Accidents are Caused by Poor Blocking Under Floats

USE SOLID BLOCKING UNDER ALL FLOATS

THE CRANE’S BEARING PRESSURE MUST BE DISTRIBUTED TO THE GROUND BY USING LARGE TIMBER BLOCKING

WARNING:Only cranes with approved free on wheels ratings can be used without

outriggers set.

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Set Outriggers Correctly

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OUTRIGGERS:

Capacities are based on all outriggers fully extended. Working with outriggers partially retracted will reduce capacities and

machine stability considerably and may cause an accident. If it is absolutely necessary to operate a machine with outrigger beams partially retracted, reduce capacities to those shown on the chart

for “on rubber”. Remember — the machine must be level.

DON’T OPERATE WITH ONLY REAR OUTRIGGERS EXTENDED. If you swing over the side, the machine may tip over, or the boom

may be damaged from side loadings because the machine is not level.


120

When working a machine with mechanical (non-hydraulic) outriggers, make sure the beams are pinned in place, otherwise

they can “creep in” while operating, causing an unstable condition and possibly tipping the machine over.

WARNING

Before travelling make sure mechanical outriggers are securely pinned in position otherwise they can come out on the road and

cause serious damage.


121

HYDRAULIC OUTRIGGERS:

When setting hydraulic outriggers make sure that the outriggers are set evenly otherwise severe twisting of the

crane’s chassis frame will result.


122

Exceeding the Rated Capacity of any Crane is Dangerous

Overloads can damage the machine and such damage causes failure and accidents.

It looks like about10 tonnes.

Whoops!

123

Spreads out the load so the supporting surface can support it

Transmits the load without bending or breaking

124

WRONG

125

Do not set up too close to trenches etc., as the machine vibration can cause the walls to collapse.

Setting Up and Parking

126

WRONG

127

WRONG

128

Know Conditions and Use Precautions

129

Ensure Handbook and Chart are with

Crane

130

131

Required Clearance for Operations near High Voltage Power Lines

To 50 KV 10 ft. 3.05 M

over 50 to 200 KV 15 ft. 4.60 M

Over 200 to 350 KV 115 ft. 4.60 M

Over 350 to 500 KV 25 ft. 7.62 M

Over 500 to 700 KV 35 ft. 10.67 M

Over 700 to 1000 KV 45 ft. 13.72 M

All overhead Lines and other apparatus should be treated as live unless officially declared “DEAD” and “SAFE”.

If in doubt, seek advise

132

During Thunderstorms and Lightening STOP Work and retract/lower Boom

133

Mechanical Advantage

WrongCorrect

134

MECHANICAL ADVANTAGE

135

Wedge Socket

136

Two Block Cutout

137

Watch for boom drawdown as thecrane takes the load. This increases the radius and can result in the load drifting away from the crane.

THE RADIUS WILL INCREASE WHEN A LOAD IS LIFTED.

MEASURE THE LOAD RADIUS BEFORE MAKING CAPACITY LIFTS.

Know The Radius Of The Load

138

Always Ensure that the Hook

has got a Safety Catch

139

Never let the Boom touch a

Structure

140

It

Might

Cause

the Boom

to

Collapse

Or Damage

141

Use Taglines

142

Always Stand Clear of Suspended Loads

Never Let Anyone Ride on a Suspended Load

143

IDENTIFICATION OF CRANE HAND SIGNAL

144

The Users Responsibilities

Rigger

Crane Operator

145

Protecting Rigging FromDamage 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!

Don’t use makeshift rigging or attempt to repair any rigging components.

Knots tied in rigging reduces the strength by 50% or more!

146

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

147


• 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.

148


– 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.

149


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

150


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.

151


Communication

– An effective communication system shall be in place for all lifting operations.

– The type of system will depend on the nature of the task i.e., radio communication may be necessary when visibility between the crane operator and the Banks-man is restricted.

152


Color Code System

– 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.

153


Lifting Operations Check List – A Risk assessment shall be conducted prior to

any lift being performed.– The lifting operations check list acts as a

reminder and guidelines to the personnel concerned, and basically consists of the items shown below and listed in the Lifting Operations Procedure.

154

CRANE OPERATION ANALYSIS"our plan for a safe job"

Crane: Date: Time: Crane has been inspected/ safe condition:.YesNoJob Location:Job Description:

The weight of the load is:The swing radius of the lift is:Net crane capacity at this radius is:Is operator qualified to operate this crane? Yes NoIs operator’s certification card current? Yes NoCritical lift permit required for this lift? Yes No Crane level/outriggers fully extended? Yes NoIs the rigger qualified for this task? Yes NoIs sling/hardware in safe condition? Yes No Sling sizing/hookup reviewed? Yes NoDo sharp edges have softeners? Yes NoTag lines needed to help control load? Yes NoCenter of gravity of load located? Yes No

EMERGENCY INFORMATIONWhat is the wind direction?Reviewed emergency alarms/phone numbers YesEscape route(s):Location of eyebath/shower station:

Our evacuation assembly point is:Operator Signature:Rigger Signature:Signalman Signature:Supervisor Signature:

155

RIGGING PLAN

156

RIGGING COMPONENTSList each component

Slings

Type Hitch Cap. Sling Angle Actual Cap.

Sling 1

Sling 2

Sling 3

Sling 4

Shackles

Size Capacity

Shackle 1

Shackle 2

Shackle 3

Shackle 4

Other Devices:

Description Capacity

How has the lifting area been restricted? _____________________________________________________________________________________________________________________________________________________________________________________________

Documents

Basic Rigging