rigger

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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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INTRODUCTIONA.Mission

This course on Lifting Equipment, Rigging, and

Slinging is designed to identify and detail the

mandatory requirements for the safe utilizationof 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 requiredbefore putting a crane in use.

State the main precautions that apply toworking with cranes.

Explain at least three ways to eliminatehazards that may lead to injury when usingcranes 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 toprocedure

Ensuring that onlyqualified and competentriggers/slingers/banks-men

are assigned to any liftingoperations

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Appointed Competent Person (Lifting

Equipment)Third Party Appointed Competent Person (Lifting

Gear)Third Party

Responsible for ensuring that the testing,

examination and certification of liftingEquipment / 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 beencarried out

Ensuring that areas around the lifts are suitablybarricaded and warning signs posted

Ensuring that the Load weight, shape and radius of liftare 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 liftingoperation

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 acentre 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 layersRotational Resistant Low RotationRotates

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

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Rope Dimensions

Actual (measured) diameter

22.2 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 metreapart.

(Measurements taken over strand crowns)

Average of the four measurements is therope 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

WIRE ROPE SLINGS

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WIRE ROPE SLINGS

Inspection 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 arenot to exceed 3 in a close group or in any one strand within alength of 6 diameters).

Ensure rope end of the looped parts does not terminate insideferrule.

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 oflubricant, 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 unserviceableinclude;

Kinking

Badly worn strandsCorrosionKinking.

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 atnarrow and wide angles. The arms represent the

sling and lift angle.

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SKETCH A SHOWS THE ARMS VERTICAL AND AREASONABLY EASY LIFTING CONDITION.

SLING

A

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SKETCH B SHOWS THE ARMS STRETCHED BEYOND ITS LIMIT WITH THE LOADTHE 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 8or better ALLOYChain 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 achain 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 minimizethe effect of UV deterioration.

Be stored on a non-corrodible rack, away fromany 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 discardedand taken out of service.

BELT SLINGS

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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

SlingsTypes 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.


Slings

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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).


Slings

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Damage to the label or stitching.

Damage to the eyes or any terminalattachments 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.


Slings

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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 forregular 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.


Slings

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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.

Flat Webbing and Round SyntheticSlings

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Slings

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

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Slings

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

(f) Broken load-bearing yarn

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Slings

(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

ROUNDSLINGS

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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 Green

3.0 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 andexamined 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 3months 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 aswell.

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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 ShacklesGreatly 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 Shackle

Reduced Sling Bearing Area in Shackle Bow

Wide Body Shackle

Increased 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 willbe:

25/30

5.0

2.1

5.01 - = 1- = 10.416 = 0,584

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Rigging Hitches & Slinging Methods

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 USINGLIFTING GEAR

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Slinging Hazards

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Slinging Hazards

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SOFT EYE

Not to be hammered

down

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DOUBLE CHOKERORA 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

Equipmentis safe to operate.

CENTER OF GRAVITY

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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.

STABLE Hook is directly aboveCenter of Gravity

UNSTABLE

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Load is not above

Center of Gravity

Load will shift until

Center of Gravity is

below the Hook

UNSTABLE

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Load is not above Center of Gravity

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Rules to Follow When Slinging and

Handling a Load

RaiseMove

Lowerslowly

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Basic Knots

ROUND TURN AND

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TWO HALF HITCHESUsed 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 bestknown 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 orlines 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

USING CHAIN BLOCKS

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Ensure that the SWL of thechain block is adequate forthe load to be lifted.Attach the head fitting to asuitable anchoragePull the operating chain todetermine the hoisting andlowering sides of the chain.Attach the load to the hookusing correct slings and / orshackles.Pull down the relevant side ofthe operating chain to hoistor 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

PULL LIFT OPERATION:

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HOISTING OR PULLING:

1. Turn the lever to the neutralposition.

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

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

4. Turn the lever to the up position.

5. Turn the hand wheel to take up theslackness in the chain.

6. Operate the handle backwards and

forwards to lift or pull the load.

LOWERING:

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To lower the load, turn the leverto the down position.

Operate the handle backwardsand forwards to lower the load.

When the load is securely inposition, operate the handle toslacken the chain.

Turn the lever to the neutral

position and turn the handwheel to give sufficient lengthof chain to be able to releasethe slings and / ore shackles.

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Examine achain beforeusing it.Look forstretched linkswear distortionand any othersign ofweakness.

HAND OPERATED WINCH / TIRFOR

Id tifi ti

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IdentificationA hand operated, lever controlled friction drive mechanism for lifting,

lowering and pulling a load.

Identification Safe working load stamping.

Identity number.


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.

IdentificationThis is a multi purpose tool made to pull and

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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 byhand, 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 toopen 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

positionRelease

handle

A

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

exit B.

5. Anchor the machine using the correct slings. Fit

them to the hook attached to the machine.

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B

6. Pull the wire rope through the machine until the

desired length is reached and the ropebecomes 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

Lowering or slackening offFit the operating handle to the lowering Lowering lever

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p g g

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 autom atical ly lock the

rope in posit ion. It is therefore impossible to

release the wire rope form the winch whi lst there

is any strain ( load) on it.

COLLAR EYE BOLT

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This bolt has a small eye;a large collar with amachined under facewhich is relieved to allowa radius between collarand shank and to providea thread run out.

EYE BOLT WITH LINK

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This bolt is used fornormal liftingpurposes and has alink forged in theeye.

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DYNAMO EYE BOLTThis is designed forvertical lifting only.

PLATE CLAMPS

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IdentificationThere 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


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

Action

If any of the above faults are present refer to a competent person for thoroughexamination.

Maintenance Keep clean and free from grit.

Lubricate moving parts if necessary.

Re-apply colour code if necessary.

Universal Vertical Horizontal

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

PLATE CLAMPS

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a lifting beam) for handling plates in the horizontal position. (These clamps can also lift from horizontal to vertical and vice versa, but

should NOTbe used to transport plates horizontally).

Selection

The 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.

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

Never Fast lower onto the floor as this could cause the clamp to open and release the

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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.

COMMON TURNBUCKLE

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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 Jawand Eyetype.

Eye Jaw Stub Hook

(Has Reduced

capacity)

Jaw & Eye combination

Jaw & Jaw combination

Hook & Hook combination

Hook & Eye combination

When using a turnbuckle in an application where vibration is present, (most areas in an engineering

) f f f

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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 fig2). 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)

Preferred

Fig - 1

Acceptable

Fig - 2

Caution Required

Fig- 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.

PRE-USE EXAMINATIONPrior to using a turnbuckle in a lifting situation, visually examine it and ensure that:

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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.

Safety

Turnbuckles must always have the threaded shank protruding into the body to ensurethat the load is borne over the correct length of the threaded shank.

Particular care must be taken when using ClosedBodytype 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 unsafecase is avoided.

Check for cracks & bends

Check for thread damage & bent rods

CORRECT UNSAFE

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SWIVEL HOOKS WITH SAFETYCATCHESThese allow the load to bemoved round withouttwisting and possiblyendangering slings wireropes and chains. Thesafety catch ensures thatthe rope or chain does notslip off the hook.

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CARE OF HOOKS:Fit a shackle between thelifting hook and the eye bolt toprevent the point of the hookbeing strained.The shackle will swivel toallow the sling and hook tomake a correct lift asillustrated along side andbelow.

Note: Collar eye bolts arenot designed to take hooks.

CARE OF EYE BOLTS:

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Always tighten eye bolts to

the correct position, but donot over strain them. Fit a

shackle so that the

minimum strain is imposed

when the lift is madeunless 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.

WEIGHT OF SPREADER BEAM AND

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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

manufacturersspecification.

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LIFTING APPLIANCES

LIFTING APPLIANCES

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CRANES (Tower, Mobile, Crawler.)

Identification

Hand signals Safety Procedures

Inspection

Rough Terrain(RT) All Terrain (AT)

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Crawler

Truck Crane (TC)

Crane Selection

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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 anyUnderground Hazards

RESPONSIBILITIES

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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 sufficientcapacity 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 workingarea.

Check that the area around the load to be lifted is clear and thatthe load is attached to the floor, transportation cradle or adjacentequipment.

Ensure that the escape route is identified.

THE PROCEDURE FOR SETTING UPAND WORKING WITH A CRANE

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Set up the crane as close as possible to the load , set the outriggersand 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 thanthe rigging crew are within the barricade.

Prepare the load for lifting making sure all equipment used is ofsufficient size and Safe Working Load including crane radius andboom length

Rig the load once everything has been checked float the loadmaking sure it is balanced this assists the crane to check hisbrakes and stability

When all the checks have been completed continue with the liftfollowing 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 theequipment and barricades.

WHEN WORKING WITH CRANESYOU MUSTBARRICADE THE WORKING AREA

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BARRIERTAPE

Z

A

W

E

D

Z

A

W

E

D

Z

A

W

E

D

WARNINGSIGNS

.

.

..

CONES

BARRICADE THE WORKING AREA

.

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Crane Mats

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Isolate Working Area

CRANE HOOKS

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Most cranes are fitted with Ctype 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 slingdesign.

Soft

Eye

Soft

Eye Hard

Eye

C Hook Ramshorn Hooks

IDENTIFICATION OF TYPES OF CRANE THEIR

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PARTS

Poor Ground Conditions are a Factor in

M A id t

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Many Accidents

Never attempt to make a lift

from soft or unstable ground

Poor Ground Conditions are a Factor in

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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.

Failure to Level the Crane is a

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Common Accident Cause

Just a little side tilt whenlifting a load over the rear

can become dangerous

when swung over the side.

What can happenwhen you swing

over the side!

Load radius increases when

swung over the side.

LEVELING THE CRANEThe line

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The 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

Possible Capacity Loss Due to being out of 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 %

Accurate Calculations are available from the specific, applicable Crane Manufacturers

Failure to Level the Crane is a

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Remember capacity chart ratings arebased 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 equippedas when leaving the factory.

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

DONT FORGET:

If a tipping condition is suddenly sensed

start lowering the load and retract orelevate the boom to bring the load in. Neverlower the boom and aggravate thecondition.

Common Accident Cause

The machine must be level

Many Crane Accidents are Caused by

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y y

Poor Blocking Under Floats

Many Crane Accidents are Caused by

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Poor Blocking Under Floats

USE SOLID BLOCKING

UNDER ALL FLOATS

THE CRANES 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.

S t O t i C tl

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Set Outriggers Correctly

S t O t i C tl

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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 beamspartially retracted, reduce capacities to those shown on the chart

for on rubber. Remember the machine must be level.

DONT OPERATE WITH ONLY REAR OUTRIGGERS EXTENDED. If

you swing over the side, the machine may tip over, or the boommay be damaged from side loadings because the machine is not

level.


S t O t i C tl

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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.


S t O t i C tl

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HYDRAULIC OUTRIGGERS:

When setting hydraulic outriggers make sure that

the outriggers are set evenly otherwise severe

twisting of the cranes chassis frame will result.


Exceeding the Rated Capacity of any

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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!

Spreads out the load so the supporting surface can support it

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Transmits the load without bending or breaking

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WRONG

Setting Up and Parking

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Do not set up too close

to trenches etc., as the

machine vibration can

cause the walls tocollapse.

Setting Up and Parking

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WRONG

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WRONG

Know Conditions and UsePrecautions

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Ensure Handbookand Chart are with

Crane

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Required Clearance for Operations near

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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

During Thunderstorms and Lightening STOP

Work and retract/lower Boom

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Mechanical

Advantage

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g

WrongCorrect

MECHANICAL ADVANTAGE

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MECHANICAL ADVANTAGE

Wedge Socket

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Two Block Cutout

Know The Radius Of The Load

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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 WHENA LOAD IS LIFTED.

MEASURE THE LOAD RADIUS BEFORE

MAKING CAPACITY LIFTS.

o e ad us O e oad

Always Ensure

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Always Ensure

that the Hook

has got a

Safety Catch

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Never let the

Boom touch a

Structure

It

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Might

Cause

the Boom

toCollapse

Or Damage

Use Taglines

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Always Stand Clear

of Suspended Loads

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Never Let Anyone Ride on a

Suspended Load

IDENTIFICATION OF CRANE HAND SIGNAL

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The Users Responsibilities

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Rigger

Crane

Operator

Protecting Rigging From

D E i t

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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!

Lifting Operations Procedure(Cont.)

Lif i i l i

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Lifting operation planning:

Planning shall basically contain and consider the followingsteps:

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


Ground stability

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G y When planning a lift, consideration must be

given to the ground conditions. Outriggers

Sound timber packing or metal plates shallbe positioned under each outrigger pad /

Crawler to distribute the load.These should be aminimum of 3 timesthe area dimensionof the outrigger pad.


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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 mountedin each crane.


Lifting Equipment

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g q p The lifting equipment operator shall not begin

the machine movement, until the banks-man iswithin his range of vision, or in radio contact,and the signal is given and understood.

Where several individuals are involved, thecrane operator shall obey the signal of thebanks men ONLY.The only exception shallbe in the case of an emergency,when the crane operator canreceive the Emergency StopSignal from anyone


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Restrictions to crane operations

The most common restriction to liftingoperations is bad weather, specifically highwind.

However, No lifts will be permitted at windspeeds exceeding 30 Knots or 35 Miles perhour.

When working in close proximity to overheadelectric lines or cables, the crane shall not bepositioned closer to the plumb of the nearest

line or cable than a distance equal to the lengthof the crane Jib fitted, plus 6 meters measuredalong the ground.


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Communication

An effective communicationsystem shall be in place for all

lifting operations. The type of system will dependon the nature of the task i.e.,radio communication may benecessary when visibility

between the crane operator andthe Banks-man is restricted.


Color Code System

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y

The Color Code System shall be developed andimplemented 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 prominentlocations at each work site where it is

anticipated lifting operations will take

place.


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Lifting Operations Check List

A Risk assessment shall be conducted prior to

any lift being performed.

The lifting operations check list acts as areminder and guidelines to the personnel

concerned, and basically consists of the items

shown below and listed in the Lifting Operations

Procedure.

CRANE OPERATION ANALYSIS

"our plan for a safe job"

Crane: Date: Time:

Crane has been inspected/ safe condition:.YesNo

Job Location:

Job Description:

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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 No

Is operators certification card current? Yes No

Critical lift permit required for this lift? Yes No

Crane level/outriggers fully extended? Yes No

Is the rigger qualified for this task? Yes No

Is sling/hardware in safe condition? Yes No

Sling sizing/hookup reviewed? Yes No

Do sharp edges have softeners?

Yes

NoTag lines needed to help control load? Yes No

Center of gravity of load located? Yes No

EMERGENCY INFORMATION

What is the wind direction?

Reviewed emergency alarms/phone numbers Yes

Escape route(s):

Location of eyebath/shower station:

Our evacuation assembly point is:

Operator Signature:

Rigger Signature:

Signalman Signature:

Supervisor Signature:

RIGGING PLAN

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RIGGING COMPONENTSList each component

Slings

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Type Hitch Cap. Sling Angle Actual Cap.Sling 1Sling 2Sling 3Sling 4

Shackles

Size CapacityShackle 1Shackle 2Shackle 3Shackle 4

Other Devices:

Description Capacity

rigger

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