Lifting Equipment

& Operations
(Safety &
Inspection)

DESCON

Warm up Discussion

What are the major hazards of

Lifting Operations & Lifting
Equipment?
How can we control these?

Lets see some pictures of Crane Accidents.

For each of these pictures, ask yourself if
these were preventable.

 Were these
accidents
preventable?
How can we
avoid them?

Avoiding Crane Accidents

4 Key Elements
Equipment Reliability
Personnel Competence
Pre-planning & Risk Assessment
Job Supervision & Safe Execution

Establishing Where we are

Self Evaluation

Quiz
1.Crane capacities are generally greater
over the:
a. front
b. rear
c. right side
d. left side

Quiz
2.When setting a crane up on outriggers,
the wheels of the crane should:
a. just touch the ground
b. be as high as possible off the ground
c. be just high enough off the ground to
relieve the tires of crane weight
d. stay firmly on the ground to support the
crane

Quiz
3.What is the difference between Working
Load Limit (WLL) & Safe Working Load
(SWL) of any lifting equipment.

Quiz
4.The operator can leave his seat with a
suspended load only if the machine is in
perfect condition & all brakes are set.
true
false

Quiz
5.When lifting with cranes in general, as
the lifting radius increases, the lifting
capacity:
Increases
decreases

Quiz
6.The lifting capacity of a mobile crane
increases with:
a) An increase in the load radius.________
b) An increase in the boom angle
________
c) An increase in the boom length_______

Quiz
7.The cranes stability is effected by:
a) Quadrant of operation ______________
b) Projection / Extension of outriggers____
c) Leveling of the crane _______________
d) Condition of the crane hook._________

True or False
A mobile crane generally has a higher lifting
capacity on its outriggers than on its wheels.
Timber blocks placed underneath the outrigger
pads should have at least 3 times the area of the
outrigger pads.
The lifting capacity of a 2 legged bridle sling
increases as the included angle between the two
legs increases.

Basic Principle of Lifting

All cranes use levers & fulcrums

Remember Archimedes!

Lifting Equipment
Lifting equipment consists of two sets of items:
Lifting Appliances: (devices for raising / lowering)
Cranes, Forklift Trucks, Powered Hoists, Manual Hoists, Lever
Hoists, Rope Hoists, Beam Trolleys, Winches, etc.
&
Lifting Accessories: (for connecting load to appliances)
Wire Rope Slings, Chain Slings, Man-made Fiber Slings, Hooks
and Fittings, Shackles, Eye Bolts, Wedge Sockets, Plate
Clamps, Scissor Clamps, etc.

CRANE KINETICS

Cranes Centre of Gravity

Cranes Tipping Axis

Leverage

Stability

BASIC CRANE MOTIONS /

MOVEMENTS

BOOM / JIB
- UP / DOWN
HOIST
- LOWERING / RAISING
SLEWING / SWINGING - LEFT / RIGHT
BOOM EXTENSION / RETRACTION - IN / OUT
Travel
FORWARDS / BACKWARDS

Safety Devices
Jibbing Up
Limits to prevent the jib or boom coming into contact with the back
stops.

Jibbing Down
Limits to prevent the jib angle becoming less than approx. 15 degrees
to the horizontal. (this limit can be overridden to allow parking of the jib
in the rest or other maintenance work).

Hoisting
Limit trip to prevent the hook block being pulled through the sheaves.

Lowering
Limit trip to prevent running the hoist rope completely off the drum
which would cause the loss of the rope & hook (& load).

Slewing
Limits sometimes fitted but care still has to be exercised by the
operator & signal man / rigger.

Boom Extension
Limits maximum extension

Safety Devices
In addition to the limit trips:
Safe Load Indication (SLI) with visual and / or
audible alarms
Gross Overmoment (Overload) Protection
(GoP)
Wind Speed Indicator (Anemometer)
Wind Direction Indicator (Wind Sock)

WEIGHT MEASURES

US Ton (Short Ton) = 2000 lbs = 909 kg

Metric Tonne (Te) = 2204 lbs = 1000 kg
British Ton (Long Ton) = 2240 lbs = 1018 kg

LIFTING RISK ASSESSMENT

Five Components of Lift Assessment
1. Load
2. Equipment
3. Task
4. Environment
5. Personnel

LIFTING
LIFTING
RISK OPERATIONS
ASSESSMENT
1. Load

Weight,

2. Equipment

Geometry,

3. Task

Center of gravity,

4. Environment

Lifting lugs / eyebolts,

5. Personnel

Fragile,
toxic, explosive, etc.

LIFTING
LIFTING
RISK OPERATIONS
ASSESSMENT
1. Load
2. Equipment
3. Task
4. Environment
5. Personnel

Specifications.,
Tested,
Certified,
Safety devices functional

LIFTING
LIFTING
RISK OPERATIONS
ASSESSMENT
1. Load
2. Equipment

Hoisting,

3. Task

Lowering,

4. Environment

Swinging,

5. Personnel

Transporting

LIFTING
LIFTING
RISK OPERATIONS
ASSESSMENT
Ground,
1. Load

Weather,

2. Equipment

Winds,

3. Task

Visibility,

4. Environment

Congestion,

5. Personnel

Maneuverability,
Overhead lines.
Simultaneous
Operations

LIFTING
LIFTING
RISK ASSESSMENT
OPERATIONS
1. Load
2. Equipment

Trained,

3. Task

Competent,

4. Environment

Certified

5. Personnel

Lift Categorization

Lifting Operations

Routine Lifts

Simple Lifts

Non-Routine Lifts

Complicated Lifts

Complex Lifts

ELECTRICAL CLEARANCES
OPERATING NEAR HIGH VOLTAGE POWER LINES
Normal Voltage (Phase to Phase)

Minimum Required Clearance

Up to 50 kV

10 ft (3.05m)

50 to 200 kV

15 ft (4.60m)

200 to 350 kV

20 ft (6.10m)

350 500 kV

25 ft (7.62m)

500 750 kV

35 ft (10.67m)

750 to 1,000kV

45 ft (13.72m)

IN TRANSIT WITH NO LOAD AND BOOM LOWERED

Normal Voltage (Phase to Phase)

Minimum Required Clearance

Up to 75 kV

4 ft (1.22m)

75 to 150 kV

6 ft ( (1.83m)

150 to 345 kV

10 ft (3.05m)

345 to 750 kV

16 ft (4.87m)

750 to 1,000 kV

20 ft (6.10m)

CRANES LOAD CAPACITY

Configuration of the Crane
+

Quadrant of Operation

Boom Length

Boom Angle

Load Radius

Deduction of Gross Weight

------------------------------------------------=

Load Capacity

CRANE LOAD CHART

Upper part
strength
Bottom part stability

Gross Capacity Vs Net Capacity

The capacities listed in the load are not the loads
that can be suspended from the crane hook. The
figure given in the charts are gross capacities.
The weight of the actual load that the crane can
lift is the net capacity.
The gross loads include the weight of everything
mounted or stowed on the main boom, as well as
hanging from the boom tip.
GROSS CAP - CAP DEDUCTIONS = NET CAP

Determining Parts Of Line, Weight Of Line

And Sizing The Hook Block
Hoist rope is not usually built into the load chart,
the operator must ensure before any lift is made,
not only that the crane has sufficient net
capacity to lift the load but also that it is rigged
with enough parts of line to lift the load
without breaking the hoist rope.

To Calculate Parts of Line

Add: load weight + Weight of hook block + Weight of slings & rigging hardware
= Suspended weight

Divide:

Suspended weight

Safe working load of hoist rope

Answer = parts of line required

The figure calculated indicates how many parts of line are required to
support the lift. This number also determines the size & weight of the hook
block that must be used, (because of the number of sheaves required)

CRANE SET-UP
Ground condition
Entry & exit
Maneuverability
Weather conditions & wind speeds
Crane leveling
Area cordoning off (Danger zone)
Overhead clearance
Overhead or buried utilities (Pipes, cables, equipment, etc.)
???

CRANE SETUP
Proper & Improper Blocking

At least 3 x larger in area than the float

PRE-USE INSPECTION

Hooks Inspection

Deformation any bending or twisting

exceeding 10 deg. (or as recommended by the
manufacturer) from the plane of the unbent
hook.

Hook

Hook pulley block

Sheave Groove Contact

A proper fitting sheave groove should
support the rope over 135 - 150
degrees of rope circumference.

Cable Drum Shaft & Bushing

Drum, cable & brake ratchet

The Driver/Operators Cabin

Never saddle a dead horse!!!

Right way of using rope clips

U- bolt clips should be on dead end of rope, and the

saddle on the live side

Wire Rope Clips

Clips should be spaced at least 6 rope diameters
apart
Number of clips required varies with diameter
1/4' - 7/16'

2 clips

1/2' - 5/8'

3 clips

3/4' - 1'

4 clips

1 1/8' - 1 1/4

5 clips

Clips should not be used to make slings!

Rope Nomenclatures

Rope Lay

The length along the rope in which one strand

makes a complete revolution around the rope.

Wire Rope Inspection

Rigging
Corrosion
Kinks
Electric Arc
Metal Fatigue
Diameter Reduction

The Rope Must Be Replaced If

In Running Ropes- There are six or more
randomly distributed broken wires in one rope
lay, or three or more broken wires in one strand
in one rope lay.
In Pendants or Standing ropes - There are three
or more broken wires in one rope lay.
Any Rope Near Dead End Fittings - More than one
broken wire that occur near attached fittings such
as sockets, are usually the result of fatigue
stresses concentrated in these localized section.
This should be caused for replacement or the
rope

SAFE RIGGING
PRACTICES

SLING CAPACITIES

Sling dia
Sling material & type
Type of hitch
Type of end fitting
Angle of lifting
2-leg, 3-leg and 4-leg bridles

TYPES OF HITCHES
VERTICAL
BRIDLE
BASKET
CHOKER

xxxxxxxxxxxxxxx

Type of end fitting

Mechanically spliced
Socket or swage type
Hand tucked eye spliced

or Mechanical splice

Hand-tucked splice

Poured Socket or Swage type

Wire Rope Capacities

Wire Rope Capacities

SAFE RIGGING VIDEO

OVERHEAD ELECTRIC TRAVELLING CRANES

Overhead Traveling Crane

Overhead Cab-Operated Crane

Overhead Floor-Operated Crane

Gantry Crane

Wall Crane

Daily Pre-operational Check

1.
2.
3.
4.

Controls & operating mechanisms for proper operation.

Hoist upper-limit switch/device for proper operation.
Hooks for cracks, deformation & damage from chemicals.
Hoist rope for significant wear, kinking, crushing, birdcaging, & corrosion. Inspection shall be made by running out
as much of the rope/chain as is necessary to visually examine
those portions that flex over sheaves, sprockets & other areas
subject to wear or abrasion.
5. Hoist chain for nicks, gouges, distortion, wear, & corrosion.
6. Hook latch, if used, for proper operation.

Daily Functional Control Check

Check isolating switch for damage (i.e.) handle

or cover broken, making it possible to expose
live parts.
In the case of a pendant operated overhead
travelling crane, the rope, cable and control
panel must be in good condition with good
mobility in all directions of travel.

Crab Examination
Structure

Check frame for loose rivets, bolts, broken welds & damage.

Crab Hoist Motor

Examine motor frame & fixings for possible defects.

Check the slip rings, brushes & brush holders for wear & ensure that they are secure with bearings in good
condition & sufficiently lubricated.

Crab Coupling Bushes

Ensure that coupling is correctly aligned with bolts & bushes in good condition & keys tight.

Crab Electro-Magnetic Brake

Examine coils & armature. If wear has taken place on the armature & laminations, it is important to
ascertain that the air gap has not been reduced to less than 0.005 or in the case of the plunger type
solenoid that no distortion of the plunger or coil formers has taken place.
Check that all fixing bolts are secure, that the spring is correctly tensioned & the brake properly adjusted,
shoes correctly balanced & linings not unduly worn. All pivots should be free from excessive wear &
properly lubricated.

Crab Gear Box

Examine for wear or damage. Where the gears are in an enclosed gearbox & an unusual noise is being
emitted indicating a possible defect then the box should be opened up for an in-depth examination
Check oil level.

Crab Examination
Crab Bearings
Check for wear, damage & proper lubrication
Crab Drum
Examine for wear, damage or cracks with particular attention to the grooves. If the tips of the grooves have been
damaged but can be considered safe for use the broken surfaces should be dressed to remove any sharp edges.
Crab Limit Switch
Remove the cover to ensure that the contacts are free from excessive wear, burning or pitting.
Lubricate all moving parts & check they are free from undue wear.
Levers & return springs should be in good condition.
Crab Load rope
Check for wear or damage. Ropes should be considered unusable when broken wires exceed 10% over a length of
eight times the diameter of the rope, if the reduction in diameter of the outside wires is 50% over the whole of the
working length or any sign of necking indicating internal damage. Ensure adequate lubrication.
Crab Bottom Block
Examine for wear in the grooves, bore of the sheave & on the crosshead. Ensure that these parts & the guard
plates are free from damage or defects.
Examine for wear in the saddle of the hook, this should not exceed 10%. Check throat opening against standard
dimension to ensure hook has not stretched or deformed.
The top nut should be securely locked.

Frequent Inspections

1. Normal servicemonthly.
2. Heavy serviceweekly to monthly.
3. Severe servicedaily to weekly.

Frequent Inspections
In addition to daily pre-operational checks:
1. Hoist braking system for proper operation.
2. Hoist rope or chain reeving for compliance with
hoist manufacturer's recommendations.
3. Observations during operation.

Frequent Inspections

Frequent Inspections

Frequent Inspections

Frequent Inspections

Any Questions