Rigging & Slinging Safety

(Lifting & Supporting Load)

Faculty: Satishkumar Nair

Assisted By: Vishal Salunkhe

Vijay Parse
Important information

• Emergency exits
• Evacuation brief
• Sessions
• Mobile phones
• Rest rooms/breaks
• Any other issues
Course Overview

The “Rigging & Slinging”- Basic course is in two parts:-

1.Theory – class room
2.Practical -- field activity
The participants will be provided with the required
information and technical skills necessary to execute a
safe lift..
 ASSESSMENT METHOD

• Written and/or oral test conducted by the

facilitator. Must qualify with minimum score.(70%)
• Field Exercise –Participants will be assessed
during the field activity.(70%)
Course Contents

• Section1
– Safety Culture • Section 4
– Hooks
• Section 2 – Eye Bolts
– Lifting devices – Shackles
– Wire ropes – U-Bolt clamps
– Slinging Theory – Pad Eyes
• Section 3 • Section 5
– Wire Rope Slings – Signalman
– Web Slings (Dogman)/Banksman
• Section 4 • Section 6
– Field Training
Section 1

– Safety Culture
 Responsibilities for employers
• Safe workplace : PPE, Warning signs, hand rails, First
Aid Station or Medic.
• Safe Work practices : Work practices are steps we
take and methods we use to carry out a job.
• Training.
• Information and Alerts.
• Supervision.

7
 Supervision

• Supervision is Important

• Supervisors must Set

the example

• Supervisors must get

First-hand Information.
 Boss !

I think there is a small water leak in front of the

excavator

I installed a pump to get rid of it.

Water leak
Water leak
 Boss !!!

There is a strange Groaning sound from behind

the water leak??!!
Why didn’t you tell me this
before?
 Safety-Responsibilities for employees

• Work Safely, and ensure the safety

and well-being of all other employees.
• Report all accidents and near-hit
incidents
• Do not interfere with or misuse any
safety equipment or safety signs.
• Co-operate in carrying out any health
or safety measures introduced into the
workplace.
• Know your Equipment
• Take care of the Equipment
Section 2

– Lifting devices-definitions & examples

– Wire ropes
– Slinging Theory
Rigging & Slinging Course
Lifting Devices

Classification:

LIFTING MACHINES

LIFTING TACKLES
Definition-Lifting Machines & Tackles

LIFTING MACHINE
• An appliance, which actually effects the lift and
movement of the load.

LIFTING TACKLE
• Are appliances used to connect a load to a
Lifting Machine but itself incapable of providing
any movement to lift or shift the load.
Lifting Machines

• Chain Pulley Blocks

• Hoists
• E.O.T. Cranes
• Mobile Cranes
• Fork Lifts
Lifting Tackles

• Wire Rope Slings

• Chain slings
• Web Slings
• Hooks
• Shackles
Lifting Tackles

• Eye Bolts
• Plate Clamps
• Spreader Beams
• Man Basket
 Wire Ropes

All wire rope is manufactured with three basic

components: Wires, Strand and Core
Wire Rope Construction

• Wire rope is manufactured with individual wires which

are helically laid together to form a strand.
• Individual strands are then helically laid on the core
to form a wire rope
• The number of strands and wires in a wire rope will
influence the flexibility of the wire rope.
Wire Rope Core

WIRE STRAND CORE IWRC

FIBRE CORE

Wire ropes are supplied with either a fibre core or steel core.
The core provides the stability (foundation) to the outside
strands and several different types are available:
WIRE ROPE LAY
Non-rotating Wire Rope

• Wire rope will tend to spin or rotate under

load. Therefore it is important to determine
if a rotation resistant wire rope is required.
• Inner & outer layers oppose line twisting.
 Wire Rope Construction

6 x 19

One Rope Lay: A rope lay is the length along the

rope in which one strand makes a complete
revolution around the rope. May be termed as the
pitch of the wire rope ( like pitch of a screw)
One Lay Length
Rope Construction
 Wire Rope Construction

• The number of strands and wires in a wire rope

will influence the flexibility and abrasion
resistance of the wire rope.
Pre-forming

Pre-forming is the process in which each individual

strand and each individual wire is permanently formed
in the helical shape it will assume in the finished wire
rope. This process causes the strands to lay in place
and removes the tendency of wires and strands to fly
apart when cut.
Non-Pre-formed Wire Rope

– When this type of wire is cut, it just

opens out and doesn’t lay together
like preformed wire.
– Essential the ends of wire to be cut
are well secured BEFORE the wire is
cut !

• Very rare to find now.

Wire Rope End Termination
 Wire Rope End Termination

WEDGE

SOCKET

Wedge & Socket

SLINGING TERMINOLOGY

• SWL

• WLL

• SAFETY FACTOR
Slinging Terminology

• SWL
– Safe Working Load is the load the
equipment can safely lift in the
workplace
• WLL
– Working Load Limit is the stated
capacity of the lifting equipment when
new and used under perfect conditions.
Wire Rope – Safety Factor

• For Lifting tackles it is about 5, for equipment

intended to carry personnel, it is 10.
Note :- The factor of safety shall not be
considered as “Reserve strength”. It is meant
for various contingencies like fittings clamps,
extra loads imposed due to accelerations and
impacts, reduced strength of wire due to
bending over sheave etc.
SLINGING THEORY
Applying Slings to the Loads
Direct/Vertical Hitch

In direct/vertical hitch there is no bend in the

sling
 Bridle Hitch

VERTICAL

In bridle hitch the slings make an

angle with the vertical.
Caution: sling angle cannot be more
than that given in the load chart
Sling Angle Effect

500 Kg 500 Kg 578 Kg 578 Kg 1000 Kg 1000 Kg

90 60 ? 30
?

1000 Kg 1000 Kg 1000 Kg

Included angles

• When using a multi leg sling, the

angle created between the sling
legs, is called the Included Angle.
• Sling charts generally deal with
60,90,120 degrees
• Maximum included angle shall not
be more that 120 degrees
Sling Angle Effect

Stress (pull) in each Sling = W x L

NxH
N = No. of slings L = Length of sling leg
H = Vertical Height W= Weight of load
Basket Hitch

In a basket hitch the same sling is

wrapped around the load to form a
basket.
Caution: A single basket hitch may
make the load unstable.
True Vertical Basket Hitch

Effective SWL = 2XSWL of Sling

Angled Basket Hitch

Angle % of effective sling leg

capacity
90 200
60 170
45 140
30 100
Lifting Beam

Lifting beams are designed to be loaded in bending. A

simple lifting beam will have an eye or link on the top side
to connect to the lifting machine hook and two or more
lifting points on the underside to connect to the load.
Spreader Beam

A spreader is designed to be loaded as a strut in pure

compression. It gets its name from the earliest designs
which were used, quite literally, to spread the legs of a
sling.
It could be used, for example, with a two leg sling to lift a
cable reel by its axle and hold the legs apart to prevent the
reel flanges being crushed
 Choker Hitch

The sling reeved to make a choker hitch.

The choker hitch has a better stability
since it chokes/grips the load.
Choker Hitch

NEVER
Choker Hitch Load rating

Angle % of effective sling leg

capacity
120-135 85
90-120 75
60-90 50
30-60 40
Safe-Unsafe Choking Methods

1 3

4
2
Section 3 SLINGS

• Wire Rope Slings

• Web Slings
Slings
Wire Rope Sling- PPE

• Slinger PPE
– Helmet

– Leather gloves

– Safety shoes

– Safety goggles
Basics

• Know the load weight and other tools

used to lift the load.
• Never exceed rated capacity.
• Use softeners at corners and edges
to protect both the slings and the
load.
• Plan the operation
 Weight Calculations

Weight of Load= Volume x Density

Weight (Tonnes) Volume (Cubic meter)

Density in T/cu.m
Example

Solid Steel Box Density of Iron= 8t/m3

Dimension:
L= 2.0m
W= 1.0m
H= 1.0m

Calculate the weight of the cube in tons

Weight of Box = Volume(LxWxH) X Density

= 2x1x1(m3) X 8 T/m3
= 16 T
Ans: 16 T
Density
Density of some common materials:

Aluminium 2.7 Tons/m3

Bricks ,clay common (2.5 t/1000) 1.6
Cast iron 7.2
Cement (20 bags/t) 1.5
Concrete ,wet or set 2.4
Concrete panels (steel reinforced) 3.0
Petrol 0.7
Earth ,loose 1.8
Glass 2.6
Hardwood 1.1 to 1.4
Lead 11.3
Road metal (crushed rock) 1.9
Sand dry 1.7
Sand wet 1.9
Softwood (average) 0.6
Steel 8.0
Water , fresh(1 kg per liter) 1.0(1000 lit / M3)
Scaffold tubes, (4.9 mm thick) 0.5 kg/M
 Sling Eyes
• STANDARD SLING-EYE SIZE:
• Length of eye =16x wire rope diameter (L=16xD)
• Width of eye =8x wire rope diameter (W=8xD)
• Length between the eyes is called the STANDING PART.

Length of Sling

Standing part
Thimble

Ferrule
Wire rope Sling-Advantages

• Lower price (compared to

chain slings)
• Lighter than chain slings.
• More durable than web
slings.
• Damage is easy to see.
Disadvantages

• More difficult to work with than chain slings.

• Kink (deform) easily.
• Difficult to store.
• Higher strength loss when choked on square
loads.
Sling Inspection Criteria
 Sling Inspection Criteria

Six(6) randomly distributed broken wires in one lay

length
 Sling Inspection Criteria

Four(4) broken wires in one strand in one lay

length.
Sling Inspection Criteria

Wire Rope/ Sling localized wear or defects

Sling Inspection Criteria

Wire rope/sling deterioration from

rust/corrosion
Sling Inspection Criteria

Deformations
Sling Inspection Criteria

Core protrusion.
Sling Inspection Criteria

Cracked, deformed or worn end attachments

Sling Inspection Criteria

• More than 1 broken

wire in vicinity of a
zinced-on or swaged
fitting, including resin-
poured sockets
• Indication of strand or
wire slippage in end
attachments.
Sling Inspection Criteria

Defective or damaged fittings, ferrules or splices. No

SWL indicated on ferrule.
Sling Inspection Criteria

Loss of diameter not to exceed 10% for 6 strand, or

3% for non-rotating, of the nominal diameter.
Vernier caliper

The vernier caliper should not be used to measure

the outside diameter of a cylinder having a radius
greater than the depth of the caliper opening.
Sling Inspection Criteria

• Welding a suspended job

• Slings stored near heat source
• Slag from gas cutting
• Cutting wire rope with gas

Thermal damage
Flat-Web Sling
Type of Web Slings

Endless/Looped
Flat-Web Sling Capacity

• The capacity of the

sling shall be clearly
marked on the label
• Most manufacturers
also use the thread
marking system as
shown.
Web Sling

Advantages
• Light Weight
• Absorbs Shock
• Minimize Spinning & Twisting
During Lift
• Non Sparking (non-metallic
slings)
• Flexibility: Moulds to the Shape
Of The Job
• Does Not Rust / Corrode (non-
metallic)
• Less Tendency To Mar Or
Scratch Finely Polished Surface
• Minimizes slipping of job
Flat Web Sling

Disadvantages:

One major disadvantage of the woven

webbing sling is that when used to lift loads
such as concrete slabs, grit can penetrate
the sling causing internal fiber damage ,
which is not always obvious. Because of
this weakness , the safety Factor for
these slings are as high as 7or 8
Web Sling

Don’ts
• Never drag the sling along the ground
• Never drag over sharp or rough edges
• Never use the slings near welding or flame cutting
operations
• Never knot the sling
• Never store slings in direct sunlight
Web Sling Inspection
Web Sling Inspection
Web Sling Inspection
Web Sling Inspection
Web Sling Inspection
Wear Pads
Tag Lines

Ensure that taglines are

attached to all lifts , more than
one tagline may be required on
long or awkward loads.
•Use cotton/manila rope
•Use appropriate knot
•Never wrap around your
body or arms
•Avoid tripping on excess
rope length
Note: Min dia of tag line
=10-12mm
Section-4

Chain Pulley Block (CPB)

&
Winch
Chain Pulley Block

• Was the most

extensively used
lifting machine
• IS: 3832 – 2005
(Third Revision)
Chain Pulley Block

TYPES
• Worm & Worm wheel
type.
• Spur gear / Triple
gear type.

Spur gear type is most

widely used.
Chain Pulley Block

Salient Features

• Easy to handle and maintain

• Simple in construction
• Cheaper in cost.
Chain Pulley Block

• CPB is composed of :
– a chain guide case which
guides the chain, maintains it in
the correct position and protects
the chain wheel,
– treated steel mechanisms :
shafts, cogs, sprockets,
– a lifting pulley
– lifting and suspension hooks in
steel alloy with safety latch,
– an automatic self locking brake,
– a lifting chain,
– a galvanized maneuvering
chain.
Safe Use Of Chain Pulley Block

• Never Overload in excess of

the SWL marked on the CPB
• Never use a load chain as a
sling i.e. by back hooking.
 Ensure that there is no twists
 Twist can arise from the
bottom block being
accidentally turned over.
Safe Use Of Chain Pulley Block

 Keep Load chain lubricated and free from dirt

 If Load chain
 a) jumps the load wheel
 b) does not work smoothly
 c) makes noise then;
 It is probably out of pitch, and should be
replaced.
 CPBs are designed for lifting loads Vertically
 Never use for pulling load Horizontally or at
an angle beyond 30 deg !
Safe Use Of Chain Pulley Block

 Never run load chain out too far

 Replace chains with those of the
appropriate grade
 Check the suspension structure,
trolley, method of fixing the top
hook, for adequate strength to
support the load and the CPB.
 Never lift more than the Lifting
Capacity of CPB
Note: Anchor Point
Minimum 2 times the Lifting Capacity of the CPB
Unsafe use of Chain Pulley Block

Spot unsafe condition

Unsafe use of Chain Pulley Block

Lifting cap

• Always use the correct size hook for the lift

Wrong way of Sling Leg Shortening

• Do not Knot the Sling

• Do not Twist the sling
• Do not use bolt
Chain Inspection
Chain Sling Inspection

• Chain slings are designed

for rugged, lasting service,
precautions should be
observed to extend the
product's useful life.
• Regular inspection and care
should be taken for safe use
of all chain sling and its
products.
Inspection of Chain Pulley Block

Every Month:( Visual)

• External condition
• Condition of mechanism
• Check that the loading chain and attachments are in
good condition
• Check the hooks are in good conditions
• Check the condition of accessories
• Check that there is no dust
Every Six monthly: (In-depth)
• Correct operation of the brake
• See that the sheave is in good condition
• Check for wears
Chain Inspection

Stretch
Links tend to close up and get longer
Chain Inspection

• When new, measure the length of chain.

• Re-measure the same section after use to determine amount of
stretch or,
• Use a Vernier Caliper to calculate the stretch in individual links
Chain Inspection

• Wear exceeds 10% of a link diameter

Chain Inspection

• Cut, nicked, cracked, gouged, burned, or

corrosion pitted
Unsafe use of Chain Pulley Block

• Never overload a chain

block, if it takes more
than one person to
operate the hand chain,
there must be a problem
either with the chain
block or the load could
be heavier than expected
WINCH SAFETY
WINCH USE & SAFETY
• MOVING PARTS ENTANGLEMENT HAZARD. Failure
to observe these instructions could lead to severe
injury or death.
• Use a device or tool, never your hand, to keep
the winch line spooling properly.
• Always wear heavy leather gloves when handling a
wire rope, and never let wire rope slip through your
hands.
• Always stand clear of wire rope and load during
operation, and keep bystanders away as well.
WINCH USE & SAFETY

• Never use as an overhead hoist, or to suspend a load.

• Never use to lift or move persons.
• Never exceed the winch or wire rope rated capacity.
• Never apply load to hook tip or latch. Apply load to only
the center of the hook.
• Never use a hook whose throat opening has increased,
or whose tip is bent or twisted.
• Never touch wire rope or hook while in tension or under
load.
• Never hook wire rope back onto itself.
WINCH USE & SAFETY

• Enclose the winch drum in a cage if practical.

• Never stand in, on, over, or in line with lines or cables
connected to winches when they are under tension. The danger
zone lies within 15 degrees of either side of a line under
tension.
• Never step on or walk over the winch drum.
• Inspect the winch system regularly for problems associated with
general or localized deterioration, cracked welds, and other
structural, mechanical, or electrical deficiencies.
• Inspect lines and cable systems regularly, including blocks,
hooks, and associated components, for signs of damage or
deterioration.
• A guard should be installed between the winch operator and
the connected cables to protect the operator from potential
whiplash.
• Never stand in the bight of a line.
WINDING

WRONG

CORRECT
 WINDING
OVERWIND

Left to right Right to left

use right lay rope use left lay rope
 WINDING
UNDERWIND

Right to left Left to right

use right lay rope use left lay rope

 FLEET ANGLE

Fleet angle
 WINDING

WARNING
• The rope should, be of such length that at the
extreme position (ie where the top and bottom
blocks are at their furthest apart) at least 5 turns
remain on the winch drum. This is to prevent any
load being transferred to the rope anchor, which
is not a load bearing component.
Section-5 Lifting Tackles

• Hooks
• Shackles
• Eye-bolts
• U-bolt clamps
• Pad -eyes
Hooks
Hook Parts

• Back
• Saddle
• Toe
• Safety Latch
• Throat
• Neck
• Shank
Hook Loading

• Never Load the Toe of the Hook

Hook Loading

• Tip loading of hook severely reduces its load

carrying capacity (in the extreme by 60%)
Hook Inspection
1. Check for distortion
2. If hook has opened
by more than 1/5th
of original
dimension destroy it.
3. Examine carefully
for cracks, cuts,
dents and corrosion
pits.
4. Swivel hooks to
rotate freely. Nut
securing hook to
trunnion, should be
split pinned or
otherwise secured
5. Always use hooks
with safety catches.
Make sure they
operate freely
Defective Hooks

• Saddle wear should

not be more than 10%
of original thickness
Defective Hooks

Twist not more than 100

Defective Hooks

• Throat opening not more than 15% of original

Hook Inspection
Eye Bolt

Dynamo Collared
Swivel
Application of Eye bolts

• Dynamo eye bolt for vertical lifting

• Collar eye bolt for angle lift of maximum 450
• Swivel eye bolt for vertical and horizontal lifting
Eye Bolt

Gap

• There shall be no gap between the base of

eye bolt and surface.
Swivel Eye Bolt

• Higher version than dynamo & collar eye bolt

• Adjusts to the direction of pull
• Vertical to horizontal and vice-a -versa
Swivel Eye Bolt

The two main advantages are that:

1. They will swivel to the correct
orientation
2. They pivot to suit the sling angle
between 0o and 90o and do NOT
require to be derated.
3. As with collar eyebolts, ensure the
bushing flange is in full 360o
contact with the surface of the
load.

NEVER replace the bolt with a

standard bolt as the assembly
would likely fail thereafter.
Safe Use of Eye Bolts

• Bending of collarless bolts leads to severe

reduction in load carrying capacity.
• Collared bolts must come in complete contact
with the surface of load to take any bending
stress.
• As far as possible shackles should be used
along with eye bolts and tip of hook should never
be inserted.
Eye-bolt Inspection

• Examine for damaged

threads.
• Check type of thread
• Shoulder or collar should
be flat, free of damage
and at right angles to the
threaded portion.
• Check center line of eye
is central with threaded
portion.
• Examine for cracks, cuts,
dents and corrosion pits.
• Check for eye wear; if
1/10th or more of original
diameter, destroy it.
Shackles

• Anchor Shackle
• Chain Shackle

– Round Pin Shackle

– Screw Pin Shackle
– Bolt - Type Shackle
Anchor/Bow Chain/DEE

What is the difference?

Allowable Force Components

THREE OR MORE
COMPONENTS
Bow shackle

TWO COMPONENTS
Dee shackle
Don’ts

• The shackle pin shall

never be replaced with
a bolt.
• Only proper fitted pin
should be used
• Do not use screw pin
shackle if load can
unscrew the pin.
Inspection of Shackles

• Check cracks, bending

& twisting of bow
• Check wear and
straightness of Pin
• Check if Pin is seated
properly
• Check leg opening
width
• Check wear on the
entire shackle
Dos & Dont’s

1. Use the right type of shackle for the job

2. Check SWL
3. Color code and SWL must be present
4. Examine bow and pin for damage or distortion
5. Check bow and pin for excessive wear. Destroy
when wear is 1/10th or more form original.
6. Make sure pin is free, but not loose, in tapped
hole
7. No thread damage
8. Check alignment of holes
9. Pin should be free to rotate when nut is tight
10. Sound shackles, they must have clear ring
11. Use split pin where required, not welding rod
12. Don’t use shackle where pin can unscrew by
rolling under load
U- Bolt (Bull dog) Clamp
Right or Wrong
Right or Wrong
 Right

• The saddle must always be fitted to the “LIVE”

part of the rope.
IS 2361-2002
Fist clamp or double grip clamp

• Both the live end and dead end are seated on

the saddles
Rules to use clamps

• Saddle must be close to

the size of the wire rope
• How many clamps should
be used
• Spacing between clamps
is equal to 6 times the
diameter of wire rope
• Bolts must be equally tight
 Rule to use the clamp

The minimum number of clamps-depends on the wire rope diameter and the
core.
– Fiber core
5 to 12 mm diameter 3 clamps
13 to 16 mm diameter 4 clamps
17 to 25 mm diameter 5 clamps
26 to 35 mm diameter 6 clamps
36 to 50 mm diameter 7 clamps
Above 50 mm diameter 8 clamps

– For steel core (WSC/IWRC) add 1 clamp to the above value

Rule to use the clamp

As per IS 2361-2002

• Upto & Including 20mm diameter - 3 Nos

• Over 20mm upto & including 32mm- 4 Nos
• Over 32mm upto & including 38mm- 5 Nos
• For 41mm -6 Nos
Torque table u-bolt (bulldog) clamp

• All personnel using a torque wrench must be competent in

the use of the torque wrench and the correct settings for the
job in hand, and have completed training as required
Pad Eyes
Usage

• Alternative to eye bolts

• Certification required
(SWL, certificate number)
• Use correct size of
shackles to avoid high
stress due to point
loading
• Construction – profile
should be smooth, free
from any flame cutting
marks and the hole
should be drilled after
fitting of cheek plates.
Loading Method

• Make sure the load is applied “ in-line” only.

• Do not apply side loads
Non-standard Pad Eyes
Section-4 Signal Man or Banks Man

• Signal man/Dog man or Banks man

Signalman/Dogman (Banksman)

• The Banksman controls the initial lifting

of the load and its final positioning on the
landing area or site.
• He shall be assisted in each lift by the
Slinger who also acts as the load
handler.
Signalman/Dogman (Banksman)

• The Banksman and Slinger shall discuss each

lifting program with the Crane Operator
• Ensure that each understands the sequence
relative to the priority of the lifts.
• Problems that are known or that may occur.
• The methodology to achieve a safe and efficient
lifting operation.
Signalman/Dogman (Banksman)

• The STOP signal can

be used by anyone,
you do not have to be
involved in the lifting
operation.
Signalman/Dogman (Banksman)

• EMERGENCY STOP
• Use both hands to tell
the Crane Operator
the urgency to stop
the load.
Signalman/Dogman (Banksman)

HOIST/LOAD UP HOIST/LOAD DOWN

Signalman/Dogman (Banksman)

Swing Right Swing Left

Signalman/Dogman (Banksman)

Boom Up Boom Down

Signalman/Dogman (Banksman)

Hoist-up Slowly Hoist-down Slowly

Signalman/Dogman (Banksman)

• Hoist Slowly/
• Boom Slowly/
• Slew slowly
Signalman/Dogman (Banksman)

BOOM IN BOOM OUT

Signalman/Dogman (Banksman)

MARCH FORWARD MARCH BACKWARD

Signalman/Dogman (Banksman)

DOG EVERYTHING
(Hoist up, Retract boom, put in
saddle)
 Signalman/Dogman (Banksman)

• Always use clear and distinct signals

(either by hand or by radio) to control
lifting operations
Any Questions?