My Industrial Rigging and Cranes

BASIC INDUSTRIAL RIGGING AND CRANES
Basic Rigging
Rigging and Cranes

This Rigging and Cranes Presentation will review general rigging principles, general cranes types and components , crane safety and hand signals to direct crane operation. Click on the subject below to hyperlink to a specfic presentation.

Basic Industrial Rigging & Cranes
Industrial Rigging Cranes Crane Safety Crane Hand Signals
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INDUSTRIAL RIGGING
Basic Rigging
Objectives


Define Rigging Principles Define Loads Define Sling Angles Define Sling Safe Working Load Define Hitch types Define Rigging Equipment Define Block and Tackle Define Levers and Mechanical Advantage
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Rigging

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Hoisting and Rigging refers to the lifting and moving of loads using mechanical devices Objectives of rigging training programs: Protect personnel from injury Protect equipment from damage Protect property from damage Protect the environment from harm
Basic Rigging Principles

Rigging is the process of moving heavy loads with ropes, chains, hoists and other special tools. The equipment used for lifting and moving loads is also called rigging. Safety must be the foremost concern: any task involving airborne loads can be extremely dangerous if not handled carefully and properly.
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Definitions
Static load: the load resulting from a constant applied force or load. Working load limit: the maximum mass or force which the product is authorized to support in general service when pull is applied in-line. Interchangeable with the following terms: Working load limit (WLL). Rated working load (RWL). Resultant working load (RWL).
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Definitions
Proof load: the average force applied in the performance of a test. Proof test: A test applied to determine manufacturing defects. Ultimate load: the average load of force at which the product fails or no longer supports the load. Shock load: A force that results from rapid application of a force or rapid movement of a static load. Design (safety) factor: an industry term denoting a products theoretical reserve capability. Usually expressed as a ratio (example 5 to 1).
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Finding the Weight

The weight of the load is the first piece of information required when planning a rigging job. The first place to look for the weight is on the load itself. The weight could be found in the equipment manual or operators guide. The weight could be estimated.
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Estimating Weight
There are two ways to estimate load weight 1. Estimate the weight by comparing it to the known weight of a similar piece. 2. Calculate the volume of the load and multiply that figure by the density of the material. Example: steel weighs 490 pounds per cubic foot. 10 cubic feet of steel = 490 x 10 = 4,900 pounds.
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Basic Rigging Principles

Rigging safety involves three elements: Planning the job. Inspecting the equipment. Using the equipment properly. Planning a rigging job consists of four steps. 1. Finding the weight of the load. 2. Determining the balance of the load. 3. Checking the clearances for moving the load. 4. Selecting the rigging equipment to be used.
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Determining the Balance

Every load must be balanced if it is to be lifted safely, therefore unbalanced loads will tilt or swing when they are lifted. Some loads are much more easily balanced than others, which makes a regularly shaped load easier to lift from a point balanced above its center. Loads with irregular shapes may be more difficult to balance and will take greater care when rigging is to be done.
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Determining the Balance

Every object has a point at which it will balance perfectly. This point is call the objects center of gravity. When a load is lifted from a point directly above its center of gravity, it will remain stable. One way to find a loads center of gravity is to make a model of the load .
To find the model center of gravity, it is lifted from several points. While the model is suspended from each lift point, a line is drawn straight down from the lift point being used. Since the center of gravity always shifts so that it hangs directly beneath the lift point, all the lines will intersect at the center of gravity.
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Checking Clearances and Route

Checking clearances is the third step in planning a rigging job. Before a load is moved, the size of the load must be compared to the size of the corridors and the tight spots along the way to make sure that the load will fit. The best way to avoid mistakes is to measure the load and path to make sure there is sufficient clearance for the load and equipment being used to transport the load.
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Checking Clearances and Route

When planning the route over which a load will travel, several other considerations are as important as clearances. The load should be kept as close to the floor as possible. Loads should not be lifted over other equipment unless no other route is possible. People must be kept out of the way. Loads should never be lifted above a person.
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Selection of Equipment
Once a loads weight, balance and the necessary clearances have been determined, enough information exists to select the equipment for the job.
Rigging equipment, in general can be grouped into four categories:

Hoists and Cranes provide lift. Slings short lengths of wire rope, chains or synthetic fibers used to attach a load to a hoist or crane. Connectors hooks, eyebolts, and shackles used to link different pieces of rigging together. Adjustors load levelers and turnbuckles used to balance loads.
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Slings

Three types of fiber-line and wire-rope slings are commonly used for lifting a load are

the endless sling single- leg sling bridle slings
The ENDLESS SLING, can be made by splicing together the ends of a piece of fiber line or wire rope to form an endless loop. The endless sling is easy to handle and is frequently used as a choker hitch. A SINGLE-LEG SLING, commonly referred to as a STRAP, can be constructed by forming a spliced eye in each end of a piece of fiber line or wire rope. Sometimes the ends of a piece of wire rope are spliced into eyes around thimbles, and one eye is fastened to a hook with a shackle. With this arrangement, the shackle and hook are removable. A single-leg sling also may be used as a choker hitch. Bridle slings are usually made from single-leg slings.
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Sling Angle
When slings are to be used the least amount of tension is exerted when using vertical slings. When shorter slings are being used, their angle moves farther away from vertical, creating steeper angles and therefore more tension is produced. In extreme cases, the greater the angle, the greater the tension, causing overloading of the slings. The prevent overloading slings, their angle must be no greater than 60 degrees from the vertical.
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Sling Angle Load Examples

Examples of how sling angles affect the loading on the legs of a sling. Sling capacity decreases as the sling angle decreases
500 lbs
1000 lbs 1000 lbs 1000 lbs
500 lbs
90r
60r
45r
30r
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1000 lbs
1000 lbs
1000 lbs
1000 lbs
Calculating Sling Load

In order to calculate the load on a sling two items are needed:

Sling angle Load to be lifted

1000 lbs The following table gives the load angle calculation factor for some common angles. Use the formula Sling Load = Load x Load Angle Load in each sling = Factor 500 x Load Angle
Sling Angle Degrees 90 60 50 45 30 Load Angle Factor = L/H 1.000 1.155 1.305 1.414 2.000
Factor L H A 1000 lbs
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Load on each leg of sling. Sling = Vertical Load x Load Angle Factor
Load in each sling = L/H x 500
Sling Angle What it means basically


To gain a perspective assume that a 3/8 inch wire rope is rated for 2000 lbs in a vertical lift. In a four point lift the maximum load can then be 8000 lbs (4 tons). If the sling angle is changed to 60 degrees then the max load seen by each sling is 2310 pound and the total load seen by the slings is a total of 9240 pounds. This exceeds the lifting capacity of the wire rope. The solution would be to use a larger wire rope or reduce the load size. 2310 lbs 2000 lbs
60r
8000 lbs
8000 lbs
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Ropes and Chains

Ropes and chains are perhaps the most common of all rigging tools. They are used on hoists and cranes and as slings to attach a load to a lifting device Rope is the oldest of all tools still used in rigging. In the past, all ropes were made of vegetable fibers twisted together to make a sturdy line for lifting and hauling. Although natural fiber ropes have some use in rigging today, ropes made of synthetic fibers or wire are much more common.
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Ropes and Chains

Rope made of synthetic fibers such as nylon or polyester is often constructed in much the same way as natural fiber ropes. Synthetic fiber ropes have the advantage of greater strength and the additional characteristic of an increased ability to stretch and then return to its original size. Stretch is sometimes an advantage, since the rope can rebound from a sudden shock load without snapping.
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Rope Lays
Wire ropes can be made in several ways. Each different technique is called a lay. There are four types of ropes which are used in industry.
1. Right
regular lay. 2. Right Lang lay. 3. Left regular lay. 4. Left Lang lay. .
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Rope Lays


Right regular lay, when you look at the end of the rope the strands wind to the right, but the wires composing the strands are wound in the opposite direction. Right Lang lay, when you look at the end of the rope, the strands and the wires composing the strands are wound in the same direction. This holds true for left or right lay types of rope. Right Regular lay is the most common.
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Example of Regular vs. Lang Lay

The wires in regular lay wire rope appear to line up with the axis of Rope Axis the rope. In contrast, the wires in 1 Full Wire Lang lay wire rope LANG LAY appear to form an STRAND angle with the axis of the rope.
Rope Axis 4 Full Wires
REGULAR LAY STRAND
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Basic Factors Concerning Use of Wire Rope Slings

Rated
load (rated capacity) of a wire rope sling is based
upon the nominal strength of the wire rope attachment or splicing efficiency the number of parts of rope in the sling type of hitch diameter of the body around which the sling is bent the diameter of the hook over which the eye of the sling is rigged Rated load of a sling is different for each of the three basic methods of rigging: vertical, choker and basket.
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Basic Factors Concerning Use of Wire Rope Slings

shock load a sling. The rated load of a wire rope sling can easily be exceeded by the sudden application of force Protect a wire rope sling with corner protectors when lifting on sharp edges or corners. Increasing sling angle increases the loading of a sling. Never use a sling with an angle less than 30 degrees from the load. Visually inspect slings before use. Slings should never be used over a hook or pin with a body diameter larger than the natural width of the.
Never
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Wire Rope

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The basic component of the wire rope is the wire. It may be of steel, iron, or other metal in various sizes. The number of wires to a strand varies, depending on the purpose for which the wire rope is intended. Wire rope is designated by the number of strands per rope and the number of wires per strand. Thus an 1/2-inch 6 x 19 rope has six strands with 19 wires per strand. It has the same outside diameter as a 1/2-inch 6 x 37 rope that has six strands with 37 wires (of smaller size) per strand.
Parts of Wire Rope

Strand - The design arrangement of a strand is called the construction. Wire - the wires in the strand maybe all the same size or a mixture of sizes. Core -The wire rope core supports the strands laid around it. The three types of wire rope cores arc fiber, wire strand, and independent wire rope
Strand Core Wire
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Wire Rope Inspection

Like all rigging tools, wire rope must be inspected for wear and damage before each use. Five types of damage that must be checked for are: 1. Kinks 2. Broken wires 3. Excessive wear 4. Unraveling 5. Overstretching Core Wire Center Wire
Strand
Wire Rope
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Pictorial Example of Damaged Wire Rope
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Kinks

One of the most common forms of damage resulting from improper handled wire rope is the development of a kink. A kink starts with the formation of a loop. If the loop is pulled tight enough to cause a kink this will result in irreparable damage to the rope Kinking can be prevented by proper uncoiling and unreeling methods and by the correct handling of the rope throughout its installation.
Kink
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Loop
Kink damage
WIRE ROPE SAFE WORKING LOAD

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The term Safe working load (SWL) of wire rope means the load that can be applied and still obtain the most efficient service and also prolong the life of the rope. The formula for computing the SWL of a wire rope is the diameter of the rope squared, multiplied by 8 (D x D x 8 = SWL in tons). Example: The wire rope is 1/2 inch in diameter. To Compute the SWL for the rope. The first step is to convert the 1/2 into decimal number by dividing the bottom number of the fraction into the top number of the fraction: ( 1 divided by 2 = .5). Next, compute the SWL formula: (.5 x .5 x 8 = 2 tons). The SWL of the 1/2-inch wire rope is 2 tons.
Chains
Like wire rope, chain is used on hoists and as slings to attach a load to a hoist or crane. Chain differs from wire rope in that chain weighs more than wire rope of the same capacity.
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Chain Slings

Chain slings may also be either endless or single-leg chain slings and may have rings or hooks at each end. Some single leg chain slings have a hood at one end and an eye at the other end like any other chain.
SINGLE LEG
DOUBLE-LEG
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Chains
Chain has a lesser ability to stretch and can sometimes snap without warning. Chain has the ability to turn around tight corners without suffering undue wear or damage.. There are two different types of chain used commonly for rigging: 1. Common chain. 2. Roller chain.
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Common Chain
Common chain is constructed of interlocked welded links of forged steel. The capacity of the chain is determined by the thickness of the metal of the links. There are four different kinds of damage chains are subject to: Wear. Cracks. Stretching. Twisting.
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Chain Wear
Wear exceeds 15% of link diameter
Cut, nicked, Twisted or bent Cracked, gouged, burned, or corrosion pitted.
Bent
Twisted Stretched. Links tend to close up And get longer.
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Roller Chain
Roller chains has at least two distinct constructions. Large roller chains are usually made with side bars that flare outward between the pins causing an overlapping condition or piggy back style of chain formality. Smaller roller chains are used on bikes or motorcycles and are sometimes used on lifting devices. The links are constructed that every other link is held together with a male connector.
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Roller Chain

Roller chains are made up of roller links that are joined with pin links. The links are made up of two side bars, two rollers, and two bushings. The roller reduces the friction between the chain and the sprocket, thereby increasing the life of the unit
Roller link
Roller link plate
Pin link
Pin link plate
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Roller Chain
Roller chain must be inspected for: Cracks and wear just as common chains. An additional point is to check the security of the roller pins. Each must be attached firmly to prevent the sidebars from slipping off. The chain should be worked bad and forth to check its flexibility. If it is stiff the chain should be lubricated and cleaned.
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Slings


When loads are lifted with hoists or cranes, short lengths of wire rope, chain or synthetic fibres, called Slings are used to secure the load to the lifting device. Slings made of any of these materials can be made in either of two ways: as endless slings as single leg slings. Of all the different types of slings, wire rope slings are the most common in rigging work. Endless slings are a continuous loop with no connectors.
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Sling Eyes

Single leg wire rope slings have eyes at each end. They often contain a insert called a thimble to help retain the shape of the eye.
THIMBLE
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Seizing and Cutting

When the ends of the rope are not secured properly maximum service cannot be obtained because some strands can carry a greater portion of the load than others. Before cutting steel wire rope, place seizing on each side of the point where the rope is to be cut
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1. Wrap with small wire
2 .Twist ends together counter clockwise
4. Bend twist down against rope and cut ends 3. Tighten twist with nippers
Swaged Connection

Swaging makes an efficient and permanent attachment for wire rope, as shown below. A swaged connection is made by compressing a steel sleeve over the rope by using a hydraulic press. When the connection is made correctly, it provides 100-percent capacity of the wire rope. Careful inspection of the wires leading into these connections are important because of the pressure put upon the wires in this section. If one broken wire is found at the swaged connection or a crack in the swage, replace the fitting.
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Synthetic Fiber Slings

Synthetic fiber slings are typically made of braided nylon or polyester. Although synthetic fiber slings are light and strong, they are not as durable as wire rope or chain slings. Since synthetic slings are easily cut, special care must be take to protect them where sharp corners or rough spots are a problem. Additionally, the material may melt if it is placed near hot pipes or other sources of heat.
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Synthetic Fiber Slings

Synthetic fiber slings are made up two different ways which are very handy when it comes to rigging techniques: endless or grommet slings and single leg slings (most commonly used).
Eye
Single Leg Sling
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Fiber Sling Inspection

Fiber Sling Inspection : Tell-Tails must be visible Cover damage Heat or Acid burns No knots in any sling Damaged eyes Cuts Abraded web, faded color (UV degradation) Crushed webbing or no label
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Hitches

When using slings for rigging, there are three possible hitches that can be used with rigging techniques. They are used with both single leg and endless slings. Vertical hitches. Choker hitch. Basket hitch.
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Vertical
Choker
Basket
Verticle Hitches

Vertical hitch - The load is lifted from a single point, usually and eye on top of the load.
VERTICAL HITCH
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Choker Hitches

Choker hitches-uses single leg slings that are formed by passing one end of the sling around the load and coupling it to the upright portion of the sling with a free-running shackle or a sliding hook.
CHOKER HITCH
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Double wrapped Choker Hitches

Double-wrap choker hitches are used to give the sling an extra grip on the load. The additional wrap around the load prevents the choker from slipping along the length of the load while it is being lifted.
DOUBLE WRAP CHOKER
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Basket Hitches

Basket hitches It is similar to the cradle hitch made with endless slings. The sling passes around the bottom of the load and its two eyes are gathered together at the load hook.
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BASKET HITCH
Double Wrapped Basket Hitch
DOUBLE WRAP BASKET HITCH
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Multiple-Leg Bridle Hitch

Multiple-leg bridle hitch may be made with two, three or more legs. These hitches are made up with multiple single leg slings, which usually attaches to an eye on the load with a shackle.
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MULTIPLE - LEG BRIDLE HITCH
Sling Safe Working Load

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Formulas for estimating the loads for most sling configurations have been developed. These formulas are based on the safe working load of the single-vertical hitch of a particular sling. The efficiencies of the end fittings used also have to be considered when determining the capacity of the combination.
Bridle Hitch SWL

The formula used to compute the safe working load (SWL) for a bridle hitch with two, three, or four legs is :
H SWL ! SWL(single verticle hitch) v v 4 L

When the sling legs are not of equal length, use the smallest H/L measurement. This formula above is for a two-leg bridle hitch, but it is strongly recommended that it also be used for the three- and four-leg hitches and replace the 2 with a 3 or 4.
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Four Bridle Hitch SWL

The formula for a four bridle hitch is: H SWL ! SWL(single verticle hitch) v v 4 L
L H
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Basket Hitch SWL

Single Basket Hitch

Single Basket Hitch
SWL ! SWL(single verticle hitch) v 2

Double-basket hitch
L H
SWL ! SWL(single verticle hitch) v 4

For inclined legs:

Inclined Legs Basket Hitch
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H SWL ! SWL(single verticle hitch) v v 4 L
Choker Hitch SWL

Single Choker Hitch
3 SWL ! SWL(single verticle hitch) v 4

Double-Choker Hitch
3 H SWL ! SWL(single verticle hitch) v v v 2 4 L

Note formula only works for sling angles greater than 45 degrees. Angles less than 45 are not recommended.
Sling Angle
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Estimating Sling SWL

The purpose of the 1 2 3 4 rule in the next two slides is to provide quick guidelines for the rigger in the field. Notice how the table changes for each 1/8 inch of wire rope diameter.
The 1 2 3 4 Rule for wire rope slings

Wire Rope Dia. Vertical Hitch Choker (30%) Basket 3/8 inch 1 ton .7 ton 2 ton inch 2 ton 1.4 ton 4 ton 5/8 inch 3 ton 2.1 ton 6 ton inch 4 ton 2.8 8 ton
Basket hitch must be equal or greater than diameter of load. Choker hitch less than vertical due to kink in hitch.
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Estimating Sling SWL with Angles

Based on previous 1 2 3 4 rule table the safe working load with sling angles is a multiple of the legs if:
The sling leg length is the same as or longer than the connecting points. Thus for a 3/4 inch sling times 4 legs will equal a SWL of 16 tons. If the leg length is less than the connecting point length than the SWL is half. Thus for the inch sling times 4 legs will equal 8 tons.
Connecting points Leg
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Sling Operating Practices

Slings that are damaged or defective shall not be used. Slings shall not be shortened with knots or bolts or other makeshift devices. Sling legs shall not be kinked. Slings shall not be loaded in excess of their rated capacities. Slings used in a basket hitch shall have the loads balanced to prevent slippage. Slings shall be securely attached to their load.
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Sling Operating Practices

Slings shall be padded or protected from sharp edges to their loads. Suspended loads shall be kept clear of all obstruction. All personnel shall be kept clear of loads about to be lifted and loads that are suspended in the air. Hands or fingers shall not be placed between the sling and its load while the sling is being tightened around the load. Shock loading is prohibited.
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Connectors
Connectors are rigging attachments used to link separate pieces of equipment. The most common connectors are hooks, shackles and eyebolts. Since these attachments are basic to all rigging work, riggers need to know where they are used, how they work and how they are inspected for wear and damage.
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Hooks
In rigging work, hooks are often used as connectors on hoist, cranes, adjusters, and slings, Hooks can be connected to shackles, eyebolts, or directly to eye of a sling. In rigging there are two basic styles. Grab hooks. Eye Sling hooks.
Mouth Throat
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Grab Hook
Sling Hook
Hook Maintenance
Hooks have markings stamped in the radius of the hook casting. This is to let the rigger measure to see if the hook has been over loaded. There are also markings to help indicate the approximate included angle of the sling when hooked up to a load.
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Hook Indicators
Deformation Indicators - Two strategically placed marks, one just below the shank or eye and the other on the hook tip allows for a measurement to determine if the throat opening has changed, thus indicating abuse or overload. To check, measure the distance between the marks. The marks should align to either an inch or half-inch increments. If the measurement does not meet this criteria, the hook should be inspected further for possible damage. Angle Indicators - Indicates the maximum included angle which is allowed between two (2) sling legs in the hook. This also provide the opportunity to approximate other included angles between two sling legs.
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Hook Safety
For added safety in lifting, hooks should be equipped with safety latches whenever possible. Several different types of latches are available that prevent a sling or shackle from pulling or slipping off a hook during a rigging procedure. The most common types of latches are: Gate latch. HOOK LATCH Flapper latch. MOUSING Mousing procedure.
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Mousing


Mousing is a technique often used to close the open section of a hook to keep slings, straps, and similar attachments from slipping off the hook. Hooks may be moused with rope yarn, seizing wire, or a shackle. When using rope yarn or wire, make 8 or 10 wraps around both sides of the hook. To finish off, make several turns with the yarn or wire around the sides of the mousing, and then tie the ends securely
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Shackles
Shackles come in two basic types of styles: Screw type. Round pin type. Shackles also have three basic type of bodies: Anchor shackles. Chain shackles. Sling type shackles.
Caution should be taken when using shackles to prevent overloading them. All shackles are load rated and stamped with the working load limit (WLL). Shackles also have angle indicators on them that will help identify load angles.
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Shackles Side Load

120r
Load
NEVER EXCEED 120 INCLUDED ANGLE USE BOLT TYPE AND SCREW PIN SHACKLES ONLY
SIDE LOAD CHART (for Screw-pin and Bolt Shackles only)
INLINE 45r
Angle of Side Load (from vertical in-line) 0
Angle Working Load Limit 100% of rated load 70% of rated load 50% of rated load
90r
45 90
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Shackle Inspection
Check for Wear
Check for Wear and Straightness Check that Pin is always seated Check that shackle is not opening up
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Eye Bolts
As a rule eyebolts usually come with a shoulder and are locked into place with either a tapped hole or a nut on the underside of the frame of the bolt.
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Regular Nut Shoulder Nut Eyebolt Eyebolt
Machinery Eyebolt
Shoulder Nut Eye Bolt Installation for Angular Load

The threaded shank must protrude through the load sufficiently to allow full engagement of the nut. If the eye bolt protrudes so far through the load that the nut cannot be tightened securely against the load, use properly sized washers to take up the excess space BETWEEN THE NUT AND THE LOAD. Thickness of spacers must exceed this distance between the bottom of the load and the last thread of the eye bolt.
Direction of Pull 45 degrees 90 degrees
Adjusted Working Load 30% of rated working load 25% of rated working load
45r
90r
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Eye Bolt Inspection/Safety

Inspection/Maintenance Safety Always inspect eye bolt before use. Never use eye bolt that shows signs that it is bent or elongated. Always be sure thread on shank and receiving holes are clean Never machine, grind or cut eye bolt. Never exceed load limits specified in the following table for in-line load for eye bolts.
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Eye Bolts
Inspection/Maintenance Safety Continued Never use regular nut eye for angular lifts. Always use shoulder nut eye bolts for angular lifts. For angular lifts, adjust working load as follows. Never undercut eye bolt to seat shoulder against the load. Always countersink receiving hole or use washers to seat shoulder. Always screw eye bolts down completely for proper seating. Always tighten nuts securely against the load.
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Operating Safely
Always stand clear of load. Always lift load with steady, even pull do not jerk. Always apply load to eye bolt in the plane of the eye not at eye. Never exceed the capacity of the eye bolt. When using lifting slings of two or more legs, make sure the loads in the legs are calculated using the angle from the vertical to the leg and properly size the shoulder nut or machinery eye bolt for the angular load.
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Swivel Hoist Rings

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Swivel hoist rings were perfected by Crosby and are now commonly used to move or pick up loads. Swivel rings are fastened with an allen head type bolt and need to be torqued to proper specs.
Proper Hoist Rings Usage

After slings have been properly attached to the hoist ring, apply force slowly. Watch the load and be prepared to stop applying force if the load starts buckling
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Buckling may occur if the load is not stiff enough to resist the compressive forces which result from the angular loading.
Example Swivel Hoist Rings

Do not reeve slings from one bail to another. This will alter the load and angle of loading on the hoist ring.
WRONG
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Wedge Sockets

The wedge socket attachment is used most often to attach dead ends of wire ropes to pad eyes or like fittings on cranes and earthmoving equipment.
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NOTE: The wedge socket develops only 70% of the breaking strength of the wire rope due to the crushing action of the wedge
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Parts of a Wedge Socket
Wire Rope Clips

Wire rope clips (Crosby clips) are commonly used in the joining of wire rope or for putting a loop onto the end of a wire rope with the use of a thimble. When installing wire rope clips special attention should be take to install properly, so that the wire rope does not slip under tension.
U-Bolt Saddle
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Wire Rope Clip Installation

Always place a clip with the U-bolt on the bitter (dead) end, not on the standing part of the wire rope. If clips are attached incorrectly, the standing part (live end) of the wire rope will be distorted or have mashed spots. (A rule of thumb when attaching a wire rope clip is to NEVER saddle a dead horse.) Two simple formulas for figuring the number of wire rope clips needed are as follows: 3 x wire rope diameter + 1 = Number of clips 6 x wire rope diameter = Spacing between clips
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Installation of Wire Rope Clips

Apply u-bolt over dead end of the wire rope. Live end of the rope rests in the saddle. A termination is not complete until it has been re-torqued a second time.
Turnback 1
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Example of Incorrect Installation
Right way for maximum rope strength
Wrong way the clips are staggered
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Wrong way the clips are reversed
Spreader Bars
Spreader bars are used to distribute weight evenly over the load that is being rigged. When using spreader bars caution has to be taken to be sure that the weight being lifted does not exceed the working load limit of the bar being used. Spreader bars should be certified for the maximum load it can lift with the maximum load stamped on the bar itself.
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Spreader Bars
Advantages Distributes weight more evenly, therefore putting less stress on the rigging equipment used. When making heavier loads the weight can be controlled more easily. Spreader bars use less distance between the hook and the load. Spreader bars decrease the included angle between the load and the sling. Disadvantages When rigging lighter lifts spreader bars can be awkward to sling.
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Adjusters and Load Levelers

When an unbalanced load is lifted, sling lengths must be adjusted to place the load hook of the hoist or crane directly above the loads center of gravity. Two types of adjusters are commonly used for balancing loads: Load levelers Turnbuckles
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Sling Load Levelers

Sling load levelers allow the center point of the spreader bar to be moved thereby allowing the center lift point of the load to be shifted. In the below example the crank moves the center lift point.
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Turnbuckles

Turnbuckles are adjusters that are useful for making small adjustments in the length of a sling. Turnbuckles are made with a right and left hand thread so that when adjustments are made the turnbuckle will turn both ends in or out to make fine adjustments and level loads. A turnbuckle can also be used in any part of a lift providing that it meets the weight requirements and safe working loads. The draw back of using turnbuckles is that they only provide a very limited adjustment and cannot be used to level loads that are unbalanced.
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Turnbuckles

The turnbuckle is inspected for wear and damage, the body checked for bends and cracking, especially around the threads. When using turnbuckles for load adjustments the rigger should always secure the screwed ends with either a lock nut or by mousing the rotating ends to prevent turnbuckles from rotating.
LOCK NUT
MOUSING
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Example Turnbuckle Leveling

In the example below the turnbuckle is used to change the sling length to adjust the levelness of the load
Turnbuckle
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Chain Hoists and Come-alongs


Chain Hoists and come-alongs enable a person to lift a heavy load by multiplying muscular energy. Hoists reduce the amount of effort needed to lift a load by using a series of reduction gears. Come-alongs have levers that allow a person to raise a load lightly while swinging the handle through a wide arc. Both of these devices work providing a mechanical advantage: a reduction in speed multiplies the force exerted on the load. Both hoists and come-alongs are commonly used in rigging work.
96 96
Chain Hoist

A chain hoist works on the block and tackle principle of operation. Some are manually operated while others are operated by an electric motor.
97 97
Example Come-along
Interlocking pawl to prevent slippage Cable stores in drum Handle usually designed to bend during overload
98 98
Hoists and Come-alongs

Come-alongs (can also known as chain hoists or ratchet jacks) advantages

Light in weight Easy hook up for short pulls Short pull distance compared to chain falls Limited weight
Disadvantages

99 99
Block and Tackle

10 0 100
The push or pull a human can exert depends on the weight and strength of that individual. To move any load heavier than the amount you can physically move, a mechanical advantage must be used to multiply your power. The most commonly used mechanical devices are block and tackle, chain hoist, and winches
Fiber Line Block

A block consists of one or Hook more sheaves fitted in a wood or metal frame supported by a Outer strap shackle The sheave is a round, grooved wheel over which the line runs. Usually the blocks will have one, two, three, or Swallow four sheaves. Some blocks will have up to eleven sheaves. Sheave
Face Breach
Pea Inner strap
Shell Cheek Pin
Becket Thimble
10 1 101
Tackle

A tackle is an assembly of blocks and lines used to gain a mechanical advantage in lifting and pulling In a tackle assembly, the line is reeved over the sheaves of blocks. The two types of tackle systems are:
10 2 102
simple - an assembly of blocks in which a single line is used ( Compound - an assembly of blocks in which more than one line is used
Simple Compound
Terms Used with Tackle

The fall is either a wire rope or a fiber line reeved through a pair of blocks to form a tackle. lThe hauling part of the fall leads from the block upon which the power is exerted. The standing part is the end which is attached to a becket (metal loop at end of block). The movable (or running) block of a tackle is the block attached to a fixed object or support. When a tackle is being used, the movable block moves and the fixed block remains stationary.
Hook Fixed (standing) block Standing part Hauling part Falls Moving (running) block Hook
10 3 103
BLOCK CONSTRUCTION

Blocks are constructed for use with fiber line or wire rope. Wire rope blocks are heavily constructed and have large sheaves with deep grooves. A large sheave is needed with wire rope to prevent sharp bending. According to the number of sheaves, blocks are called SINGLE, DOUBLE, OR TRIPLE blocks. Blocks are fitted with a number of attachments, such as hooks, shackles, eyes, and rings
10 4 104
Types of Blocks

A STANDING BLOCK is a block that is connected to a fixed object. A TRAVELING BLOCK is a block that is connected to the load that is being lifted. It also moves with the load as the load is moved. A SNATCH BLOCK is a single sheave block fabricated so the shell opens on one side at the base of the hook to allow a rope to slip over the sheave without threading the end through the block.
Snatch Blocks
10 5 105
Levers


Levers are machines because they help you to do your work. They help by changing the size, direction, or speed of the force you apply. You will find that all levers have three basic parts: the fulcrum (F), a force or effort (E), and a resistance (R). Look at the lever. You see the pivotal point (fulcrum) (F); the effort (E), which is applied at a distance (A) from the fulcrum; and a resistance (R), which acts at a distance (a) from the fulcrum. Distances. A and a are the arms of the lever.
A a F
10 6 106
Classes of Levers

10 7 107
There are three classes of levers. The difference is in the relative points where effort is applied, where resistance is overcome, and where the fulcrum is located. First-class levers have the effort and the resistance on opposite sides of the fulcrum, and effort resistance move in opposite directions. Second-class levers have the effort and the resistance on the same side of the fulcrum but the effort is farther from the fulcrum than is the resistance. Both effort and resistance move in the same direction. Third-class levers have the effort applied on the same side of the fulcrum as the resistance but the effort is applied between the resistance and the fulcrum, and both effort and resistance move in the same direction.
Classes of Levers

First- and second-class levers magnify the amount of effort exerted and decrease the speed of effort. First-class and third-class levers magnify the distance and the speed of the effort exerted and decrease its magnitude.
Weight (R)
Weight (R) Effort (E) Effort (E) Fulcrum
Fulcrum
Fulcrum
Effort (E) Weight (R)
First Class Lever
Second Class Lever
Third Class Lever
10 8 108
The same general formula applies to all three types of levers:

EffortArm(L) Resistance(R) ! Resistance(l) Effort(E)
Effort Arm (L) Resistance Arm (l) Effort (E)
10 9 109
Fulcrum (F) Resistance (R)
Mechanical Advantage

Levers are used to magnify the applied force, they provide positive mechanical advantages. A third-class lever provides what is called a fractional mechanical advantage, this is a mechanical disadvantage. It takes more force than the force of the load lifted. In a wheelbarrow, a 50-pound pull actually overcomes a 200-pound weight. The workers effort is magnified four times, so the mechanical advantage of the wheelbarrow is 4.
R E
F 4
11 0 110
How many levers can you find in the loader?

11 1 111

Expressing the same idea in mathematical terms: MECHANICAL ADVANTAGE = RESISTANCE divided by EFFORT
Resistance M.A. ! Effort

This rulemechanical advantage equals resistance divided by effort applies to all machines.
11 2 112

The mechanical advantage of a lever may also be found by dividing the length of the effort arm (A) by the length of resistance arm (a). Stated as a formula, this reads:

EffortArm(A) M.A. ! ResistanceArm(a)levers? How does this apply to third-class

Your muscle pulls with a force of 1,800 pounds to lift a 100-pound object. So you have a mechanical advantage of which is fractionalless than 1.
11 3 113


A single fixed block is a first-class lever with equal arms. The arms (EF and FR) in the figure are equal. The mechanical advantage is 1. A single fixed block does not magnify force nor speed. You have to apply 200 pounds of force to keep the weight suspended.
200 lbs
200 lbs
R
200 lbs
11 4 114


If you use a single block and fall to magnify the force you exert. In the figure the block is not fixed. The fall is doubled as it supports the 200pound load. When rigged this way, you call the single block and fall a runner. Each half of the fall, EF and FR, carries one-half of the total bad, or 100 pounds. Thus, with the runner, the man is lifting a 200-pound load with a 100-pound pull. The mechanical advantage is 2.
Fall 100 lbs
100 lbs
F
200 lbs
11 5 115

11 6 116
Many combinations of single, double, and triple blocks can be rigged to give greater advantages. The number of parts of the fall going to and from the movable block tells you the approximate mechanical advantage of the tackle.
If the rule is applied by which the parts of the fall going to and from the movable blocks are counted, you find that block A gives a mechanical advantage of 3 to 1. Block B has four parts of fall running to and from it, a mechanical advantage of 4 to 1. The mechanical advantage of those obtained from A is multiplied four times in B. The overall mechanical advantage is the product of the two mechanical advantages or 12.
400 lbs 100 lbs 100 lbs 100 lbs 100 lbs
B
400 lbs 400 lbs 400 lbs
11 7 117
1200 lbs
Summary

Review Objectives Question and Answer Session
11 8 118
CRANES
Basic Crane Types and Components
119
Objectives

Define Cranes and Crane Types Define typical crane parts
12 0 120
Cranes are classified as weight-handling equipment and are designed primarily to perform weight-lifting and excavating operations under varied conditions. To make the most efficient use of a crane, you must know their capabilities and limitations.
12 1 121
Definitions

Crane Consists of a rotating structure for lifting and lowering horizontally on rubber tires or crawler treads Hoist - Used to lift and lower load. Boom An inclined spar, strut, or other long member supporting the hoisting tackle Boom stops A device used to limit the angle of the boom at its highest position Brake To slow or stop motion by friction or power Block Sheaves or grooved pulleys in a frame with hook, eye and strap Jib Extension attached to the boom point to provide added boom length for lifting specified loads.
12 2 122
Types of Cranes

The following list of cranes described are just a few of the many different types of crane application. Mobile Gantry Overhead Jib
12 3 123
Mobile Crane

The most basic type of mobile crane consists of a steel truss or telescopic boom. It is mounted on a mobile platform, which may be rail, wheeled or caterpillar tracks. The boom is hinged at the bottom, and can be raised and lowered by cables or by hydraulic cylinders.
12 4 124
Mobile Crane

12 5 125
A hook is suspended from the top of the boom by wire rope and sheaves. To increase the horizontal reach of the hoist, the boom may be extended by adding a jib to the top. The jib can be fixed or, in more complex cranes, luffing (that is, able to be raised and lowered).
Mobile Crane

The wire ropes are operated by whatever prime movers the designers have available, operating through a variety of transmissions. Some examples of this type of crane can be converted to a demolition crane by adding a demolition ball, or to an earthmover by adding a clamshell bucket or a dragline and scoop.
12 6 126
Mobile Crane Parts

Jib tip Jib or whip line
Jib mast (gantry)
Jib hook & headache ball Jib section Boom tip sheaves Main line
Equalizer or outer ball Main block or hook Inner ball Gantry Upperworks or superstructure refers to entire crane structure above the swing circle
12 7 127
Counterweight Machine deck Ring gear, turntable, swing circle
CRANE DESCRIPTION

12 8 128
PEDESTAL: a fabricated tubular steel structure which supports the crane from the deck to the turntable. It gives the crane a set height over temporary and permanent structures. Allows access to machinery spaces and the cab of the crane and houses the turntable gears.. TURNTABLE: is mounted on the upper end of the pedestal. Serves as a base for crane mast and also houses machinery spaces. Allows the crane to rotate in circular motion..
CRANE DESCRIPTION

MAST: an enclosed steel structure which supports the rigging for the boom. Provides attachment points for topping lift and hoist fairlead sheaves CONTROL CAB: an enclosed structure which houses and protects all crane operator controls.
12 9 129
HOOK BLOCK

13 0 130
A hook block on a crane is the primary unit for lifting an objector load, transferring it to a new place by swinging or traveling and then placing the load.
Sheaves

Sheaves are located in the hook block boom tip, boom bridle, gantry, and boom mast. Sheaves rotate on either bearings, or bushings, and are installed where wire rope must turn or bend. The sheave grooves must be smooth and free from surface defects which could cause rope damage
Worn sheave groove
13 1 131
Boom Angle Indicators

Boom angle indicators are normally mounted on the boom butt, visually readable by the operator. On most crane the boom angle indicator is a metal plate with degree numbers (0 to 90 degrees) and a freely swinging arm that reacts as the boom angle changes The numbers and arm should remain clean and visually readable at all time.
13 2 132
Clamshell

13 3 133
The clamshell bucket is two scoops hinged together in the center with counterweights bolted around the hinge. A clamshell consists of: hoist drum lagging (hoist drum diameter) clamshell bucket tag line wire ropes to operate holding and closing lines.
Example Clamshell Rigging Arrangement

The two hoist drum wire ropes on the crane are rigged as the holding and closing lines for controlling of the bucket. The tag line winder controls the tension on the tag line that helps prevent the clamshell from twisting during operations.
Boom point sheave Closing cable Holding cable
Sheave
Cable guide roller
Tag line Cable
Tag line Winder
Cable Drum
13 4 134
Dragline

The dragline component consists of a dragline bucket and fairlead assembly. The wire rope components of the dragline are the drag cable, the bucket hoist, and the dump. Once a crane is rigged with a dragline, the crane is referred to by the name of the attachment.
Hoist Socket Dump Block Dump Cable
13 5 135
Drag and Drag Rope Socket
Example Dragline Rigging Arrangement

The drag cable pulls the bucket through the material when digging. The bucket is raised by the hoist wire rope and moved to the dump point Dump the bucket by releasing the tension on the drag cable.
Boom point sheave
Hoist cable Dump sheave Dump cable
Drag cable 3-point socket Fairlead Cable Drum
13 6 136
Crane Hazards


Improper load rating Excessive speeds No hand signals Inadequate inspection and maintenance Unguarded parts Unguarded swing radius
Working too close to power lines Improper exhaust system Shattered windows No steps/guardrails walkways No boom angle indicator Not using outriggers
13 7 137
Planning


Level the crane and ensure support surface is firm and able to support the load Contact power line owners and determine precautions. Know the location and voltage of overhead power lines. Know the basic crane capacities, limitations, and job site restrictions, such as the location of power lines, unstable soil, or high winds. Make other personnel aware of hoisting activities. Barricade areas within swing radius. Ensure proper maintenance and inspections. Determine safe areas to store materials and place machinery.
13 8 138
Load Limiting Factors

Not level Wind Side loads On its wheels Lifting over the side Use of extensions, jibs and other attachments Limits of wire rope, slings and lifting devices

13 9 139
Mobile Cranes Lifting Principles


Center of Gravity Leverage Stability Structural Integrity
14 0 140
Gantry Crane

A gantry crane has a hoist in a which runs horizontally along gantry rails, usually fitted underneath a beam spanning between uprights which themselves have wheels so that the whole crane can move at right angles to the direction of the gantry rails. These cranes come in all sizes, and some can move very heavy loads, particularly the extremely large examples used in shipyards or industrial installations
14 1 141
Gantry Crane
Trolley Bridge Hook & Block Gantry Legs
Trucks
14 2 142
Rails
Overhead Traveling Crane

Also known as a "suspended crane", this type of crane works in the same way as a gantry crane but without uprights. The hoist is on a which moves in one direction along one or two beams, which move at right angles to that direction along elevated tracks, often mounted along the side walls of an assembly area in a factory. Some of them can lift very heavy loads.
14 3 143

Trolley End Truck Hoist Bridge Bridge Drive Runway
Hook & Block
14 4 144
Jib Crane


A jib crane is a type of crane where a horizontal member (jib or boom), supporting a moveable hoist, is fixed to a wall or to a floor-mounted pillar. Jib cranes are used in industrial premises and on military vehicles. The jib may swing through an arc, to give additional lateral movement, or be fixed. Similar cranes, often known simply as hoists, were fitted on the top floor of warehouse buildings to enable goods to be lifted to all floors.
14 5 145

14 6 146
A jib crane contains a tilted strut (the jib) that supports a fixed pulley block. Cables are wrapped multiple times round the fixed block and round another block attached to the load. When the free end of the cable is pulled by hand or by a winding machine, the pulley system delivers a force to the load that is equal to the applied force multiplied by the number of lengths of cable passing between the two blocks. This number is the mechanical advantage.
Jib Crane
Rigid Support
Column
Jib Boom Rigid Support Trolley
14 7 147
Hoist
Summary

14 8 148
CRANE SAFETY
Basic Handsignals
149
Cranes

Cranes are classified as weight-handling equipment and are designed primarily to perform weight-lifting and excavating operations under varied conditions. Overhead cranes are a standard fixture in many industrial, manufacturing and assembly environments. They are devices that raise and lower a desired load and move it along a horizontal plane. This plane of movement is determined by the type of overhead cranes used. To make the most efficient use of a crane, you must know their capabilities and limitations. The most common types are the beam crane, gantry crane and the jib crane.
15 0 150
Trolley End Truck Hoist Bridge Bridge Drive Runway
Hook & Block
15 1 151
Gantry Crane
Trolley
Bridge Hook & Block

Gantry Legs
Trucks
Rails
15 2 152
Jib Crane
Rigid Support
Column
Jib Boom Rigid Support Trolley Hoist
15 3 153
Verbal Communication

Verbal communications vary upon needs. The most common method is portable radios and are widely used at construction sites.
15 4 154
Nonverbal Communication
While there is a broad range of non-verbal signals such as signal flags, buzzers and whistles the most common mode used in the industry is the ASME B30.5 Consensus Standard of Hand Signals. Unless voice communications are used then according to B30.5 the operator must use standard hand signals. A hand signal chart must be conspicuously posted at the job site. When a crane is traveling or moving, without direction from the rigger, audible signals must be given from the cranes horn Stop one signal Forward two signals Reverse three signals Never give signals to a crane operator unless you are the designated signal giver.

15 5 155
Hand Signals

15 6 156
Hand signal charts similar to this one should be posted conspicuously.
General Rigging Safety

The rigging worker must be aware of the hazards associated with the trade. The movement of loads moving around other workers can be a safety hazard where falling material and equipment can occur. It is the personal responsibility of the employee to supply full participation in an employer's safety program Safety consciousness is the key to reduction of accidents, injuries and death on job sites. Safe work habits can reduce mistakes that lead to accidents.
15 7 157
Personal Protection

Always be aware of your environment when working with cranes. Stay alert and know the location of equipment at all times when moving about the work area. Use standard personal protective equipment which includes:

Hard hats Safety shoes Gloves Barricades
15 8 158
Equipment and Supervision

15 9 159
Rigging operations must be planned and supervised to ensure the following: Proper equipment is available Correct load ratings are available for the material and equipment The rigging equipment is well maintained and in good working condition The supervisor is responsible for the following functions: Proper load rigging Crew supervision Rigged material and equipment meets required capacity and safe condition Lifting bolts and other rigging material is installed correctly Guaranteeing the safety of crew and personnel
Basic Rigging Precautions

Determine the weight of all loads before attempting a lift.
Rig the load so the load is stable and center of gravity is below hook. Always read manufacturers literature for all equipment which provides information on checks and inspections. Determine the weight of loads which includes the rigging and hardware. Know the safe working load capacity of the hardware and rigging Inspect all equipment and rigging before using, discard defective components Report defective equipment and hazardous conditions to supervisor Stop hoist and rigging operations when weather provides hazardous condition, such has lightning or high winds Recognize factors that can reduce rigging equipment capacity, such as side loads
Follow the following safety practices:
16 0 160
Barricades

16 1 161
Barricades should be used to isolate the area of and overhead lift. Always follow the site requirements for proper erection of barricades. Contact the supervisor for clearance before proceeding Be sure to account for crane swing radius in barricading, especially the rear of the crane
Load-Handling Safety

16 2 162
Safe and effective control of a load involves stric observance of safety requirements. Ensure that the swing path or load path is clear of personnel and obstructions. Keep both front and rear swing paths clear during lift. Be aware of crane movements while observing the movement of the load. With the exception of tag line tenders make sure the load placement area is clear of personnel and ensure the required blocking and cribbing for the load is in place before positioning the load. No one should work under the load If blocking load after setting load then do not remove load stress from sling.
Load-Handling Safety Contd

Follow these procedures when loads are handled: Before lifting ensure loads are securely slung and balanced to prevent shifting Use tag lines to control the load Safely land and properly block loads before removing slings Only use lifting beams for the purpose they were designed for. Ensure that the weight and working load for the beam is visible. Never wrap hoist ropes around load, only use slings and other lifting devices. Do not twist multiple-part lines around each other. 16 Bring load line over the center of gravity of the load before 3 163 beginning the lift.

16 4 164

Make sure rope is properly seated on the drum and in the sheaves if rope had been in a slack condition. Load and secure any materials and equipment being hoisted to prevent movement. Keep hands and feet away from pinch point as slack is taken up. Wear gloves when handling wire rope. Ensure that all personnel are standing clear of while loads are lifted and lowered and when slings are removed. Never ride a load that is being lifted Never lift a load over other personnel. Never work under a suspended load Never leave load suspended when hoisting equipment is unattended.


Never make temporary repairs to a sling Never lift loads with a multi-leg sling unless unused legs are properly secured. Ensure all slings are made of the same material when using two or more slings on a load. Remove or secure all loose pieces from a load before moving it. Lower load onto adequate blocking to prevent damage to the slings. Never pull a choker sling from under a load if the load has been set upon it.
16 5 165
Working Around Power Lines

The crane signalman must stationed at times to warn the operator when the load or crane is approaching the minimum safe working distance from a power line.
Crane in Operation Crane in Transit Boom or Mast Minimum Clearance (feet) 4 6 10 10 16 16 20
Power Line (kV) 0 to .75 0 to 50 50 to 200 200 to 350 350 to 500
Boom or Mast Minimum Clearance (feet) 10 10 15 20 25 35 45
16 6 166
500 to 750 750 to 1000
Method to determine line voltage

One rough method of determining the line voltage is to count the number of insulators suspending the line
Insulators in a String 2 2-3 4-5 5-6
Line Voltage (kV) 13.2 23 to 34.5 69 88 110 138 154 230 345
Suspension Insulators
6-8 8-10 9-11

High Voltage Line
12-16 18
16 7 167
Count Insulators Supporting Line to Determine Line Voltage
Crane Improperly Close to Lines
16 8 168
Power Line Procedures and Precautions

16 9 169
Ensure that a power line awareness permit (or equal) has been prepared Erect non-conductive barricades Use non-conductive tag lines for controlling load Qualified signalman shall be in constant contact with operator Supervisor shall alert and warn all personnel about electrocution hazards and how to avoid these hazards All non-essential personnel shall be removed from crane work area No one shall be permitted to touch the crane or load unless signalman indicates it is safe
Guidelines When Crane Contact Power


The operator should stay in the cab unless a fire occurs Do not allow anyone to touch the crane or load If at all possible, the operator should reverse the crane and attempt to break contact with the power line If the operator cannot stay in the cab he should jump clear of the cab and attempt to land on both feet at the same time. He should then walk away using very short steps. Call the local power authority or owner of the power line Have the power lines verified as secure and properly grounded within view of the operator before allowing anyone to approach the crane or load.
17 0 170
Site Hazards and Restrictions

There are many site hazards and restrictions related to crane operations. These hazards include the following: Underground utilities such as gas, oil, electrical and telephone lines; sewage and drainage piping; and underground tanks. Electrical lines or high-frequency transmitters Structures such as buildings, excavations, bridges and abutments Operators and riggers should inspect work areas for the following hazards: Ensure ground can support the crane and load Check for a safe path to move the crane around the site Make sure crane can rotate in the required quadrants for the planned lift
17 1 171
Emergency Response

17 2 172
Operators and riggers need to react quickly and correctly in response to any crane malfunction or emergency. They must learn the proper responses to emergency situations The first priority of any response is to first prevent injury or loss of life. The second priority is to prevent damage to equipments and structures.
Fire


The first response to a fire is to immediately cease crane operations. If time allows lower the load and secure the crane. In all cases of fire, evacuate the area even if the load cannot be lowered. Notify emergency services first then make a judgment to see if the fire can be put out with a fire extinguisher. Do not become overconfident, the first priority to consider is the prevention of loss of life or injury to anyone.
17 3 173
Malfunctions During Lifting Operations

If a malfunction or failure causes a crane radius to increase unexpectedly then the crane can tip over or collapse. Loads can also be dropped during a malfunction. This could cause a whiplash effect that could cause the boom or crane to fail. If a problem or fault occurs the operator should lower the load immediately. The operator should then secure the crane and tag the controls for out of service. Report the problem to the supervisor. Do not operate until qualified repairman has cleared the problem.

17 4 174
Hazardous Weather


Most crane operations take place out door. Extreme hot or cold weather and high winds can make work uncomfortable and hazardous. Snow and rain can affect the weight of the load. Instability can be affected by winter because freezing can give the false stable feeling to the ground. Severe rain can cause the ground under the crane to become unstable due to erosion of softening of the soil. Major weather hazards that need to be seriously take is Lightning and High Winds. Cranes, due to height and construction make them prone to lightning strikes. During high winds the boom should be lowered to the ground.
17 5 175
Using Cranes to Lift Personnel

17 6 176
Using a crane is not specifically prohibited, but OSHA regulations discourage it. The restrictions are such that it is only permitted is special situations. When it is allowed, certain controls must be in place, including the following: The rope design factor is doubled No more than 50 percent of the crane capacity, including rigging, may be used Anti two-blocking devices are required on the crane boom. Anti two-blocking devices are electrical sensing devices. They are installed on the crane to prevent the "headache ball" from hitting the sheave. Platform must be specifically designed for lifting personnel Basket must be tested with appropriate weight and then inspected Every intended use must undergo a trial run with weights rather than people
Personnel Platform Loading


Must not be loaded in excess of its rated capacity/ Number of employees, including material, occupying the platform must exceed limit established for platform. Platforms must be used only for employees, their tools and material necessary to perform their work. Materials and tools for use must be secured to prevent displacement during lift. The materials and tools must be evenly distributed in the platform while suspended. Operators may be required to shut down at a certain wind speed.
17 7 177
Personnel Platform Rigging
Hooks must be closed and locked, no mousing Legs of bridles must be connected to master link or shackle Bridles and rigging for attaching platform to hoist must not be used for any other purpose Overhead protection is required if there is danger of falling objects from above
Eyes in wire rope must be fabricated with thimbles. Attachments must be able to lock Guardrail, midrail and toeboard system. Requires inner grab rail.
17 8 178
Permanent marking for weight and rated capacity
Lift Planning

Before conducting a lift most construction sites and companies require a lift plan to be completed and signed. Lift plans are mandatory for steel erection and multiplecrane lifts. The lift plan contains information relative to:

Crane Loading Rigging Special Instructions for lift Restrictions for lift
17 9 179
A new lift plan is required if there are deviations from original plan.
Summary

18 0 180
Terms


Anti Two Blocking Device Barricades Center of gravity (CG) Cranes Kilovolts (kV) Lift Plan Line voltage Personnel Platform Personal protection equipment (PPE) Weight-handling equipment
18 1 181
HAND SIGNALS
Basic Hand signals
182
Objectives

Define a Signalman Define basic hand signals
18 3 183
Signalman


The signalman is part of the crane or lifting crew and is responsible to the operator to give signals for lifting, swinging, and lowering loads. A signalman should also be a qualified seasoned crane operator. Not only does the signalman give signals for handling loads but the signalman can visually observe what the lift operator cannot.
18 4 184
Some Checks for a Signalman

1.
2. 3. 4.
5. 6.
18 5 185
The load hook is centered over the center of balance of the load, as the weight is being lifted by the crane. The boom deflection does not exceed the safe load radius. All the rigging gear is straight and not causing damage to itself or the load. During a lift with a boom crane, check the boom suspension system and boom hoist reeving to ensure proper operation. Check the hook block and boom tip sheaves reeving to ensure proper operation. Check the stability of the outriggers especially when swinging from one quadrant of operation to another.
Some Checks for a Signalman

7. 8. 9.
10.
Use tag lines and tag line handlers to prevent the load from swinging or twisting Signal only to lift the load high enough to clear any obstacles. ALWAYS have eye-to-eye contact with the crane operator. The crane operator depends on the signalman to lift, swing, and lower a load safely. The signalman must also know the load weight being lifted and the radius and capacity of the crane.
18 6 186
Raise

With forearm vertical, forefinger pointing up, move hand in small horizontal circle
18 7 187
Lower

With arm extended downward, forefinger pointing down, move hand in small horizontal circles.
18 8 188
Use Main Hoist

Tap fist on head: then use regular signals
18 9 189
Use Whip Line

(Auxiliary Hoist). Tap elbow with one hand: then use regular signals
19 0 190
Raise Boom

Arm extended, fingers closed, thumb pointing upward.
19 1 191
Lower Boom

Arm extended, fingers closed, thumb pointing downward.
19 2 192
Move Slowly

19 3 193
Use one hand to gave any motion signal and place the other hand motionless in front of hand giving the motion signal.
Raise Boom and Lower Load

With arm extended, thumb pointing up, flex fingers in and out as long as load movement is desired
19 4 194
Lower Boom and Raise Load

With arm extended, thumb pointing down, flex fingers in and out as long as load movement is desired.
19 5 195
Swing Boom

Arm extended, point with finger in direction of swing of boom.
19 6 196
Stop

Arm extended, palm down, hold position rigidly
19 7 197
Emergency Stop

Arm extended, palm down, move hand rapidly right and left
19 8 198
Travel

Arm extended forward, hand open and slightly raised, make pushing motion in direction of travel.
19 9 199
Dog Everything

Clasp hands in front of body.
20 0 200
Travel Both Tracks

Both fists in front of body, make circular motion about each other indicating direction of travel-forward or back.
20 1 201
Travel One Track

20 2 202
Lock track on one side indicated by raised fist. Travel opposite track in direction indicated by circular motion of other fist, rotated vertically in front of body.
Summary

20 3 203

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BASIC INDUSTRIAL RIGGING AND CRANES

Rigging and Cranes

Basic Industrial Rigging & Cranes

Industrial Rigging Cranes Crane Safety Crane Hand Signals

Basic Industrial Rigging & Cranes

Basic Rigging Principles

Basic Industrial Rigging & Cranes

Basic Industrial Rigging & Cranes

Basic Industrial Rigging & Cranes

Finding the Weight

Basic Industrial Rigging & Cranes

Basic Industrial Rigging & Cranes

Basic Rigging Principles

Basic Industrial Rigging & Cranes

Determining the Balance

Basic Industrial Rigging & Cranes

Determining the Balance

Basic Industrial Rigging & Cranes

Checking Clearances and Route

Basic Industrial Rigging & Cranes

Checking Clearances and Route

Basic Industrial Rigging & Cranes

Rigging equipment, in general can be grouped into four categories:

Basic Industrial Rigging & Cranes

the endless sling single- leg sling bridle slings

Basic Industrial Rigging & Cranes

Sling Angle Load Examples

Basic Industrial Rigging & Cranes

1000 lbs 1000 lbs 1000 lbs

Calculating Sling Load

In order to calculate the load on a sling two items are needed:

Basic Industrial Rigging & Cranes

Sling angle Load to be lifted

Factor L H A 1000 lbs

Load in each sling = L/H x 500

Sling Angle What it means basically

Basic Industrial Rigging & Cranes

Ropes and Chains

Basic Industrial Rigging & Cranes

Ropes and Chains

Basic Industrial Rigging & Cranes

Basic Industrial Rigging & Cranes

Example of Regular vs. Lang Lay

REGULAR LAY STRAND

Basic Factors Concerning Use of Wire Rope Slings

load (rated capacity) of a wire rope sling is based

Basic Industrial Rigging & Cranes

Basic Factors Concerning Use of Wire Rope Slings

Basic Industrial Rigging & Cranes

Basic Industrial Rigging & Cranes

Parts of Wire Rope

Basic Industrial Rigging & Cranes

Strand Core Wire

Wire Rope Inspection

Basic Industrial Rigging & Cranes

Pictorial Example of Damaged Wire Rope

Basic Industrial Rigging & Cranes

Basic Industrial Rigging & Cranes

WIRE ROPE SAFE WORKING LOAD