Lifting Equipments

Environment, Health & Safety
General Guidelines
Lifting Equipment and Operations
Document No. CEAT-‐IMP-‐EHS-‐GEN-‐03

10-‐Mar -‐ New
00
2015 Document
Mahendra Chougule Mahendra Chougule Dilip Modak
General Manager-‐EHS General Manager -‐EHS Sr.Vice President
Manufacturing

Rev. Reason for
Date Prepared by Issued by Approved by
No. Issue
Printouts of this document shall be deemed uncontrolled.
Document No:
INTEGRATED MANAGEMENT SYSTEM CEAT-IMP-EHS-GEN-03
PROCESS Revision No:00
Lifting Equipment and Operations Page 2 of 31
Amendment Record / Control Sheet (ACS)
Rev. Reason Prepared Approved

Date Issued by Details of Amendments / Revisions
No. for Issue by by

Mahendra Dilip
New Mahendra
00 10-‐Mar-‐15 Chougule Modak New document.
Document Chougule

General Manager Sr. Vice President General Manager-EHS 10.03.2015

EHS Manufacturing
PREPARED BY APPROVED BY ISSUED BY ISSUE DATE
Document No:
INDEX
Sr. No. Content Page No.
1 Purpose 4
2 Scope 4
3 Definitions / Abbreviations 5
4 Responsibilities, Authorities & Accountabilities 5-‐6
5 Entry Criteria and Input 6
6 Work Process / Procedure 6-‐15
7 List of Work Instructions 15
8 List of Formats 15
9 List of Records 15
10 References 16

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1. Purpose
Hoists and Lifts are used for transporting people and goods between floors. If they are
properly designed and maintained, there is relatively little risk to the people using them.
However, there can be a much greater risk to the person who services and repairs the lifts.
IS codes are followed for necessary guidance for safe installation, operation and
maintenance of electric passenger and goods lifts.
The purpose of the procedure is to ensure that procedures are in place for the provision and
safe use of lifting equipment and its operation.
2. Scope
This Standard is applicable to all Manufacturing Plants, Project Sites of CEAT.
As per the requirements of Section 28 & Section 29 as per The Factories Act 1948, this
procedure is applicable for lifting equipment’s, which consists of :
• Hoist and Lifts
• Lifting Machines
• Lifting Tackles
Commonly used Lifting Equipment’s in CEAT are given below:
Lifting Equipment

Hoist and Lifts Lifting Machines Lifting Tackle

1.Lifts 1.Crane 1.Chain Sling
2.
Cage Hoist 2. Pulley Block 2. Wire Rope sling
3. Monorail Hoist 3. Scissor Platform 3. Hook, Shackle


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3. Definitions / Abbreviations
EHS -‐ Environment, Health & Safety
GM -‐ General Manager
VP -‐ Vice President

Lifting Machines – “Lifting Machines”, means a crane, crab winch, teagle, pulley block, gin
wheel, transporter or runway.
Lifting Tackle – “lifting tackle”, means any chain sling, rope sling, hook, shackle, clamp,
swivel, coupling, socket , tray or similar appliances, whether fixed or movable, used in
connection with raising or lowering of persons or loads by use of lifting machines.
Competent Person – “competent person”, in relation to any provision of this Act, means a
person or an institution recognized as such by the Chief Inspector for the purposes of
carrying out test, examination and inspections required to be done in in a factory under the
provisions of the Factories Act 1948.

4. Responsibilities, Authorities and Accountabilities
Sr.No. Description Responsibility & Accountability
Authority
1. Prepare specifications & design of new Sr.Manager-‐Engg / GM-‐Engineering
lifting equipment Sr.Manager-‐EHS
2. Procurement, Installation and Sr.Manager-‐Engg GM-‐Engineering
Commissioning of Lifting Equipment
3. Risk Assessment of all Lifting Sr.Manager – Engg GM-‐Production
Equipment’s and Lifting Operations / Sr.Manager –
Production
4. Training & Communication on Safe use Sr.Manager -‐ EHS VP-‐Operations
of Lifting Equipment’s
5. Inspection of Lifting Equipment’s Sr.Manager-‐EHS VP-‐Operations
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6. Maintenance of Lifting Equipment’s Sr.Manager-‐Engg GM-‐Engineering

7. Maintenance of List of Lifting Tackles & Sr.Manager -‐ Engg GM-‐Engineering
updation
8. Disposal of rejected & broken Lifting Sr.Manager-‐ Engg GM-‐Engineering
Equipment’s
9. Checking of Hired Crane & other heavy Manager-‐ EHS Sr.Manager-‐EHS
lifting machines

5. Entry Criteria and Inputs
Ø Statutory requirements as per Section 28 & 29 of The Factories Act 1948.
Ø Entry of any hired lifting equipment into the plant premises.

6. Work Process / Procedure
6.1 Design

• Senior Manager -‐ Plant Engineering proposes for installation of new lifting equipment within
the plant premises as per the Capex Proposal procedure.
• Upon obtaining Capex sanctions, Senior Manager – Plant Engineering arranges for planning
and design of the lifting equipment.
• Manager – Plant Engineering instructs the competent person to prepare design
specifications; as per the relevant IS code for lifting equipment.
• The competent authority submits the specifications and design to the Senior Manager –
Plant Engineering.
6.2 Procurement, Installation and Commissioning

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• Based on the specifications and design recommended by the competent authority, Senior
Manager – Plant Engineering arranges for the procurement, installation and commissioning
of lifting equipment from the approved vendor.
• The vendor supplies the lifting equipment along with a Testing and Examination Certificate
from a competent person as per State Factories Rules.
• In case, Testing and Examination Certificate as above, is not provided along with the delivery
of the lifting equipment or the specifications are not as per the requirement, Manager –
Plant Engineering ‘Rejects” the lifting equipment and arranges to return the same back to
the vendor.
• In case, the requirement of Testing and Examination Certificate and specifications as
mentioned are complied, Manager – Plant Engineering inwards of the lifting equipment.
• Sr. Manager – EHS maintains the Testing and Examination Certificate
Hoist or Lift
• In case, the valid Testing and Examination Certificate is available, Manager – Plant
Engineering arranges for installation of Hoists / Lift through the concerned vendor.
• Manager – Plant Engineering refers and instruct the concerned vendor to comply with safety
precautions mentioned in work permit at the time of installation of Hoists / Lift.
• Upon the installation of the Hoists / Lift, Senior Manager – EHS invites the competent
authority for inspection of Hoists / Lift.
• The competent authority inspects the Hoists / Lift and either approves or makes
recommendations based on his findings in writing.

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• Manager – Plant Engineering arranges to comply with the recommendations made as above
and arranges for inspection and receipt of Testing and Examination Certificate by the
competent authority.
• Upon receipt of approvals and Testing and Examination Certificate from the competent
authority, Manager – EHS maintains the same in register and permits the vendor to start
trials and commissioning of the Hoist / Lift.
• Concurrently Senior Manager – Plant Engineering submits an application to Lift Inspector
seeking permission for use of such Hoists / Lifts, as prescribed by the respective State
Factories Rules (SFR) along with following annexures.
a. Equipment details and design specification,
b. Testing and Examination Certificate issued by competent person as per SFR along
with the supply of Hoist / Lift
c. Testing and Examination Certificate issued by competent authority as per certifying
installation / commissioning of Hoist / Lift.
• Manager – Plant Engineering maintains the communications sent to or received from Lift
Inspector.
• Lift Inspector accordingly inspects the Hoist / Lifts and issues a certificate permitting the use
of Hoist / Lift.
• Manager – Plant Engineering maintains certificate received from Lift Inspector.
• Only upon receipt of Certificate from Lift Inspector, Senior Manager – Plant Engineering
permits the use of Hoist / Lift.
• Manager – Plant Engineering arranges to display the following details on the Hoist / Lift.
a. Equipment no
b. Safe Working Load (SWL)
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c. Test done on

d. Test Due on / Frequency
e. A copy of the “Certificate” received from Lift Inspector

Lifting Machines and Lifting Tackles
• Vendor reports at the Plant Security Gate with the company purchased Lifting Machine and
Lifting Tackles whereas contractor reports at Plant Security Gate with his Lifting Machines
and Lifting Tackles.
• Security personnel at the Plant Security Gate makes entry in to the register about the entry
of company-‐owned / contractor-‐owned Lifting Machines and Lifting Tackles and informs
Manager – EHS about the same.
• Manager – EHS inspects all the Lifting Machines and Lifting Tackles brought in the plant
premises by the vendor / contractor as per guidelines provided.
• The vendor / contractor supplies the lifting machines and Lifting Tackles along with a Testing
and Examination Certificate from a competent person as per State Factories Rules.
• In case, Testing and Examination Certificate as above, is not provided along with the delivery
of the Lifting Machine and Lifting Tackle or the specifications are not as per the requirement
given, Manager – EHS ‘Rejects” the Lifting Machine and Lifting Tackle and arranges to return
the same back to the vendor / contractor.
• Sr. Manager – EHS arranges for testing of lifting machine / Lifting Tackle by the competent
authority.
• The competent authority inspects the lifting machine / Lifting Tackle and recommends
acceptance or rejection of same in writing based on his findings.

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• In case, the competent authority rejects the lifting machine and Lifting Tackle, Manager –
Plant Engineering arranges to put a tag “Rejected” and returns the lifting machine /Lifting
Tackle back to the vendor / contractor.
• Upon receipt of approvals and a Testing and Examination Certificate from the competent
authority, Manager – Plant Engineering permits to inward the lifting / machine Lifting Tackle
at the Plant Engineering Stores.
• Manager – Plant Engineering maintains the list of lifting / machine Lifting Tackles.
• Sr.Manager – EHS maintains the Testing and Examination Certificate of lifting machine /
Lifting Tackles.
• Manager – Plant Engineering arranges for display, of an aluminum tag with the following
details embossed, on that equipment
a. Equipment No
b. Safe Working Load (SWL)
c. Test done on
d. Test due on / Frequency
6.3 Risk Assessment

• Senior Manager – Plant engineering & Senior Manager – Production conducts Risk
Assessment exercise for all Lifting Equipment’s and Lifting operations as part of the risk
assessment of Equipment’s and Activities as per procedure mentioned in Level I IMS Manual.

6.4 Training and Communication
• At the beginning of each financial year, each Department Senior Manager identifies
workmen / contract workmen who can be authorized to operate the lifting equipment and
forwards the name of such workmen to Senior Manager – EHS
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• Senior Manager – EHS arranges for conduct of training by an expert faculty or by the OEM
vendor, on safe operation of lifting equipment.
• Manager – HR arranges for maintenance of records of such Training Program conducted.
• Senior Manager – Production & Senior Manager – Plant Engineering authorizes workmen /
contract workmen who have successfully completed their training program to operate lifting
equipment.
6.5 Inspection and Maintenance
Inspection and Preventive Maintenance

Statutory
• Each year in the month of April, Senior Manager – EHS prepares inspection and maintenance
plan for Lifting Equipment] at frequency as mentioned in State Factories Rules and
maintained in Table 1.
Table 1
Lifting Equipment Frequency of Inspection and
Maintenance
Each Hoist and Lift At least once every six months
Each Lifting machine and Lifting Tackle At least once every twelve months

• Senior Manager – EHS maintains the plan, compliance to schedule, reschedule due to non-‐
availability of equipment, record of inspection and maintenance.
• Senior Manager – EHS hires a competent person as mentioned in Table 1, above to carry out
inspection and maintenance.
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• During inspection, competent authority identifies lifting equipment not complying with the
requirements and recommends necessary modifications to be carried out for compliance to
the same.
o If part of the lifting equipment is deteriorated, the competent authority recommends
de-‐rating of the lifting equipment or places usage restrictions in terms of load to be
carried, frequency of usage or maintenance.
• If in his assessment, competent authority finds that modifications cannot be carried out to
meet requirements, he accordingly secures and segregates such Lifting Equipment and
arranges for display of the notice “NOT IN USE” on the lifting equipment.
• Competent person submits his report of assessment to the Senior Manager – EHS with
necessary modifications carried out.
• Senior Manager – EHS maintains the record of inspections of Hoist / Lift in Form as per State
Factories Rules.
• Manager – Plant Engineering maintains the record of inspections of lifting machines and
Lifting Tackles in Form as per State Factories Rules.
• The competent person submits service report of the maintenance activity, which is
maintained by Plant Engineering.

Breakdown Maintenance
• Manager / Asst. Manager – Production inform to Plant Engineering about the breakdown of
lifting equipment.
• Manager – Plant Engineering arranges for breakdown maintenance after taking necessary
steps.

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• Senior Officer – Plant Engineering evaluates the seriousness of the breakdown and if he finds
it to be repairable by technicians, accordingly deputes necessary personnel for repair of the
same.
• In case, Senior Officer finds the breakdown of below given type, he informs Manger – Plant
Engineering.
a. Brake assembly replacement
b. Rope replacement
c. Hook replacement
d. Pulley replacement
e. Any modification which can increase the weight of cage
• Manager – Plant Engineering arranges for visit of the competent authority as mentioned in
Table 1, above, to carry out the maintenance job.
• Manager – Plant Engineering also informs Manager -‐ Safety about the breakdown type
mentioned above in point 3 and the steps taken to rectify the same.
• Manager – Plant Engineering arranges for recertification by competent authority on the
above issues before reuse of the Hoist /Lift and maintains records of the same.
• Manager – Plant Engineering arranges for submission of Testing and Examination Certificate
from the competent authority to the Lift Inspector and Factories Inspector, in case of
breakdown as mentioned in point 3 above.

6.6 Disposal
• During the course of testing and inspection, the competent authority assesses the extent and
of repair and maintenance as follows:

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a) If the entire lifting equipment is found to be beyond repair, he
recommends de-‐commissioning of the lifting equipment.
b) If a few parts of the lifting equipment’s are to be replaced, he
recommends rectification and replacement of the same and defacing of
the disposed components.
• Sr.Manager-‐ engineering accordingly decides upon the action plan and arranges for disposal
of the lifting equipment components.

6.7 Hired Cranes and other heavy lifting machines
• Manager – Plant Engineering informs Manager – Safety about the entry of a hired crane or
other heavy lifting machine in to the plant premises for purpose of execution of certain
projects involving lifting of heavy equipment.
• Contractor reports at the Security Gate with the crane or other heavy lifting machine.
• Security Personnel informs Manager-‐Safety about the same.
• Manager-‐ Safety checks the following documents with the contractor of the Cranes / other
heavy lifting machines
a) Testing and Examination Certificate;
b) Load Test of Hook;
c) PUC Certificate;
d) Vehicle Fitness Certificate of RTO;
e) Drivers License for ‘ Heavy Transport Vehicle – Crane’
• Manager – Safety checks the Testing and Examination Certificate as issued under State
Factories Rules for the Crane or other heavy lifting machine. In case the same is not
available, Manager-‐Safety does not permit the entry of the Crane or other heavy lifting
machine inside the plant premises.

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• In case the Testing and Examination Certificate is available, Manager – Safety permits the
entry of crane or other heavy lifting machine inside the plant premises.
• Security Personnel maintains the record of entry of Crane or other heavy lifting machine in
the register kept at gate.
• Senior Manager – Plant Engineering and Senior Manager of the concerned department
follows Lifting Permit before use of crane and other heavy lifting machine within the plant
premises as per the Work Permit Procedure of CEAT.
• They assess appropriation of usage of hired crane / heavy lifting machine vis-‐à-‐vis the job
requirement especially related to operating parameters like safe working load, distance of
travel, elevation and the like

7. List of Work Instructions
• Safety Precautions for Storage, Use and Inspection of Lifting Equipment as per Annexure-‐I

8. List of Formats & Checklist
• Lifting Permit – Format No. [SR][OH&S][0102014]
• Checklist for Hydra / Crane Entry and Inspection Record
9. List of Records
Title Maintained by Retention Period
Design Specifications of Lifting Equipment by Sr. Manager -‐ Engg 3 Years
Competent Authority
List of Lifting Equipment’s and their Sr. Manager -‐ Engg Ongoing
Locations
Testing and Examination Certificates of Sr. Manager -‐ EHS 3 Years
Lifting Equipment’s
List of Persons trained in use of Lifting Sr. Manager -‐ EHS 3 Years
Equipment.
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Records of Inspection of Hired Cranes & Manager -‐ EHS 3 Years

other heavy lifting machines.

10. References
• Work Permit System
• The Factories Act 1948 – Section 28 & Section 29
• State Factories Rules

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Annexure –I
Safety Precautions for Storage, Use and Inspection of Lifting Equipment
Monorail Hoist
A.1. Inspection of Monorail Hoist
• Condition of Rope (Rope condition, Rope lubrication, Rope drum, Clamp on drum, Rope
guide, Rope tightener)
• Condition of Gear box (For noise and oil).
• Condition of Brake hoisting (Shoe with liner, Actuating assembly, Coil, Brake drum,
Machined bolts/ nuts, Rubber bushes)
• Condition of Limit switches (Upper limit switches, Lower limit switches for their
operation)
• Condition of Bottom hook assembly (Pulley, center pin, center pin locking, hook, saddle
diameter, throat width, swivel of hook, Safety Latch)
• Condition of Mono rail trolley (Driving and driven pinion, Wheel bearings, Pinion, Axle,
Gear box)
• Condition of Cable carrying trolleys (Wheels, Wheel bearing, Frame, Pulling chain, End
stopper)
• Condition of Pendant push button station, Stop button on pendant
• Emergency stop button in hoist well
• Interlocking system in hoist well
• Electrical terminal connection-‐ For contact and relays
• Main power cable

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• Load test at 25% overload

A.2. Safety Precautions during operation of Monorail Hoist
• Hoist controls are moved smoothly and gradually to avoid abrupt, jerky movements of
the load. Slack is removed from the sling and hoisting ropes before the load is lifted.
• Monorail Hoist is centered over the load before starting the hoist to avoid swinging of
the load as the lift is started.
• Hoisting ropes are kept vertical. Hoists are not used for side pulls.
• The block is never lowered below the point where less than two full wraps of rope
remain on the hoisting drum. If all the rope is unwound from the drum, it is ensured that
the rope is rewound in the correct direction and seated properly in the drum grooves or
otherwise the rope gets damaged and the hoist limit switch fails to operate to stop the
hoist in the high position
• Lifts beyond the rated load capacity of the hoist, sling chains and rope slings are not to be
done.
• Monorail Hoist is not operated if limit switches are out of order or if ropes show defects
or wear.
• It is ascertained before moving the load, that the load slings, load chains or other load
lifting devices are fully seated in the saddle of the hook.
• Loads are not lifted with any sling hooks that are hanging loose (if all sling hooks are not
needed, they are properly stored or a different sling is used)

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• All slings or cables are removed from the hooks of the hoist when not in use. (Dangling
cables or hooks hung in sling rings can inadvertently snag other objects when the hoist is
moving)
• Operators do not use limit switches to stop the hoist under normal operating conditions.
(These are emergency devices and are not to be used as operating controls)
• Limit switches are never blocked, adjusted or disconnected in order to go higher than the
switch will allow.
• Upper limit switches (and lower limit switches, when provided) are tested in stopping the
Monorail Hoist at the beginning of each shift.
• The switches located on pendant, used for operating the Monorail Hoists are clearly
marked for Up and Down movements.
• Pendant is so designed that a constant push on the control button is needed to raise or
lower the load.
• Minimum of two turns remain on the drum when the load block is on the floor, except
when a geared lower limit switch is used.
• Railing at the ground floor is interlocked with the vertical movement
• While lifting the load, care is taken that the load line is in line with the swing
• Load is not lifted with the point of the hook.

B. Chain Pulley Block
B.1. Inspection of Chain Pulley Block
• Condition of hand chain
• Condition of load chain wheel (Wearing, elongation)

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• Condition of friction washers (For dryness, clearance between friction washer and pad
plate is minimum)
• Condition of guide roller
• Condition of main gear, intermediate gear
• Condition of pinion shaft
• Condition of bearings
• Condition of hook and hook assembly
• Condition of carbon steel bush
• Condition of brake disc wear
• Condition of spring mechanism and ratchet and pawl for efficient operation
• Load test

B.2. Safety Precautions during operation of Chain Pulley Block
• Chains are not twisted
• Sling loads from the centre of the hooks
• Load lifted is not beyond the marked safe working load
• While lifting the load, care is taken that the load line is in line with the swing
• Load is not to be lifted with the point of the hook
• No over-‐lifting or over-‐lowering is done
• While lifting, swinging of the load is avoided

C. Hoist
C.1. Inspection of Cage Hoists

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• Condition of wire ropes

• Condition of wire rope drum
• Condition of landing gate and cage gate and their interlocks
• Condition of enclosures of hoist way, cage, platform, guide and buffer
• Condition of hook/ attachment to the cage
• Condition of gear box
• Operation of interlocks
• Alignment of cage platform at each floor level.

C.2. Safety Precautions for use of Cage Hoists
• Do not overload the hoist beyond the safe working load.
• In case of collapsible gates, do not attempt to stop a running elevator from the lobby by
forcibly opening the car gate.
• Person is not travelling in the cage hoist.
• Every hoist and lift is:
o Of good mechanical construction, sound material and adequate strength
o Properly maintained and thoroughly examined by a competent person at least once
in a period of six months and register is kept containing the prescribed particulars of
every such examination.
• Every hoist way and lift way is sufficiently protected by an enclosure fitted with gates.
Hoist is so constructed as to prevent any person or thing from being trapped between
any part of the hoist or lift and any fixed structure or moving part.

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• Maximum safe working load is clearly marked on every hoist and no load greater than
that is carried thereon.
• The cage of every hoist or lift used for carrying persons is fitted with a gate on each side
from which access is afforded to a landing.
• Every Gate is fitted with interlocking device to secure that the gate cannot be opened
unless that cage is at the landing and that the cage cannot be moved unless the gate is
closed.

D. Lifts
D.1. Inspection of Lifts
• Condition of end clamping
• Condition of sheave pulleys
• Condition of car door
• Condition of guide rails shoe
• Condition of landing doors
• Condition of lift pit
• Condition of buffers
• Condition of counter weight (Number of ropes, Over speed governor, Guide rails fixing,
Enclosures)
• Condition of Brake (Brake assembly, brake drum, brake liner)
• Condition of gear box (Coupling, oil level, noise)
• Condition of Machine room (Ventilation, Weather protection, Guards, House keeping)
D.2. Safety Precautions for Lifts

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• Do not overload the lift beyond the safe working load

• In case of collapsible gates, do not attempt to stop a running elevator from the lobby by
forcibly opening the car gate
• In case of automatic doors, do not step in or out until the elevator has stopped at landing
and the doors have fully opened
• In case of manually operated doors, close elevator doors properly after your journey
• Do not panic or jump out of the elevator if it is stuck in between floors. Press alarm bell
to seek help. An emergency brake device is available in the machine room to enable the
elevator to be brought manually to the nearest floor

E. Chains and Chain Slings
E.1. Inspection of Chain Slings
• Excessive wear
• Cracks
• Corrosion
• Deformation
• Defective welds
• Elongation
E.2. Safety Precautions for Chain Slings
• Do Not
o Drop chain or sling from height.
o Hammer a chain to straighten links or force a link into position
o Allow vehicles to pass over a chain

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o Shorten chains by tying a knot, twisting the chain, by putting a bolt through two links
or by means of a cloth or rope
o Drag chains on the ground.
o Overload chains due to
− Lifting loads above Safe Working Load
− Load getting caught in some fixture’
− Sudden jerks
− Sudden increase in hoisting speed
− Sudden decrease in lowering speed
• Chains is hooked on a stand with a separate location for each size of chain. Chain is never
kept on the ground.
• Always use the correct pins in shackles and fasten them securely.
• Rings and shackles must ride freely on the crane hook.
• Never use worn out and damaged shackles.
• Safe use of slings :
− Inspect the sling before taking it into use
− Never overload a sling
− Lift sling vertically and not at an angle
− Avoid spinning of load
− Do not pull the sling from under the load
− Use suitable padding to protect from sharp edges
− Remove slack before hoisting
− Use guide ropes while lifting long objects.

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− Never drag slings on gritty surface.

F. Rope Slings

Ropes are classified as Wire ropes and Fibre ropes.
F.1. Description of Fiber Ropes
Fibre ropes are more flexible than wire ropes, but more easily damaged by heat, natural fibre
ropes shrink when wet and are susceptible to rotting on exposure to damp atmosphere, acid
or alkaline fumes. They are widely used for slings, cordage and to some extent for haulage. In
general fibre ropes are being replaced by synthetic ropes. Synthetic fiber ropes are generally
stronger and more resistant to moisture and chemicals than natural fiber ropes, but their
properties depend very much on the type of synthetic.
F.2. Inspection of Fiber / Synthetic Ropes
• As the fibre ropes are susceptible to damage, it is essential that before the rope is taken
into use it is carefully examined. Intervals of inspection would depend on its use. While
inspecting, the whole length is examined for wear, broken fibers, powdered fiber
between strands, displaced strands or yarn, variations in size or roundness of strands,
discoloration and rotting. The rope is untwisted at several places to examine inner yarn -‐
which is spotless.
• Sometimes the surface of the ropes gets dirty. Even if the rope is dirty, its interior is as
bright as new rope. Broken yarn inside the rope. or accumulation of powder inside
indicates excessive internal wear. The discoloration of the rope indicates its being in
contact with either hot surface or chemicals. Any rope, which shows a reduction in its
circumference, indicates that it has been stretched.
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• Natural fiber ropes loaded to over 50% of its breaking load will be permanently
damaged. Synthetic fiber ropes loaded to over 65% may be damaged. Damage of fibers
due to this cause can be detected by scratching the fibers with the fingernail -‐fibers of
poor strength will readily give way.
• During inspection if there is any doubt about the strength, the rope is discarded.
Discarded ropes is cut with a knife at various places to prevent its accidental use.
F.3. Description of Wire Ropes
• Wire ropes are composed of wires, strands and core. The wires are drawn to a
predetermined size and laid together in various arrangements having a definite pitch or
lay to form a strand. Then the required number of strands are helically laid or formed
around the core, which may be sisal rope, a metallic strand or independent wire rope
core.
• The size, number and arrangement of wires, the number of strands, the lay, and the
type of core in a rope are determined largely by the service for which the rope is to be
used.
• In general, greater the number of wires in a strand and greater the number of strands,
the more the flexibility of the rope. Wire ropes are mainly used for its greater strength /
weight ratio, its constant strength and length when wet or dry, and its greater durability.
F.4. Safety Precautions during Use of Wire Ropes
• Lay of Wire Ropes: It affects its flexibility and resistance to wear.
Wire Ropes With Regular Lay: Wires in strand laid in one direction and strands in the
rope laid in opposite direction. This is used for making slings. This rope has good
resistance to kinking, twisting and can withstand considerable crushing and distortion.
• Safe Working Load of Wire Ropes:
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SWL = 1/6th of Breaking Load.
Thumb Rule -‐SWL = 8 d2 kg,
where d is diameter of wire rope in mm.
Strength of Wire Ropes: Radius of bend has an effect on the """ strength of wire rope.
Refer table given below:

Pulley Dia / Rope Dia Strength Efficiency of Wire
Rope in %
40 95
30 93
20 91
15 89
10 86
8 83
6 79
4 75
2 65
1 50

Repeated bending and straightening of wire rope causes fatigue.
F.5. Storage of Wire Ropes

• Unwrap and examine rope after delivery.

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• If it is to be stored for long periods apply a fresh coating of rope dressing.
• Rewrap the rope and store the coil off the ground in a clean, dry and covered place.
• Examine rope periodically and apply dressing if necessary.
Manual Splicing:
• At least 3 tucks with whole strands and, .2 tucks with half the wires cut from each
strand. Splicing is served with spun yarn to cover the sharp ends of wires.

F.6. Bull Dog Grip:
Number grips to be used for temporary splicing are as follows:
Diameter of Rope in mm No of Grips Required

Upto 19 3
19 – 32 4
32 – 38 5
38 – 44 6
Over 44 mm 7
Distance between two grips is 6 times the rope diameter.
The included angle between slings is between 60° -‐ 90°. 90° is the preferred angle. Do not
spread the legs too much.
The load on the slings for various included angles for a load of 2000 kg are given below for a
two legged sling:
Included Angle in Degrees Load on the Rope

EHS Manufacturing
Document No:
0 1000
30 1035
60 1154
90 1414
120 2000
150 3864

F.7. Broken Wires:
A rope may have to continue in operation with broken wires, but an early opportunity is taken
to remove the wires. The broken wire is bent, backward and forward with the fingers until it
breaks leaving the end tucked inside.

F.8. Inspection of Wire Ropes
• Excessive corrosion
• Curls & Kinks
• Excessive wear
• Breaking of large number of wires
• Bird caging
• Damaged splice
• Rope stretch
• Reduction in rope diameter

Permissible Broken Wires:

EHS Manufacturing
Document No:
− No wire is used in hoisting or lowering if in any length of 10 diameters, the total

number of visible broken wires exceeds 5% of the total number of wires in the rope.
− The total number of broken wires in all strands in a length equal to 8 diameters of
the rope must not exceed 10% of the total wires.
− One broken wire below the metalled socket is sufficient to cause rejection, this is
evidence of fatigue in the rope below the socket. 2 to 3m of the rope is chopped off
below the socket.
Wear: Wear due to friction on sheaves, rollers, drums, etc., causes outer to become flat on
the outside.
This wear is not allowed to exceed 1/3rd the diameter of the surface wires.
Reduction in rope diameter:

• Reduction of diameter of rope by 1.2mm.is permissible up to 20mm diameter rope.
• Reduction of diameter of rope by 1.6mm is permissible for ropes between 22mm and
28mm diameter ropes.
• Reduction of diameter of rope by 2.4mm is permissible between 32mm to 38mm
diameter ropes.
Stretch:
Permissible stretch is 150mm per 30m length for a 6 stranded rope and 225mm per 30m for
8 -‐10 stranded ropes.
Corrosion:
Corrosion occurs because of insufficient lubrication. Corrosion can be infinitely more
dangerous than wear, as usually more wires are affected. Scrape free from rust, and examine
the individual wires, discard when corrosion is not purely superficial.

EHS Manufacturing
Document No:
Tit Bits:
• Certain sections of wire rope often get more worn, then others.
• Rope on a drum with two or more layers will wear at the point where the rope starts
each successive layer, and also at the points where the upper layer crosses the lower.
• Crane rope will fatigue at an equaliser sheave.
• Hoist rope will often fail from vibration fatigue at the point where they are dead-‐ ended.
Because of these wear points, it is good practice to move the rope at regular intervals in
order to distribute wear.

G. Hooks

G.1. Inspection of Hooks
• Wear on the saddle of the hook; cracks, severe corrosion and twisting of the hook body
and for throat opening.
• If a hook is overloaded or it is beginning to weaken, the throat will open. A hook is
considered unsafe for use if wear or distortion exceeds the following limits
o Wear-‐ 10%
o Throat opening-‐ 15% (over the original throat opening)
o Twist along the vertical axis-‐ 10 degree beyond the axis.

EHS Manufacturing

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Environment, Health & Safety

Document No. CEAT-­‐IMP-­‐EHS-­‐GEN-­‐03

Lifting Equipment and Operations Page 2 of 31

Amendment Record / Control Sheet (ACS)

Rev. Reason Prepared Approved

General Manager Sr. Vice President General Manager-EHS 10.03.2015

Lifting Equipment and Operations Page 3 of 31

Sr. No. Content Page No.

4 Responsibilities, Authorities & Accountabilities 5-­‐6

5 Entry Criteria and Input 6

6 Work Process / Procedure 6-­‐15

7 List of Work Instructions 15

8 List of Formats 15

9 List of Records 15

General Manager Sr. Vice President General Manager-EHS 10.03.2015

Lifting Equipment and Operations Page 4 of 31

Hoist and Lifts Lifting Machines Lifting Tackle

General Manager Sr. Vice President General Manager-EHS 10.03.2015

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Lifting Equipment and Operations Page 6 of 31

6. Maintenance of Lifting Equipment’s Sr.Manager-­‐Engg GM-­‐Engineering

6.2 Procurement, Installation and Commissioning

General Manager Sr. Vice President General Manager-EHS 10.03.2015

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General Manager Sr. Vice President General Manager-EHS 10.03.2015

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Lifting Equipment and Operations Page 9 of 31

c. Test done on

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6.3 Risk Assessment

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6.5 Inspection and Maintenance

Inspection and Preventive Maintenance

Lifting Equipment and Operations Page 12 of 31

General Manager Sr. Vice President General Manager-EHS 10.03.2015

Lifting Equipment and Operations Page 13 of 31

General Manager Sr. Vice President General Manager-EHS 10.03.2015

Lifting Equipment and Operations Page 14 of 31

General Manager Sr. Vice President General Manager-EHS 10.03.2015

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Lifting Equipment and Operations Page 16 of 31

Records of Inspection of Hired Cranes & Manager -­‐ EHS 3 Years

Lifting Equipment and Operations Page 17 of 31

General Manager Sr. Vice President General Manager-EHS 10.03.2015

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• Load test at 25% overload

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General Manager Sr. Vice President General Manager-EHS 10.03.2015

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General Manager Sr. Vice President General Manager-EHS 10.03.2015

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• Condition of wire ropes

General Manager Sr. Vice President General Manager-EHS 10.03.2015

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• Do not overload the lift beyond the safe working load

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Document No. CEAT-‐IMP-‐EHS-‐GEN-‐03

4 Responsibilities, Authorities & Accountabilities 5-‐6

6 Work Process / Procedure 6-‐15

6. Maintenance of Lifting Equipment’s Sr.Manager-‐Engg GM-‐Engineering

Records of Inspection of Hired Cranes & Manager -‐ EHS 3 Years

Thumb Rule -‐SWL = 8 d2 kg,