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Agus Supriadi,S.T. Vibration Analyst level IV

 Introduction
 •Roles and responsibilities
 •Wire ropes
 •Slings, belt slings, round slings,
 •Bow Shackles
 •Rigging Hitches & Slinging Methods
 •Basic Knots
 •Chain blocks
 •Pull lifts
 •Tirfors, eye bolts, plate clamps, turnbuckles, hooks, lifting
beams
 •Lifting Appliances
 •Procedure for lifting operations
 This course on Lifting Equipment, Rigging,
and Slinging is designed to identify and
detail the mandatory requirements for the
safe utilization of all lifting equipment
operating on the Project. The course will
also provide a clear understanding of Lifting
tackles, Rigging and Slinging practice, Safe
Working Loads, Different types of Cranes
and Crane Signals.
 Everyday, Routine Crane Operations –
 • cause most of our accident due to
lack of adequate planning.
 To analyze all lifts
 •Ground Preparations
 •Using proper lifting tackles
 •Interpretations of capacity charts
 •Operators and signalmen must
maintain continuous and undivided
communication
 Upon completion of the lesson, participants will
be able to:
 •List the four major causes of crane accidents.
 •Describe the pre-planning that is required
before putting a crane in use.
 •State the main precautions that apply to
working with cranes.
 •Explain at least three ways to eliminate
hazards that may lead to injury when using
cranes or slings to handle materials.
 Rigging Superintendent
 –Ensuring that the lifting equipment and
gear selected to work, has been
inspected, certified and is maintained
according to procedure
 –Ensuring that only qualified and
competent riggers/slingers/banks-men
are assigned to any lifting operations
 Appointed Competent Person (Lifting
Equipment) – Third Party
 •Appointed Competent Person (Lifting
Gear) – Third Party
 –Responsible for ensuring that the testing,
examination and certification of lifting
Equipment / Gear is carried out in
accordance with the Requirement
 Line Supervisors
 –Ensuring the adequate supervision of personnel,
carrying out, or involved in, lifting operations
 –Ensuring that work method statements, task risk
assessments, Lifting Plan /Rigging Study have been
carried out
 –Ensuring that areas around the lifts are suitably
barricaded and warning signs posted
 –Ensuring that the Load weight, shape and radius of
lift are suitable for selected lifting equipment and
gear
 Riggers and Slingers
 –Identifying any defects in lifting gear
 –Conforming the weight, center of
gravity and

 characteristics of a load prior to lifting

 •Banks-men
 –Preventing all unauthorized personnel
from entering the restricted area around
the lifting operation
 –Ensuring that taglines are attached and
used on all loads
 Single Layer Rope
 •One layer of outer
strands (usually 6 or
8) laid helically over
a centre core of
fibre or steel
 •Illustration - rope
with independent
wire rope core
(IWRC)
 Single layer rotate

 Two layers Rotational Resistant

 Three layers Low Rotation Rotates

 2 measurements at right angles at two
positions spaced approximately one
metre apart.
 – (Measurements taken over strand
crowns)
 • Average of the four measurements is
the rope diameter.
 Inspection
 •Safe working load stamping.
 •Identification mark.
 •Correct colour code (if applicable).
 •Broken wires (Randomly distributed wire breaks are not to exceed 5% in any length of 10 diameters.
Localised breaks are not to exceed 3 in a close group or in any one strand within a length of 6
diameters).
 •Ensure rope end of the looped parts does not terminate inside ferrule.
 •Excessive wear (max 10% loss of nominal diameter)
 •Kinks.
 •Exposure of core.
 •Flattening of rope (especially in the eye).
 •Stretch by reduction in diameter or circumference.
 •Corrosion.
 •Heat damage, look for evidence of discoloration, loss of lubricant, pitting and the presence of weld
blobs.

 Action If any of the above faults are present refer to a competent person for through examination.
Maintenance
 •Keep ropes clean and free from grit.
 •Lubricate at regular intervals.
 •Slings should be suspended from storage rack if not in use.
 Examine all wire ropes for damage
before use. Faults which may render a
rope unserviceable include; Kinking
Badly worn strands
 •Corrosion
 •Kinking.
 •Broken and fraying strands.
 The stresses in the legs of the sling
increases as the angle between them
increases. Using the human body and
two buckets filled with water it will not be
difficult to demonstrate the effects of
lifting a load at narrow and wide angles.
The arms represent the sling and lift
angle.
 Only Grade 8 or better ALLOY Chain can be used for
overhead lifting purposes! All chain is not rated the
same!
 Chain must have a capacity tag attached to it.
 Chains will withstand more rough handling and
abuse, but a chain with the same rated lifting
capacity of wire rope will be much larger in diameter
and heavier in weight.
 Chains must be inspected daily before use and as
often as necessary during use to assure safety.
 It is the riggers responsibility to do the inspections!
 All webbing sling shall;
 • Be stored away from direct sunlight to
minimize the effect of UV deterioration.
 • Be stored on a non-corrodible rack, away
from any source of heat.
 • Not be used in knotted or twisted condition.
 • Never be repaired. A damaged webbing
sling or sling with damaged cover shall be
discarded and taken out of service.
 Identification
 •Safe working load marking.
 •Identification mark.
 •Colour inspection code (if used).
 •Condition of stitching.
 •Tears or abrasions
 •Burning of outer surface.
 •Excessive wear. If any of the above faults are present refer to a
competent person for through examination. Maintenance
 •Keep surface clean and free from grit.
 •Re-apply colour code if necessary.
 •Sling should be suspended in storage when not in use.
 Belt Sling with Eyes Endless Belt Sling
 INSPECTION
 •Synthetic slings must be inspected before
each use.
 •They must also be inspected by a competent
person at least once every 3 months. If a sling
is subject to severe conditions the inspections
should be more frequent.
 •Send slings for a proof load test at least every
12 months.
 LOOK FOR:
 •Any external wear such as abrasion or cuts
and contusions.
 •Internal wear which is often indicated by a
thickening of the sling or the presence of grit
and dirt.
 •Damage to the protective coating of the sling.
 •Damage caused by high temperatures,
sunlight or chemicals (indicated by
discolouration).
 Damage to the label or stitching.
 •Damage to the eyes or any terminal
attachments or end fittings.
 •Where the sling is covered by a sleeve,
the sleeve must cover the sling for the full
length from eye to eye.
 DISCARD A SYNTHETIC SLING IF:
 •It is considered that it has lost more than 10%
of its original breaking strength. (Send the sling
to the manufacturer for regular testing.)
 •The label has been removed or destroyed.
 •There is any damage to the sleeve or
protective coating.
 •A nylon sling comes into contact with acid.
 •A polyester sling comes into contact with
alkaline substances.
 •A polypropylene sling comes into contact
with an organic solvent such as, paint, coal tar
or paint stripper
 •There are any visible cuts on the sling.
 NB: A nylon sling will lose more than 10% of its
strength
 when it is wet.
 After 6 months exposure to sunlight send a sling
in for
 testing.
 Identification A further category of man-made fiber slings is the
round sling. This is manufactured from an endless polyester yarn
and covered with a protective polyester sleeve stitched as
illustrated. Maintenance
 •Safe working load markings.
 •Identity number.
 •Colour inspection code.
 •Broken load bearing internal yarn.
 •Cuts and abrasions to external cover.
 •Cuts in stitching.
 •Discoloration (due to chemical attack).
 •Burn marks on outer surface.
 •Knots. Action If any of the above faults are present refer to a
competent person for thorough examination. Maintenance
 •Keep clean and free form grit.
 •Re-apply colour code if necessary
 •Sling should be suspended in storage when not in use.
 inspecting the sling;
 •Sling should be laid out in good light and examined
over its entire length for:

 1.Damage caused by sharp edges (cuts)

 2.Damage caused by abrasion (burning or scuffing)
 3.Impact damage.
 4.Contamination by chemicals.
 5.ID tag with SWL marked ID number and length.
 6.Certification.
 The project operates a system where by all
―Lifting Equipment‖ is color coded with a
unique color, at monthly intervals, after
inspection where applicable.

 •Red color is reserved especially for items

scrapped or not to be used. We have to
comply with the project color coding
system every 3 months or depending upon
the project requirement.
 Three types of shackles are commonly used for
rigging applications. They are the anchor (bow
type), chain shackle (D-shackle) and wide-
body type shackle. Many more different type
shackles are available in the market-place
which should not be considered for rigging use.
Three suppliers of shackles are well known in
the construction industry with Crosby and
Green Pin being the leaders and most widely
utilized. Le Beon shackles can occasionally be
found as well.
 This bolt is used for normal lifting purposes
and has a link forged in the eye.
 This is designed for vertical lifting only.
 Identification There are various types of plate clamps in use, the following three being the most common:

 Inspection
 •Safe working load stamping.
 •Identity number.
 •Plate thickness marking
 •Colour inspection code (if used).
 •Free working of assembly.
 •Condition of ―teeth‖
 •Wear at all bearing points and on pins.
 •Cracks, nicks and gouges.
 •Inspect weld (if used).
 •Security of all pins.
 •Deformation.
 •Corrosion.
 •Condition of springs

 Action
 If any of the above faults are present refer to a competent person for thorough examination.
 Maintenance
 •Keep clean and free from grit.
 •Lubricate moving parts if necessary.
 •Re-apply colour code if necessary.
 Plate clamps are available in two basis designs, i.e horizontal plate
clamps (sued in pairs and usually suspended by a two leg sling from a
lifting beam) for handling plates in the horizontal position. (These clamps
can also lift from horizontal to vertical and vice versa, but should NOT be
used to transport plates horizontally).

 Selection
 The first consideration when selecting the clamp is how the plate is to be
transported and stacked, ie horizontal or vertically.
 The second consideration is the weight of the plate to be handled which
will determine the SWL of the clamps.
 The third consideration is the plate thickness which will determine the
correct model of clamp with the appropriate jaw opening.
 Pre-use Examination
 Before using any plate clamps, the following checks should be made:
 •The SWL is adequate for the load.
 •The colour coding (where applicable) is current and the clamp has a
plant number / ID mark.
 IDENTIFICATION OF RIGGING HITCHES
 CURVATURE: Sharp bends
in a wire rope sling
reduce its strength and
cause crushing. Fit a wire
rope sling so that the
minimum radius around
which it is bent is atleast
3 times the diameter of
the rope. Packing may
be inserted to increase
the radius of the bend.
 A calculated, design approved and
certified maximum load, normally
specified in Kilograms (kgs) or Tones, up
to which, an item of ―Lifting Equipment‖
is safe to operate.
 The center of gravity
of an object is that
point at which the
object will balance.
The entire weight may
be considered as
concentrated at this
point. Any suspended
object (load) will
center itself directly
under the hook.
 CRANES (Tower, Mobile, Crawler.)
 •Identification
 •Hand signals
 •Safety Procedures
 •Inspection
 Weights, Dimensions and Lift Radii
expected Type of Lifting to be done
 The Crane Position, where the Load is to
be lifted from, Access, Erection and
Dismantling restraints
 Site Conditions
 Character of the Ground and Soil
Conditions. Access and Stability Working
Area
 Presence and Location of any
Underground Hazards
 Be familiar with the lifting capabilities of the crane.
 •Check the lifting equipment being used is in good
condition, certified for use, correctly color coded,
and is of sufficient capacity to carry out the lift.
 •Ensure taglines are attached to loads which are
likely to swing.
 •Be aware of any obstruction within the crane radius
and working area.
 •Check that the area around the load to be lifted is
clear and that the load is attached to the floor,
transportation cradle or adjacent equipment.
 •Ensure that the escape route is identified.
 Set up the crane as close as possible to the load , set the outriggers and
block out securely ensuring that the crane is as level as possible. You
can use a level or the main block to level the crane.
 Barricade the area making sure that no other personnel other than the
rigging crew are within the barricade.
 Prepare the load for lifting making sure all equipment used is of sufficient
size and Safe Working Load including crane radius and boom length
 Rig the load once everything has been checked float the load making
sure it is balanced this assists the crane to check his brakes and stability
 When all the checks have been completed continue with the lift
following all safety procedures only one person giving the signals, using
tag lines to control the load if required.
 Once the load has been placed into its final position remove all the
equipment and barricades.
 Set up the crane as close as possible to the load , set the outriggers and
block out securely ensuring that the crane is as level as possible. You
can use a level or the main block to level the crane.
 Barricade the area making sure that no other personnel other than the
rigging crew are within the barricade.
 Prepare the load for lifting making sure all equipment used is of sufficient
size and Safe Working Load including crane radius and boom length
 Rig the load once everything has been checked float the load making
sure it is balanced this assists the crane to check his brakes and stability
 When all the checks have been completed continue with the lift
following all safety procedures only one person giving the signals, using
tag lines to control the load if required.
 Once the load has been placed into its final position remove all the
equipment and barricades.
 Most cranes are fitted with ‗C‘ type hooks to prevent snagging on protrusions such as
handrails, etc., and in certain cases also have safety catch to prevent the eye of the lifting
sling being accidentally displaced in the figure. Large cranes however tend to be fitted with
ramshorn type hooks which could have an effect on the sling design.
 Never attempt to make a lift
 from soft or unstable ground
 Over 50% of all crane accidents are the result of mistakes
made and rushed sloppy work done when the crane was
being put together, readied and placed to make its lifts.

 REMEMBER: Failure to follow just one safety precaution can

cause that accident, to men or machine.
 Just a little side tilt when lifting a load over the rear can become dangerous when
swung over the side.

 Load radius increases when swung over the side.

Required Clearance for Operations near High
Voltage Power Lines
To 50 KV 10 ft. 3.05 M
over 50 to 200 KV 15 ft. 4.60 M
Over 200 to 350 KV 115 ft. 4.60 M
Over 350 to 500 KV 25 ft. 7.62 M
Over 500 to 700 KV 35 ft. 10.67 M
Over 700 to 1000 KV 45 ft. 13.72 M
 Watch for boom
drawdown as the
 crane takes the
load. This increases
the radius and can
result in the load
drifting away from
the crane.
 THE RADIUS WILL
INCREASE WHEN
 A LOAD IS LIFTED.
 MEASURE THE LOAD
RADIUS BEFORE
MAKING CAPACITY
LIFTS.
 Always Ensure that
the Hook has got a
Safety Catch
 Lifting operation planning:
 Planning shall basically contain and consider the
following steps:
 Weight of the load
 Method of lifting
 Working radius
 Communication system
 Ground stability
 Existing services (AG / UG)
 Height restriction
 Competent resources
 Over head power line
 Selection of equipment
 Ground stability
 –When planning a lift, consideration must
be given to the ground conditions.
 •Outriggers
 –Sound timber packing or metal plates shall
be positioned under each outrigger pad /
Crawler to distribute the load. These should
be a minimum of 3 times the area
dimension of the outrigger pad.
 Outriggers must be fully extended on
both sides when performing a lifting
operation.
 –Outrigger pads are not to be
permanently attached to outriggers
 •A sign warning of the danger of
overhead power lines shall be mounted
in each crane.