BASIC RIGGING

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 Contents
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

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 INTRODUCTION
A. Mission

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.

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 B. Problem Analysis

Everyday, Routine Crane Operations

cause most of our accident due to lack of
adequate planning.

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 C. Expectation
To analyze all lifts
Ground Preparations
Using proper lifting tackles
Interpretations of capacity charts
Operators and signalmen must
maintain continuous and undivided
communication

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 D. Objectives
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.

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Roles and Responsibilities (Cont.)
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

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 Roles and Responsibilities (Cont.)
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

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Roles and Responsibilities (Cont.)
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

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 Roles and Responsibilities (Cont.)
Riggers and Slingers

Identifying any defects in lifting gear

Conforming the weight, center of gravity and
characteristics of a load prior to lifting

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 Roles and Responsibilities (Cont.)
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

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Wire Ropes

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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)

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 Wires in a Stranded Rope

Outer wire Centre wire

Inner wire Core wires

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 Stranded Ropes
Single layer Two layers Three layers
Rotates Rotational Resistant Low Rotation

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Rotation-resistant rope
(Illustration is 35LS - Low rotation rope)

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 Rope Dimensions

Actual (measured) diameter Nominal diameter (d)

22.2 mm 22 mm

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 Measurement of Rope Diameter
(New rope)
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.

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 Sheave Groove Profile

Wrong Wrong

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WHIP LASH:
A damaged or overstrained rope may break and cause serious
injury to anyone in its path.

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Slings

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 WIRE ROPE SLINGS
Inspection
Safe working load stamping. Soft Eye
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 Soft Eye Endless
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.
Grommet

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CARE AND USE OF WIRE ROPES.

Examine all wire ropes for damage before use.

Faults which may render a rope unserviceable
include;
Broken and fraying

Badly worn strands strands

Corrosion
Kinking.
Broken and fraying strands.

Corrosion Kinking

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Wire Rope Capacities

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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.

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SKETCH A SHOWS THE ARMS VERTICAL AND A
REASONABLY EASY LIFTING CONDITION.

SLING

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 SKETCH B SHOWS THE ARMS STRETCHED BEYOND ITS LIMIT WITH THE
LOAD. THE BODY AND SLINGS ARE NOT DESIGNED TO TAKE UN-NECESSARY
STRAINS.

SLING

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28
Caution Slung Angles are Critical

Slings should always On two leg sling work always be

be used as near aware of the changing SWL factor
vertical as possible. with the changing angles of the
In general if L is slings.
greater than S then
the slinging is OK

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 Chain Slings
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!

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Chain Slings

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 SPECIFIC REQUIREMENTS FOR THE
WEBBING SLING (FLAT & ROUND)
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.

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 BELT SLINGS
Identification
Safe working load marking.
Identification mark.
Colour inspection code (if used).
Condition of stitching.
Tears or abrasions
Burning of outer surface.
Excessive wear. Belt Sling with Eyes
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.

Endless Belt Sling

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Flat Webbing and Round Synthetic
Slings
Types of synthetic slings and fittings

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 Flat Webbing and Round Synthetic
Slings
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.

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 Flat Webbing and Round Synthetic
Slings
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).

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 Flat Webbing and Round Synthetic
Slings
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.

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 Flat Webbing and Round Synthetic
Slings
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.

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 Flat Webbing and Round Synthetic
Slings
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.

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Flat Webbing and Round Synthetic
Slings

(b) Some damage to load-bearing fibres (c) Badly damage sleeve

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 Flat Webbing and Round Synthetic
Slings

(e) Cut load-bearing fibres

(d) Load-bearing fibres have been cut (f) Broken load-bearing yarn

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 Flat Webbing and Round Synthetic
Slings

(g) The use of hooks that are too narrow (h) Burn damage to sleave and (i) Surface wear evident by furry surface
load-bearing yarn
has damaged the eye of the sling

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 ROUNDSLINGS
Identification Typical Round sling colour coding
(Basic Configuration)
A further category of man-made fiber slings is the round sling. WLL Tonnes Colour
This is manufactured from an endless polyester yarn and
1.0 Violet
covered with a protective polyester sleeve stitched as illustrated. 2.0 Green
3.0 Yellow
4.0 Grey
Maintenance 5.0 Red
Safe working load markings. 6.0 Brown
Identity number. 8.0 Blue
10.0 Orange
Colour inspection code.
Broken load bearing internal yarn.
Cuts and abrasions to external cover. Endless Round Sling
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.
Round Sling with eyes

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 SLING INSPECTION
while 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.

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 COLOR CODING
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.

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Thumb Rules

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Bow Shackles

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 SHACKLES
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.

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Screw Pin Anchor Shackle Bolt Type Anchor Shackle

Screw Pin Chain Shackle Bolt Type Chain Shackle

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 Wide Body Shackles
Greatly improve wear-ability of wire
rope slings and can be used to connect
high strength Synthetic Round Slings
or Wire Rope Slings by improving the
D/d ratio. The sling bearing area
increases by a minimum of 58 %
which increases sling strength by a
minimum of 15 %. Pins are smaller
than equally rated quenched and
tempered shackle pins and for
instance a 75 Tonne wide body
shackle can be utilized where a 55
Tonne normal quenched and
tempered shackle is intended to fit.

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 Normal Shackle
Reduced Sling Bearing Area in Shackle Bow

Wide Body Shackle

Increased Sling Bearing Area up to 58 %.
Increases usable sling strength up to 15 %

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A simple Formula is used to calculate the
Factor of D/d

0.5
Factor = 1 -
D/d

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This means if a 25 mm Diameter Sling is
used over a 30 mm Pin the Equation will
be:

0 .5 0.5
1- = 1- = 1 0.416 = 0,584
30 / 25 1.2

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54
Rigging Hitches & Slinging Methods

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IDENTIFICATION OF RIGGING HITCHES

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 PRECAUTION WHEN USING
LIFTING GEAR

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.
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Slinging Hazards

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Slinging Hazards

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60
 SOFT EYE
Not to be hammered
down

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 DOUBLE CHOKER
OR
A PAIR OF CHOKER HITCHES

Not to be hammered down.

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 DOUBLE BASKET
OR
PAIR BASKET HITCHES

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64
SAFE WORKING LOAD (SWL)
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.

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 CENTER OF GRAVITY
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.

STABLE Hook is directly above

Center of Gravity

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UNSTABLE
Load is not above Load will shift until
Center of Gravity Center of Gravity is
below the Hook

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 UNSTABLE
Load is not above Center of Gravity

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69
Rules to Follow When Slinging and
Handling a Load

Move
Raise

Lower
slowly

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Basic Knots

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 ROUND TURN AND
TWO HALF HITCHES
Used to secure a rope to a column or post. Easily tied and does not jam.
Will stand heavy strain without slipping.

BOWLINE
A favorite knot with riggers and one of the best
known and widely used of all knots.
It is easily constructed and used wherever a
hitch is required that will not slip, jam or fail.

REEF KNOT
Also known as the square knot. Used to join two rope or
lines of the same size. Holds firmly and is easily united.

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Chain Blocks,
Pull lifts,
Tirfors, eye bolts, plate clamps,
turnbuckles, hooks, lifting
beams

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 USING CHAIN BLOCKS
Ensure that the SWL of Head Lifting
the chain block is
adequate for the load to
be lifted.
Attach the head fitting
to a suitable anchorage
Pull the operating chain
to determine the
hoisting and lowering Load Chain

sides of the chain.

Attach the load to the Safety catch
hook using correct slings
and / or shackles. Hook
Pull down the relevant
side of the operating
Operating Chain
chain to hoist or lower
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the load.
 USING PULL LIFTS
Head fitting

Hand wheel

Pawl Lever

Attach the head fitting to a Operating Lever

suitable anchorage taking
into account the load to be
Step Line
lifted, lowered or pulled.

Hook with Safety catch

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 PULL LIFT OPERATION:
HOISTING OR PULLING:

1. Turn the lever to the neutral

position.
2. Turn the hand wheel to adjust the
chain to the required length.
3. Attach the load to the bottom hook,
using appropriate slings and / or
shackles.
4. Turn the lever to the up position.
5. Turn the hand wheel to take up the
slackness in the chain.
6. Operate the handle backwards and
forwards to lift or pull the load.

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 LOWERING:
To lower the load, turn the lever
to the down position.
Operate the handle backwards
and forwards to lower the load.
When the load is securely in
position, operate the handle to
slacken the chain.
Turn the lever to the neutral
position and turn the hand
wheel to give sufficient length
of chain to be able to release
the slings and / ore shackles.

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Examine a
chain before
using it.
Look for
stretched
links, wear,
distortion
and any
other sign of
weakness.

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 HAND OPERATED WINCH / TIRFOR
Identification
A hand operated, lever controlled friction drive mechanism for lifting,
lowering and pulling a load.

Identification
Safe working load stamping.
Identity number.
Colour inspection code (if used).
Check for free operation of operation, reversing and rope release lever.
Check that correct shear pins are fitted, and pin condition is satisfactory.
Inspect complete machine for cracks, indentations or distortion.
Wear in operation jaws
Corrosion.
Inspect wire rope and hooks.
Correct rope.
Damage to casing.

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 Identification
This is a multi purpose tool made to pull and
pay-off wire rope.
A special wire rope is fitted through the
machine and cannot be removed whilst
there is a load on the winch.
When the operating handles are actuated by
hand, the rope is either pulled or paid-out
through the machine.
These machines are available in a range of
Sizes to suit different working conditions.

Using the hand-operated winch 2. Push the release handle into the notched position to
1. Uncoil the special wire rope, used with the machine, in a straight open the jaws inside the machine.
line to prevent loops which might untwist the stands or form kinks 3. Insert the tapered end of the wire ripe into the
under tension. machine at the hole in position A

Notched Release
position handle

A
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4. Push the rope through the machine until it emerges at 5. Anchor the machine using the correct slings.
exit B. Fit them to the hook attached to the machine.

B
Hoisting or Pulling
Fit the operating handle on to the actuating lever and work the handle
to and fro.
6. Pull the wire rope through the machine until the
This action pulls the rope through the machine and automatically
desired length is reached and the rope
locks it in position when the operating handle is released.
becomes tight on the load.
7. Lift the release handle out of the notched
position and allow it to return to the operating
position under its spring pressure. The rope is
now firmly held in jaws fitted inside the
machine.

Actuating lever

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Lowering or slackening off
Lowering lever
Fit the operating handle to the lowering
lever and work the handle to and fro.
this action pulls the rope back through the
machine and when the handle ceases to
move automatically locks the rope in
position.

Releasing the wire rope

from the machine
1. Fit the operating handle on to the lowering lever
and work the handle to and fro until all the
tension is taken off the rope.
2. Remove the anchoring slings.
Push the release handle to the notched position
to open the jaws inside the machine
3. Pull the rope back through the machine.

The jaws in the machine automatically lock the

rope in position. It is therefore impossible to
release the wire rope form the winch whilst there
is any strain (load) on it.

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 COLLAR EYE BOLT

This bolt has a small

eye; a large collar
with a machined
under face which is
relieved to allow a
radius between collar
and shank and to
provide a thread run
out.

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 EYE BOLT WITH LINK

This bolt is used

for normal lifting
purposes and has
a link forged in
the eye.

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 DYNAMO EYE BOLT

This is designed for

vertical lifting only.

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PLATE CLAMPS
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. Universal Vertical Horizontal
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.

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 PLATE CLAMPS
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 Horizontal Clamps Universal (Vertical) Clamps

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.

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Lock the jaw in the closed position and ensure the jaws have a firm bite on the plate.

Always
i) Check that the plate is clean and free from mill scale, dirt, Oil and grease.
ii) Double check that the jaws are locked.
iii) Use an adequate number of clamps to balance the load.
iv) Lift slowly to allow the jaws to obtain a good grip.

Never
Attach clamps to the side of the plate

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Never
Fast lower onto the floor as this could cause the clamp to open and release the
plate.
Lift horizontally with a vertical clamp.
Lift more than one plate at a time.
Use large capacity clamps to lift light loads.

When using horizontal plate clamps, do not exceed the sling angles indicated
below and do not lift more than one plate at a time unless the clamps are suitable,
i.e. sheet bundle clamps

Never
Use endless slings with clamp pairs as this practice
can drastically overload the clamps.

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 COMMON TURNBUCKLE
Turnbuckles (Rigging Screws) can be obtained with various types and combinations of end
fittings, the most popular being the Jaw and Eye type.

Jaw & Eye combination

Jaw & Jaw combination

Hook Hook & Hook combination

Eye Jaw Stub
(Has Reduced
Selection capacity)
The first consideration when selecting turnbuckles
Hook & Eye combination
is the SWL which is determined by the thread diameter.
The second consideration is the adjustability (commonly known as Take-up) of
the turnbuckle. The take-up often varies with different patterns.

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When using a turnbuckle in an application where vibration is present, (most areas in an engineering
environment), it is extremely important to lock the end fittings to the frame or body to prevent them from
unscrewing and possible releasing the load. The most popular and preferred method is to wire the eye or jaw
to the body (see fig. 1). As an alternative (for open body type only) a split pin through the end of the screwed
shank is acceptable (see fig 2). The split pin has to be removed to facilitate adjustment. Should lock nuts be
used, care must be taken not to over tighten them as this can put undue stress on the threaded shank (see fig
3)

Lock wire will hold

Preferred Acceptable Caution Required

Fig - 1 Fig - 2 Fig- 3

WARNING
When turnbuckles are to be left under load for any length of time, eg temporary hangers for
pope work, etc they should be visually checked on a daily basis to ensure they are still secure.

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 PRE-USE EXAMINATION
Prior to using a turnbuckle in a lifting situation, visually examine it and ensure that:
i) The SWL is adequate for the load.
ii) The colour code is current and the turnbuckle has a plant number / I.D. mark.
iii) The threads are free from wear, stretch and impact damage.
iv) The eyes/hooks are not worn or stretched.
v) The clevis pin and pin holes are free from distortion/wear.
vi) The threads are suitable lubricated.

Check for cracks & bends

Safety
Turnbuckles must always have the threaded shank protruding into the body to ensure
Checkshank.
that the load is borne over the correct length of the threaded for thread damage & bent rods

Particular care must be taken when using Closed Body type screws. It may be necessary
CORRECT
to dismantle to dismantle the turnbuckle, measure the length of the UNSAFE
threaded shanks,
reassemble and use measurement to ensure the above unsafe case is avoided.

92
 SWIVEL HOOKS WITH SAFETY
CATCHES
These allow the load
to be moved round
without twisting and
possibly endangering
slings, wire ropes and
chains. The safety
catch ensures that the
rope or chain does not
slip off the hook.

93
CARE OF HOOKS:
Fit a shackle between the
lifting hook and the eye
bolt to prevent the point
of the hook being
strained.
The shackle will swivel to
allow the sling and hook
to make a correct lift as
illustrated along side and
below.

Note: Collar eye bolts

are not designed to take
hooks.
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CARE OF EYE
BOLTS:
Always tighten eye bolts to
the correct position, but do
not over strain them. Fit a
shackle so that the
minimum strain is imposed
when the lift is made
unless an eye bolt with link
is used.

Ensure the collar is hard

down on the material and
the eye in the right
direction for the lift.

95
 WEIGHT OF SPREADER BEAM AND
LIFTING BEAMS

Weight of spreader beams can be calculated from weight tables of

the steel section, from which they are made, or obtained from the
manufacturers specification.

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LIFTING APPLIANCES

97
 LIFTING APPLIANCES

CRANES (Tower, Mobile, Crawler.)

Identification
Hand signals
Safety Procedures
Inspection

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Rough Terrain
(RT) All Terrain (AT)

Crawler

Truck Crane (TC)

99
Crane Selection
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

100
Site Review and Crane Setup
Character of the Ground and Soil
Conditions.

Access and Stability

Working Area

Presence and Location of any

Underground Hazards

101
 RESPONSIBILITIES

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.

102
 THE PROCEDURE FOR SETTING UP
AND WORKING WITH A CRANE

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.

103
 WHEN WORKING WITH CRANES YOU MUST
BARRICADE THE WORKING AREA

BARRIER .
TAPE
Z
A
W

CONES
E

.
D

Z
.
A
W
E
D

. .
WARNING Z
A

SIGNS
W
E
D

104
Crane Mats

105
Isolate Working Area

106
 CRANE HOOKS
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.

Soft
Eye Hard
Soft Eye
Eye

C Hook Ramshorn Hooks

107
IDENTIFICATION OF TYPES OF CRANE &
THEIR PARTS

108
Poor Ground Conditions are a Factor in
Many Accidents

Never attempt to make a lift

from soft or unstable ground

109
 Poor Ground Conditions are a Factor in
Many Accidents

Over 50% of all crane accidents are REMEMBER: Failure to follow

the result of mistakes made and just one safety precaution can
rushed sloppy work done when the cause that accident, to men or
crane was being put together, readied machine.
and placed to make its lifts.

110
 Failure to Level the Crane is a
Common Accident Cause
What can happen
when you swing
over the side!

Just a little side tilt when

lifting a load over the rear
can become dangerous Load radius increases when
when swung over the side. swung over the side.

111
 LEVELING THE CRANE
The line
Should lie dead in the centre of the boom in all
positions, end, side and corner.

WRONG RIGHT

Leveling With the Load Line 112

Check That Cranes are Level
113
Possible Capacity Loss Due to being out of Level

Boom Length and Radius Capacity Lost

When out of Level
1 2 3
Short Boom, Minimum Radius 20 % 20 % 30 %

Short Boom, Maximum Radius 8% 15 % 20 %

Long Boom, Minimum Radius 30 % 41 % 50 %

Long Boom, Maximum radius 5% 10 % 15 %

Accurate Calculations are available from the specific, applicable Crane Manufacturers

114
 Failure to Level the Crane is a
Common Accident Cause
The machine must be level Remember capacity chart ratings are
based on ideal conditions:
Standing on firm, level surface
CALM wind
No side loads or outswing of load
Good visibility
Machine in A-1 condition and equipped
as when leaving the factory.

When such conditions cannot be attained,

loads being handled must be reduced to
compensate.

DONT FORGET:

If a tipping condition is suddenly sensed

start lowering the load and retract or
elevate the boom to bring the load in. Never
lower the boom and aggravate the
condition.

115
Many Crane Accidents are Caused by
Poor Blocking Under Floats

116
Many Crane Accidents are Caused by
Poor Blocking Under Floats

USE SOLID BLOCKING

UNDER ALL FLOATS

THE CRANES BEARING PRESSURE MUST BE DISTRIBUTED TO THE GROUND BY USING

LARGE TIMBER BLOCKING

WARNING:
Only cranes with approved free on wheels ratings can be used without outriggers set.

117
Set Outriggers Correctly

118
 Set Outriggers Correctly
OUTRIGGERS:

Capacities are based on all outriggers fully extended. Working

with outriggers partially retracted will reduce capacities and
machine stability considerably and may cause an accident. If it is
absolutely necessary to operate a machine with outrigger beams
partially retracted, reduce capacities to those shown on the chart
for on rubber. Remember the machine must be level.

DONT OPERATE WITH ONLY REAR OUTRIGGERS EXTENDED. If

you swing over the side, the machine may tip over, or the boom
may be damaged from side loadings because the machine is not
level.

119
 Set Outriggers Correctly

When working a machine with mechanical (non-hydraulic)

outriggers, make sure the beams are pinned in place, otherwise
they can creep in while operating, causing an unstable
condition and possibly tipping the machine over.

WARNING

Before travelling make sure mechanical outriggers are securely

pinned in position otherwise they can come out on the road and
cause serious damage.

120
 Set Outriggers Correctly
HYDRAULIC OUTRIGGERS:
When setting hydraulic outriggers make sure that the
outriggers are set evenly otherwise severe twisting of the
cranes chassis frame will result.

121
 Exceeding the Rated Capacity of any
Crane is Dangerous
Overloads can damage the machine and such damage causes
failure and accidents.

It looks like about

10 tonnes.

Whoops!

122
Spreads out the load so the supporting surface can support it

Transmits the load without bending or breaking

123
WRONG

124
Setting Up and Parking

Do not set up too close

to trenches etc., as the
machine vibration can
cause the walls to
collapse.

125
WRONG

126
WRONG
127
Know Conditions and Use
Precautions

128
Ensure Handbook
and Chart are with
Crane
129
130
 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

All overhead Lines and other apparatus should be treated

as live unless officially declared DEAD and SAFE.
If in doubt, seek advise
131
During Thunderstorms and Lightening STOP
Work and retract/lower Boom

132
Mechanical
Advantage

Correct
Wrong

133
MECHANICAL ADVANTAGE

134
Wedge Socket

135
Two Block Cutout

136
Know The Radius Of The Load
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.

137
Always Ensure
that the Hook
has got a
Safety Catch

138
Never let the
Boom touch a
Structure

139
 It
Might
Cause
the Boom
to
Collapse
Or Damage

140
Use Taglines

141
 Always Stand Clear
of Suspended Loads

Never Let Anyone Ride on a

Suspended Load

142
IDENTIFICATION OF CRANE HAND SIGNAL

143
The Users Responsibilities

Crane
Operator
Rigger

144
 Protecting Rigging From
Damage or Environment
Rigging components are expensive to buy and to replace!
Use them properly and store them properly!
Keep wire rope slings lubricated and all rigging stored out of
the weather.
Treat the rigging as though your life depended on it!
Because it does if it fails!
Dont use makeshift rigging or attempt to repair any rigging
components.
Knots tied in rigging reduces the strength by 50% or more!

145
 Lifting Operations Procedure
(Cont.)
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

146
 Lifting Operations Procedure
(Cont.)
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.

147
 Lifting Operations Procedure
(Cont.)
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.

148
 Lifting Operations Procedure
(Cont.)
Lifting Equipment
The lifting equipment operator shall not begin the machine
movement, until the banks-man is within his range of vision, or
in radio contact, and the signal is given and understood.
Where several individuals are involved, the crane operator shall
obey the signal of the
banks men ONLY.
The only exception shall
be in the case of an emergency,
when the crane operator can
receive the Emergency Stop
Signal from anyone

149
 Lifting Operations Procedure
(Cont.)
Restrictions to crane operations
The most common restriction to lifting operations is bad
weather, specifically high wind.
However, No lifts will be permitted at wind speeds
exceeding 30 Knots or 35 Miles per hour.
When working in close proximity to overhead electric
lines or cables, the crane shall not be positioned closer
to the plumb of the nearest line or cable than a distance
equal to the length of the crane Jib fitted, plus 6 meters
measured along the ground.

150
 Lifting Operations Procedure
(Cont.)

Communication

An effective communication system

shall be in place for all lifting
operations.
The type of system will depend on the
nature of the task i.e., radio
communication may be necessary
when visibility between the crane
operator and the Banks-man is
restricted.

151
 Lifting Operations Procedure
Color Code System
(Cont.)
The Color Code System shall be developed and implemented for all
Lifting Gear used within the Project such as for slings, shackles, rope
wire, belts.
The color shall indicate to the user and the inspector, that an examination
has been performed within the prescribed period.
A new color shall be introduced on regular basis as per the Project Color
Coding System and each color shall be current for a specified period
Information boards showing the current
color coding shall be posted at prominent
locations at each work site where it is
anticipated lifting operations will take
place.

152
 Lifting Operations Procedure
(Cont.)

Lifting Operations Check List

A Risk assessment shall be conducted prior to
any lift being performed.
The lifting operations check list acts as a
reminder and guidelines to the personnel
concerned, and basically consists of the items
shown below and listed in the Lifting Operations
Procedure.

153
 CRANE OPERATION ANALYSIS
"our plan for a safe job"

Crane: Date: Time:

Crane has been inspected/ safe condition:. Yes No
Job Location:
Job Description:

The weight of the load is:

The swing radius of the lift is:
Net crane capacity at this radius is:
Is operator qualified to operate this crane? Yes No
Is operators certification card current? Yes No
Critical lift permit required for this lift? Yes No
Crane level/outriggers fully extended? Yes No
Is the rigger qualified for this task? Yes No
Is sling/hardware in safe condition? Yes No
Sling sizing/hookup reviewed? Yes No
Do sharp edges have softeners? Yes No
Tag lines needed to help control load? Yes No
Center of gravity of load located? Yes No

EMERGENCY INFORMATION
What is the wind direction?
Reviewed emergency alarms/phone numbers Yes
Escape route(s):
Location of eyebath/shower station:

Our evacuation assembly point is:

Operator Signature:
Rigger Signature:
Signalman Signature:
Supervisor Signature:

154
RIGGING PLAN

155
 RIGGING COMPONENTS
List each component

Slings

Type Hitch Cap. Sling Angle Actual Cap.

Sling 1

Sling 2

Sling 3

Sling 4

Shackles

Size Capacity

Shackle 1

Shackle 2

Shackle 3

Shackle 4

Other Devices:

Description Capacity

How has the lifting area been restricted?

________________________________________________________________
________________________________________________________________
_____________________________________________________________

156