Metals

Mechanic III

Module 3.2
Rigging Hardware

Saudi Aramco Training

 TABLE OF CONTENTS

Unit 3: Rigging

Module 3.2

Rigging Hardware

TRAINEE HANDBOOK
Information Sheets

Exercise A 21

Exercise B 30

Exercise C 39
 INFORMATION SHEET

Enabling Objectives Terminal Objective

3.2.1 Unaided, the trainee will
Unaided, the trainee will correctly state the functions correctly inspect basic
of and inspection requirements for rigging hardware. rigging hardware to
determine serviceability in
3.2.2 accordance with relevant
Unaided, the trainee will correctly state the functions Saudi Aramco GIs.
of and inspection requirements for manual hoisting
equipment.

3.2.3
Unaided, the trainee will correctly state the functions
of and inspection requirements for slings.

INTRODUCTION

As you learned in the last module, the ability to

perform rigging and lifting tasks is and important
skill for metals mechanics.

In this module, you will learn to identify various You must perform a
common items of rigging equipment and learn why pre-use inspection on
ALL rigging equipment.
they are used. You will also learn how to perform Remember, safety is YOUR
pre-use inspections on rigging equipment. responsibility.

Module 3.2 1
 INFORMATION SHEET

PART I OBJECTIVE 3.2.1

State the Functions Of and Inspection

Requirements for Rigging Hardware

In Saudi Aramco, when heavy loads are moved with

ropes, chains, hoists, etc., the process is called lifting
and rigging.

As a field metals mechanic, you will be tasked with

using rigging and lifting equipment. Therefore, you
must learn to identify, use, and inspect rigging
hardware.

CONNECTING EQUIPMENT

Rigging hardware includes a number of different

connectors. To be able to use these connectors, you
must be able to identify them – and know their
purpose and use.

Shackles

Shackles are U-shaped connectors. You will use them

KLE to connect up (couple) slings to eyes, and hooks to
eyes. While a number of different shackle types are
available, all shackles consist of two parts: a body
TH
and a pin.

Two types of shackle are in common use: the Bow

COTTER
type and the D-type. Both Bow and D-types are
KEY
available with screw pins, round pins, or safety pins.
(See figure 2).
ST

A screw pin has threads that screw into the shackle

body, while safety pins are held in place by a cotter
Figure 1 pin. (See figure 1)

2 Metals Mechanic III

 INFORMATION SHEET

BOW SHACKLES

EW PIN ROUND PIN SAFETY PIN

D-TYPE SHACKLES

Figure 2
Shackles

Shackles are sized by their body diameter, not the

pin size. The safe working load (SWL) and
manufacturer’s name are stamped on each shackle.
The safe working loads of selected sizes of bow
shackles are shown in Figure 3.

Module 3.2 3
 INFORMATION SHEET

STOCK INSIDE WIDTH MAX. SAFE MAX. SAFE

DIAMETER AT PIN WORKING LOAD WORKING LOAD
( INCHES ) ( INCHES ) SINGLE VERTICAL SINGLE VERTICAL
PULL PULL
A B (POUNDS) (kg.)
3/16 3/8 665 302
1/4 15/32 1,000 454
5/16 17/32 1,500 680
3/8 21/32 2,000 907
A 7/16 23/32 3,000 1,361
1/2 13/16 4,000 1,814
5/8 1 1/16 6,500 2,948
3/4 1 1/4 9,500 4,309
7/8 1 7/16 13,000 5,897
1 1 11/16 17,000 7,711
B 1 1/8 1 13/16 19,000 8,618
1 1/4 2 1/32 24,000 10,886
1 3/8 2 1/4 27,000 12,247
1 1/2 2 3/8 34,000 15,422
1 3/4 2 7/8 50,000 22,680
2 3 1/4 70,000 31,751
2 1/2 4 1/8 100,000 45,359
3 5 150,000 68,038
3 1/2 5 3/4 200,000 90,718
4 6 1/2 260,000 117,933

Figure 3
Examples of Shackle Safe Working Loads

The load on a shackle pin must be as close as

possible to the shackle’s vertical centerline. To do
this, you may sometimes have to use washers to
center the load on the pin.

Capacity is the ability to support The purpose of centering the load is to prevent the
a load of a certain weight. loss of capacity when the load pulls the shackle at an
angle from the vertical position.

4 Metals Mechanic III

 INFORMATION SHEET

WASHERS HOOK

NEVER USE SCREW PIN SHACKLES

IF THE PIN CAN ROLL UNDER LOAD.
ALWAYS HAVE THE PIN THROUGH THE
SLING EYE.
PULL
N TURNS
GETS
TIGHT.

INCORRECT CORRECT

Figure 4 Figure 5
Center Load the Pin Unfastening Screw

Shackle Inspection

Before use, you must ensure that rigging hardware

has the capacity for the task (SWL) and is safe to
use. Because shackles can be damaged from
overloading and misuse, before use you must
perform a visual inspection to check:

❏ Safe Working Load (SWL) visible stamp

❏ Cracks
❏ Distortion (bent or stretched by overloading)
❏ Stripped or damaged screw heads
❏ Worn shackle or pin

Refer to the shackle inspection points shown in

Figure 6. During your inspection, check that all pins
are straight, and all screw pins are completely seated.
For round or safety pins, ensure that a cotter pin is
securely fitted.

Module 3.2 5
 INFORMATION SHEET

THREADS ON
PIN AND BODY

CHECK FOR
WEAR

CHECK FOR
WEAR AND
BODY STRAIGHTNESS

CHECK THAT PIN

IS ALWAYS
SEALED

CHECK FOR CHECK S.W.L. CHECK THAT

CRACKING IS STAMPED ON SHACKLE IS NOT
AROUND EYES THE SHACKLE "OPENING"

Figure 6
Shackle Inspection Points

Eyebolts

Eyebolts are threaded connectors. They are installed

on loads to provide a place to attach slings.
Commonly, eyebolts are permanently installed on
equipment that must be removed/dismantled
regularly. When eyebolts are permanently installed,
they are usually placed so that the load can be
raised in a balanced position.

Rigging work typically uses two types of eyebolts: the

shoulder type and the straight shank. (See figure 7)

Shoulder type eyebolts are specially designed to be

SHANK
stronger when weight must be taken up at an angle
Figure 7 to the shank. Even so, shoulder type eyebolts will
Eyebolts bend or break if too great an angle is used.

6 Metals Mechanic III

 INFORMATION SHEET

FOR SAFETY, IT IS
BEST TO USE
STRAIGHT SHANK
EYEBOLTS
VERTICALLY.

Figure 8
SWL – Straight Shrank Eyebolts

To prevent damage to the eyebolt and potential

accidents from equipment failures, the force on a
shoulder-type eyebolt must never be at an angle
greater than 45° from the shank. (See figure 9 for
safe working loads for shoulder-type eyebolts.)

VERT. 75 O
O
65
O
45
EYE BOLTS DO NOT USE
SHOULDER TYPE ONLY
FORGED CARBON STEEL

STOCK
TO ANGLE OF PULL
DIAMETER
(INCHES) O
VERTICAL 75 O 60 O 45 O LESS THAN 45
1/4 500
5/16 800
RECOMMENDED

3/8 1,200
1/2 REDUCE REDUCE REDUCE
2,200
VERTICAL VERTICAL VERTICAL
NOT

5/8 3,500
LOADS LOADS LOADS
3/4 5,200
BY 45% BY 65% BY 75%
7/8 7,200
1 10,000
1 1/4 15,200
1 1/2 21,400

NOTE: S.W.L. FOR PLAIN (SHOULDERLESS) EYE BOLTS ARE SAME AS FOR SHOULDER BOLTS UNDER VERTICAL LOAD.
ANGULAR LOADING IS NOT RECOMMENDED.

Figure 9
SWL – Shoulder-Type Eyebolts

Module 3.2 7
 INFORMATION SHEET

Eyebolt Inspection

As will all rigging hardware, you must inspect

eyebolts before use. Check for:

❏ Signs of any cracks (often found on the inside

and outside diameters at the top of the eye).
❏ Stripped threads (most commonly caused by
cross threading or inadequate screw depth on
lift).
❏ Bending of shank or body (often caused by
incorrectly angled lift).
❏ Distortion of the eye (overloading commonly
causes eye to distort out of shape).

Hooks

Hooks are used as connectors on hoists, cranes, and

THR EYE
slings. Hooks can be connected to shackles, chains,
or directly to the eyes of slings. While hooks come
in many different sizes and shapes, they all have the
same function.

Hook Inspection
SHANK Before use, you must check the hook has the
capacity (SWL) for the task, and is safe to use.
Figure 10
Hooks Check for

❏ The SWL stamp - it must be visible and of the

NOTE: All detached
hooks must have their
required capacity.
SWL or Code Number
stamped. Hooks permanently ❏ Any cracks.
attached to hoist chains, chain
slings, cranes, and wire rope ❏ Safety latch is fitted, and operates correctly.
slings will have been tested to
the SWL stamped on the hoist, ❏ Signs of excessive wear.
crane, and chain slings etc.
❏ Bending of the hook.

8 Metals Mechanic III

 INFORMATION SHEET

Wire Rope Clips

Wire rope clips are a method of attaching a wire

rope to other equipment. The clips are used to form
U-BOLT
an eye, or connect wires of the same size.
BRIDGE
The most common wire rope clip used in Saudi
Aramco is the U-bolt. This consists of a U-bolt, a
bridge, and two nuts. (See figure 11).
NUT

There is only one correct method of attaching U-bolt

wire rope clips. The bridge (flat) of the clip must bear Figure 11
U-Bolt
against the live end of the rope, while the U section
presses against the dead (short) end. (See figure 12.)

DEAD END
SEIZINGS OF ROPE

LIVE END
OF ROPE CLIPS THIMBLE

Figure 12
U-bolt Wire Rope Clips

To ensure holding power, clips are usually spaced

about six rope diameters apart. Heavy-duty thimbles
should be provided for each eye. - If properly made,
a clipped eye should develop about 80% of the
strength of the rope.

NOTE: If using this method, before placing ropes under Wire rope clips must
tension, tighten the clip nuts. – Tighten them again after not be used to
the load is on the rope. manufacture a sling.

For safe use, permitted number of clips and their

spacing is shown in table 1.

Module 3.2 9
 INFORMATION SHEET

Rope Approx. Min. No. Spacing of

Dia. Weight Clips for Each Clips
in lb. Rope End in.

3/16 0.10 2 1 1/8

1/4 0.19 2 1½
5/16 0.29 2 1 7/8
3/8 0.47 2 2¼
7/16 0.70 2 2 5/8
1/2 0.78 3 3
5/8 1.06 3 3¾
3/4 1.59 4 4½
7/8 2.40 4 5¼
1 2.72 4 6
1 1/8 3.20 5 6¾
1¼ 4.50 5 7½
1 3/8 4.60 6 8¼
1½ 5.80 6 9
1 5/8 7.20 6 9¾
1¾ 9.50 7 10½
2 12.50 8 12
2¼ 15.50 8 13½
2½ 18.00 8 15

Table 1
Number of clips and Spacing for Application

Wire Rope Clip Inspection

Wire rope clips are subject to damage by over

tightening of nuts and other misuse. Therefore,
before use you must check for:

❏ Stripped threads.
❏ Corrosion (on threads, wire and U-bolt itself ).
❏ Improper clips (clips must be correct for task
and all of same type).
❏ Improper spacing (clips should be approx. six
rope diameters apart).
❏ Improper positioning (U-bolts must bear on
short or dead end of rope).
10 Metals Mechanic III
 INFORMATION SHEET

Spreader and Lifting Beams

Spreader and lifting beams are custom-made steel

devices. They are designed to distribute the load
from one or more points to different points as
required by the load.

The terms spreader and lifting beams are often used

interchangeably. For example, the beam supporting
the two slings and tubing load shown in figure 13
can be called a lifting beam or a spreader beam.

HOIST BLOCK

BEAM

SLING

Figure 13
Spreader or Lifting Beam

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 INFORMATION SHEET

Purpose of Spreader Beam

The purpose of a spreader beam is to prevent loads

from being crushed. The beam is used when existing
pick (lifting) points on a load are to be matched or
to provide load stability by preventing the load from
sliding, tipping, or bending. The beam moves up
and down with the load. (See Figure 14.)

Purpose of Lifter Beam

A lifting beam is attached to the load end of a line

or to a fall block. Their use distributes load weight
Figure 14 from one point to two (or more) points. In this
Spreader Beam way, load weight is evenly dispersed over two or
more lift points rather than overstressing one single
point. This allows a number of smaller rigging items
to be used in place of a single large item.

The beam moves up and down with the load. The

beam is used when two or more slings or other
lifting devices are combined to lift a single load. All
of the rigging equipment must be counted as part of
the load.

12 Metals Mechanic III

 INFORMATION SHEET

Figure 15
Lifting Beams

Although custom made, beams can often be

modified and used for other applications. Large
rigging contractors and companies usually have a
variety of beams on hand.

Each beam should be marked with its weight and

capacity (safe working load). If a beam’s weight is
not marked, it can be calculated from weight tables
of the steel sections they are made from, or obtained
from the manufacturer’s specifications

NOTE: Beams made for Saudi Aramco are tested at 125%

of their safe working load (SWL) every three months. Figure 16
Beam Marking

Module 3.2 13
 INFORMATION SHEET

Refer to the engine lathe mounted on wood skids

shown in Figure 17.
a b
A B Note: a lathe has a very high center of gravity, (shown by
the letters CG).

CG
In 17 A, lines have been drawn from the center of
gravity to where the skids rest on the basket slings
a b
(a and b). Compare these angles to the slings above
ANGLES A B MUST BE
the spreader. To insure stability, angles A and B
GREATER THAN ANGLES a b must be much larger than the angles a and b.

17 B shows what can happen if the angles are

incorrect. The center of gravity will to the lowest
point below the point of support (the hoist hook).

CG You must take the same precautions when using a

rigid spreader, as shown in 17 C.

Beam Inspection
IF ANGLES INCORRECT, THE CENTER Before use, you must inspect a beam to ensure that:
OF GRAVITY SHIFTS

❏ Its capacity (SWL) is adequate for the task.

❏ The beam is straight and true (not warped or
A B bent).
❏ The eyes and connections are not distorted or
Figure 17 cracked.
Ensure Slide Angle Maintained
❏ None of the beam fittings are damages, worn,
cracked or distorted.

14 Metals Mechanic III

 INFORMATION SHEET

Beam Clamps

Beam clamps are temporary overhead attachments

for hoisting when lifting a load. The clamps fit on FLANG
I - BEAM

the flange of an I-Beam and are fixed in place by

tightening of a securing bolt. (See figure 18.)

Design calculations for beam clamp capacity are

based on straight lifts; therefore, you must not use CLAMP ECURITY
OLT
these attachments for angle lifts as you may exceed
design specifications.

Clamps must fit the beam flange correctly

Figure 18
and be securely fastened to the beam
Beam Clamp
before use.

Beam Clamp Inspection

Before use, you must inspect a beam clamp to

ensure that:

❏ Its capacity (SWL) is adequate for the task

(stamped on body).
❏ The clamp body, bolt, and nut have no cracks.
❏ The body is not distorted or showing signs of
excessive wear. CRANE HOO

Plate Clamps

Plate clamps permit steel plates to be lifted without PLATE CLAM

the need for holes being cut or lugs welded to STEEL PLAT
attach lifting equipment. Plate clamps have jaws
which when attached correctly, securely grip the
plate. (See figure 19.)

Plate clamps have a self-tightening action. The Figure 19

heavier the load, the tighter the grip. Plate Clamp Use

Module 3.2 15
 INFORMATION SHEET

Plate clamps come in various capacities and sizes to

take the various thicknesses of plate. (See Figure 20).

Figure 20
Plate Clamp Variations

Plate Clamp Inspection

To inspect plate clamps, in addition to checking the

SWL/capacity stamp:

❏ Check the handle function. The handle must

unlock and lock the clamp jaws correctly.
❏ Check for signs of stress over all the body and
fitting. Pay particular attention to the clamp
eye. This area is most commonly subject to
cracks, distortion, and excessive wear.
❏ Check the jaw teeth for excessive wear. Worn
teeth can prevent the clamp from obtaining a
safe, secure grip.

ADJUSTING EQUIPMENT

When an unbalanced load is lifted, sling lengths

must be adjusted. This is done to place the load
hook of the hoist or crane directly above the load
center of gravity.

16 Metals Mechanic III

 INFORMATION SHEET

Adjusters are rigging attachments specially designed

for this task. One type of common adjuster used for
balancing loads is the turnbuckle.

Turnbuckles

The turnbuckle is used to adjust the length of a

END FITTING
rope. It can be used to increase or decrease tension THREADED
RODS
in a sling or line.

The turnbuckle consists of threaded rods with 3 BODY

CLEVIS AND EYE
types of end fittings and a threaded body.
SAFETY CATCH

One rod is threaded to turn to the right, the other

to turn to the left. This means that when you rotate OOK AND EY
(turn) the turnbuckle body, the distance between the
Figure 21
ends of the rods is shortened or lengthened Turnbuckles
(depending on the direction of rotation).

End fittings can be combinations of:

❏ Clevis - Clevis* ❏ Hook - Eye

❏ Eye - Eye ❏ Hook - Clevis *Note: Clevis/clevis combination
is also called a jaw.
❏ Hook - Hook ❏ Clevis - Eye

Turnbuckles are often placed between an eye on a load

and a sling. Alternately, turnbuckles can be placed
between a sling and a shackle, or a sling and a hook.

As turnbuckles can be installed on each of the slings

attached to a load, you can use them to balance a
load suspended from any number of slings. However,
turnbuckles are not capable of making large
adjustments. When used, you must calculate sling
lengths accurately so that no large adjustments are
needed.

Module 3.2 17
 INFORMATION SHEET

Figure 22
Fitted Turnbuckles

The SWL of a turnbuckle depends on: the diameter

of threaded rods (D), and the type of end fitting.
(See Figure 23). This shows that for the same size
turnbuckle, the SWL with hooks is less than the
SWL of clevis (jaw) or eye fittings.

ROD MAXIMUM LOAD, IN POUNDS

DIAMETER
( Inches ) CLEVIS AND EYE HOOK
FITTINGS FITTING
1/4 500 400
1/2 2, 200 1, 500
3/4 5, 200 3, 000
1 10, 000 5, 000
1-1/2 21, 400 7, 500
2 37, 000
2-1/2 60, 000 JAW

Figure 23

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 INFORMATION SHEET

Precautions

You must use caution when using turnbuckles with

wire rope or when the system is subject to vibration.
These conditions can cause the turnbuckle to
unwind. The simplest method of preventing the
turnbuckle from unwinding is to run a short piece
of wire through the body of the turnbuckle and
fasten the ends of the wire around the end fittings.
(See figure 24.) In addition, when tightening a
turnbuckle, never apply more force than you would
Figure 24
use to tighten a bolt of the same size. Securing Turnbuckle End of Fitting

Turnbuckle Inspection

You must inspect Turnbuckles for several different

kinds of wear and damage. Check the body and
both rods.

❏ Check the bodies for bending, stripped threads,

or cracking - particularly near the threads.
❏ Check the rods for straightness and thread
damage.
❏ Check end fittings for cracks, wear - and in the
case of hooks - spreading.

CRACKS & CRACKS &

O O

& BENDS

Figure 25
Inspection Points for Turnbuckles

Module 3.2 19
 INFORMATION SHEET

SUMMARY

In this part, you have learned to identify various

common items of rigging hardware. You have
learned how these equipments are use, what they
look like, and how to inspect them before use.

20 Metals Mechanic III

 INFORMATION SHEET

EXERCISE A

Part 1
Directions: Write the correct answers in the spaces
provided.

1. What must you do with all items of rigging

hardware before use?

2. What two types of shackle are in common use

by Saudi Aramco?

3. What is the purpose of centering a load?

4. What angle must the force on a shoulder type

eyebolt never exceed?

5. What must be stamped on all detached hooks?

6. What is the only correct method of attaching

U-bolt wire rope clips?

Module 3.2 21
 INFORMATION SHEET

7. What is the purpose of a lifter beam?

8. What can be used to increase or decrease

tension in a sling or line?

9. What permit steel plates to be lifted without

the need for lugs welded to attach lifting
equipment?

10. How can you find a beams weight if it is not

marked on the side of the beam?

Part 2
Directions: Your instructor will hand out items of rigging
hardware. You must perform a pre-use inspection on this
equipment. You must state whether the equipment is safe
to use, or unsafe to use. If unsafe, you must state why it
must not be used.

Your instructor will tell you how he wishes you to record

your inspection results.

22 Metals Mechanic III

 INFORMATION SHEET

PART II OBJECTIVE 3.2.2

State the Functions Of and Inspection

Requirements for Manual Hoisting Equipment

Saudi Aramco plants commonly use three types of

hoisting equipment. These are the:

❏ Come-Along (also called pull lifts or ratchet

hoists)
❏ Chain Hoist
❏ Hand Operated Winch (Tirfur)

COME-ALONG

Come-alongs are in common use in Saudi Aramco.

OOK
They can be used for vertical lifts, horizontal pulls, SAFETY
or as adjustors when balancing loads. The small size LATCH TCHET
ECHANISM
BODY
of the come-along makes it very versatile.
SWL
STAMP RATCHET
However, using the come-along does have some HANDLE

disadvantages:
RATCHET
LOAD
❏ They are not available in large capacities – so CHAIN
PAWL

can not lift more than a few tons.

❏ As they have short load chains, they can lift
SAFETY
only a short height and pull a small distance. LATCH
K

❏ The ratchet action is not smooth and may

cause problems when precise lowering into Figure 26
Come-Along
positions is required.

The come-along works on a ratchet principle -

operated by a handle instead of a hand chain. You
use a ratchet pawl attached to the handle to change
the direction of the load chain.

Module 3.2 23
 INFORMATION SHEET

CHEL PAWL When lifting, you move the handle up and down.
When pulling, move the handle back and forth.
Figure 27 shows the ratchet pawl on the side of the
UP
handle. You can set the pawl so that the come-along
DN either raises the load (UP) or lowers it (DN).

You connect the come-along differently for different

applications (see figure 28).

Figure 27
Come-Along Ratchet Pawl

BALANCING A LOAD HORIZONTAL PULLS VERTICAL LIFTS

VERTICAL
T RATCHET
WL TO UP
TION, AND
E HANDLE
FOR HORIZONTAL PULLS, SET RATCHET PAWL TO ND DOWN
UP POSITION, AND MOVE HANDLE BACK AND AISE THE
FORTH TO PULL LOAD FORWARD. D CHAIN.

Figure 28
Use of Come-Along in Different Applications

Come-Along Inspection

Before use, you must perform a full inspection on

the come-along and its component parts.

❏ Check the SWL stamp. Ensure the come-along

has the capacity for the task.
❏ Check the body for any signs of cracks or
broken casting.

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 INFORMATION SHEET

❏ Check the load chain and hooks for cracks,

broken welds, spreading, distortion and signs of
excessive wear.
❏ Check the ratchet mechanism for cracks, worn
pawl, worn gear wheel, and signs of excessive
wear.
❏ Check the friction brake for slip page and signs
of excessive wear or friction).

When you have performed a visual inspection,

remember to check that the mechanism operates
correctly!

Your instructor will now demonstrate the correct

way to inspect and check the operation of a come-
along.

CHAIN HOIST

Chain hoists are used to lift and move machinery

With a hoist, you can lift a load
and equipment. By using a series of reduction gears, of up to ten tons with your own
hoists reduce the effort needed to lift a load. muscles!

Hoists are so versatile that you will find them in

many workshops. They cost little and are very
dependable. Hoists have three advantages:

❏ they are portable

❏ light weight
❏ easily transported to different locations

In Saudi Aramco, the most commonly used type of

chain hoist is the spur gear chain hoist.

Module 3.2 25
 INFORMATION SHEET

Spur Gear Chain Hoist

UPPER HOOK While this type of hoist is the most expensive, it is

GEAR
also the most efficient. To reduce friction, the spur
CASING
OR BODY gear chain hoist has a gear reduction unit. It also
HAND CHAIN has a brake built into the gearbox.

LOAD CHAIN
Operation is simple. You pull on the right-hand
chain to raise a load, pull on the left-hand chain to
LOWER HOOK
OR
LOAD HOOK
lower a load.

Refer to Figure 29 for a spur gear chain hoist with

its main parts named.
LOW RAISE

Hoist Inspection

You must inspect all chain hoists before use. Inspect

Figure 29
Spur Chain Hoist
the hoists and check:

Note: There are some inspection points and kinds of

damage that are common to all chain hoists.

❏ SWL - must be visible and of the required

capacity.
❏ Hoist body free from cracks, broken/distorted
castings.
❏ Load chain free from cracks, distortion, broken
welds or excessive wear.
❏ Load hook and upper hook free from cracks
distortion or signs of excessive wear. Also
ensure the safety latch fitted and undamaged.
❏ Anchor pin or bolt – securely fitted and
undamaged.
❏ Chain sprockets free from cracks, distortion,
and excessive wear.

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 INFORMATION SHEET

At completion of your visual inspection, you must

also check that the hoist’s mechanism operates
correctly.

Your instructor will now demonstrate the correct

way to inspect and check the operation of a hoist.

HAND OPERATED WINCH

A hand-operated winch (also called Tirfur) is a A special wire rope

multi-purpose tool made to pull and release tension is fitted through the
machine. This cannot
on wire rope. By operating the handles, you either be removed while the winch is
pull or release the rope through the machine. on load.

Hand-operated winches are available in a range of

sizes for different applications. Refer to Figure 30 to
see a hand-operated winch with its main parts
named.

NOTE:
THE WIRE ROPE USED WITH
A TIRFUR IS TAPERED TO FIT
EASILY INTO THE MACHINE.

Figure 30
Hand Operated Winch (Tirfur)

Module 3.2 27
 INFORMATION SHEET

Refer to the following text and figure 31 for

instructions on how to use the hand operated winch.

A. Prepare the wire rope and then push the release

handle to open the winch jaws. Feed the
tapered end of the wire rope through the
machine.

B. Attach a sling to the anchor point and then

attach the hook on the winch.

C. Attach rigging to load and load to winch pull

line, then pull the wire rope through the winch
PULL
LINE
to take up slack. With this done, set the release
handle. The winch is now ready for use.

D. Attach the operating handle to the actuation

lever and when signaled, move lever back and
forth to move the load.
OPERATING
HANDLE
E. When task completed, move the operating
handle to the lowering lever and move lever
back and forth to release tension.

ACTUATING
LEVER
Tirfur Inspection

Before use, you must inspect both the winch and its
LOWERING associated parts.
LEVER

On the winch, check that:

❏ SWL is visible and of the required capacity.

❏ Winch body is free of any cracks, or broken
Figure 31 body parts.
❏ The release handle operates smoothly and does
not bind.

28 Metals Mechanic III

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❏ Winch hook is free of cracks, distortion and

that the safety latch is undamaged and operates
correctly.
❏ The actuating and lowering levers operate
without binding.

On the special rope used with winches, check:

❏ No overstretching/reduction in rope diameter

❏ No corrosion
❏ No kinks
❏ No broken wires
❏ No unraveling
❏ No excessive wear

You must also inspect the hook attached to the wire

rope (pull line). Look for signs of cracks, spreading,
broken wires near the attachment and correct
operation of the safety latch.

Your instructor will now demonstrate the correct

way to inspect and check the operation of a Tirfur.

SUMMARY

In this part, you have learned about various types of

manual hoisting equipment. You can now identify
and state the functions of a come-along, chain hoist,
and hand operated winch. You can now also
perform the important pre-use inspections required
by these equipments.

Module 3.2 29
 INFORMATION SHEET

EXERCISE B

Part 1
Directions: Write the correct answers in the spaces provided.

1. What must you do with all manual hoists

before use?

2. What are three applications for which you can

use a come-along?

3. What do you move to change a come-along

from lifting a load to lowering a load?

4. What chain do you pull on to raise a load

attached to a spur gear chain hoist?

5. How do you know the capacity of a come-

along, chain hoist or Tirfur?

6. After performing a pre-use visual inspection, what

else must you do before using a manual hoist?

30 Metals Mechanic III

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Part 2
Directions: Your instructor will hand out manual hoists.
You must perform a pre-use inspection on this equipment
and state whether it is safe to use. If you think it is
damaged or otherwise unsafe, state why.

Your instructor will tell you how he wishes you to record

your inspection results.

Module 3.2 31
 INFORMATION SHEET

PART III OBJECTIVE 3.2.3

State the Functions Of and Inspection

Requirements for Slings

A sling is a length of wire rope, chain, or synthetic

fibers used to attach a load to a lifting device. There
are three types of slings in common use in Saudi
Aramco:

❏ Wire Rope Slings

❏ Belt Slings (Synthetic Fiber)
*Note: Chain slings are not
commonly used by metals
mechanics and so are not
❏ Chain Slings*
covered in this module.
These slings are made in two basic types:

• Endless slings
• Single-leg slings

Endless Slings

Endless slings are made in a continuous loop.

Examples are shown in Figure 32.

Figure 32
Endless Slings

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Single-Leg Slings

Single-leg slings have eyes at each end. These eyes

are soft, thimble, or a combination of both.
Thimble-eyed slings have metal inserts (thimbles) in
the sling-eyes. These protect and help retain the
shape of the eyes when used for lifting.

HARD EYE OR

Figure 33
Single Leg Slings

Mechanical Splices

A mechanical splice is a loop formed by a Flemish

eye splice with a sleeve pressed on the rope at the
base of the loop. This holds the ends of the strands
in place. Pressure applied by a mechanical or
hydraulic press elongates (stretches) the sleeve. This
makes the bond between sleeve and rope compact
Figure 34
and permanent. Mechanical Splice

Using mechanical splices provides some advantages

and disadvantages:

❏ Advantages - develop 92½ to 96% of catalog

strength, reduce chance of hand injury, and
cover tuck to reduce interference.
❏ Disadvantages - cannot be applied in the field,
can only be used on independent wire rope
core (IWRC) ropes.

Module 3.2 33
 INFORMATION SHEET

WIRE ROPE SLINGS

Wire rope slings are used to secure loads to hoists,

cranes and other rigging equipment. They come in
many different lengths and sizes to suit the task. Soft-
eyed and thimble-eyed types are commonly available.
Refer to Figure 35 for examples of wire rope slings.

EFFECTIVE LENGTH

THIMBLE MECHANICAL SPLICE THIMBLE

SOFT EYE SOFT EYE

THIMBLE REEVING
THIMBLE
ENDLESS

THIMBLE BROTHER
SOFT EYE SLINGS

Figure 35
Wire Rope Slings
Wire Rope Sling Inspection

Through use, wire rope slings can be damaged and

so unsafe for use. Therefore, you must inspect them
before use.

You inspect wire rope slings the same way as you

inspect winch wire ropes that you learned about in
the last part of this module.

❏ Check the SWL stamped on the mechanical

SWL STAMP
splices.
❏
SWL SWL

Check for signs of excessive wear, such as shiny

flat spots.
Figure 36
SWL Marking ❏ Check for signs of corrosion and ensure the
wire has been correctly lubricated.

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❏ Check for any kinks, unraveling (bird caging) If you find kinks,
or broken wires. unraveling or more
than 10 wires broken
❏ Check for signs of overstretching. Measure the along any 1" length – do not
use the sling!
wire diameter as shown in Figure 37.

DIAMETER OF WIRE ROPE

WIRE ROPE COMPONENTS EACH HAVE A SMALL BUT DEFINITE SIZE
TOLERANCE. THEREFORE, THE ROPE MUST HAVE A DIAMETER TOLERANCE.
ALL WIRE ROPE MUST HAVE A DIAMETER AT LEAST EQUAL TO THE NOMINAL,
OR CATALOG, SIZE... NEVER SMALLER. STANDARD ROPES MAY EXCEED THE 11/2" 11/4"

1
NOMINAL DIAMETER BY THE AMOUNTS SHOWN BELOW.

2
NOMINAL DIAMETER
UNDERSIZE OVERSIZE
OF ROPE
0" 3/4" 0 1/32"

3
13/16" 1 1/8" 0 3/64"
1 3/16" 1 1/2" 0 1/16"
1 9/16" 2 1/4" 0 3/32" CORRECT INCORRECT
2 5/16" and LARGER 0 1/8" METHOD METHOD

Figure 37
Measuring Wire Rope

BELT SLINGS

Synthetic fiber slings (commonly called belt slings) are

typically made of braided nylon or polyester. Because of
their softness, they are used for lifting equipment that
would be marked or damaged by wire or chain slings.
There are three commonly used types of belt slings:

METAL EYES SOFT EYES ENDLESS Figure 38

SLING
Belt Slings

Module 3.2 35
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While synthetic slings are light and strong, they are

not as durable as wire ropes or chain slings. They are
easily cut and damaged. This means that you must
take special care to protect them when handling loads
with sharp edges and abrasive surfaces. Also, note that
the sling material can melt if placed near hot pipes or
other heat sources.

The eye or end fittings are where you attach the

sling to the load and hoist. You can also use them
in forming different sling hitches.

CHOKER END
TRIANGULAR FITTING
END FITTING
SIZE WIDTH IN INCHES

E E

Figure 39
Belt Sling Parts

Belt Sling Inspection

Before use, you must inspect belt slings for damage.

Slings are manufactured
with red yarn (threads) Check for the following types of damage during
imbeded within the your inspection:
material. These threads only
become visible when the sling is
excessivly worn. So, if you see ❏ SWL – must be clearly marked.
red yarn showing – do not use
the sling! ❏ Belt free of cuts, broken stitches, excessive
wear*, discoloration (burns), bent or cracked
metal eyes, and excessive oil or grease.

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USE OF SLINGS

When using any type of sling, you must first select

the correct size (e.g., diameter of wire rope) and
length that will allow a safe lift.

Slings require careful inspection and maintenance

because in normal use they undergo the following:

❏ Wear ❏ Crushing
❏ Abrasion ❏ Kinking
❏ Impact loading ❏ Overloading

As you complete the Units of this course, you will

learn more about each of these. One important
point about selecting slings is the length. If a sling is
too short, tension can break or damage it during a
lift. In this course, you will learn how tension
changes with sling length (or sling angle) and the
type of hitch used.

Because of the service expected of slings, errors in

deciding load weight, and the effect of sling angle
on the loading, it is recommended that all safe
working loads be based on a safety factor of at least
5. If slings are used on sharp corners, use chafing
gear or softeners.

Chafing Gear or Softeners

Chafing gear protects slings from sharp edges on the
load and also protects the load from being damaged
by the sling. Materials commonly used as chafing
gear are:

❏ Canvas ❏ Wood blocks

❏ Rubber sheets ❏ Pipe half

Module 3.2 37
 INFORMATION SHEET

Fit a wire rope sling so that the minimum radius

around which it is bent is at least 3 times the
diameter of the rope.

Chafing gear may be inserted to increase the radius

of the bend. Wood blocks and pipe half should be
lashed to the load to avoid falling off as the load
slackens.

Figure 40
Use of Chafing Gear

SUMMARY

In this module, you began by learning about rigging

hardware and the inspections you must perform on
this equipment before use.

In part II, you then went on to learn about manual

hoisting equipment – how it’s used and how to
inspect it.

In this last part you have learned about slings: why

they are used, and how to inspect them prior to use.

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EXERCISE C

Part 1
Directions: Write the correct answers in the spaces
provided.

1. What type of sling is a continuous loop of

material?

2. Why are metal inserts placed in the eyes of a

thimble-eyed single leg sling?

3. If you inspect a 1 meter long wire-rope sling and

find 24 broken wires spaced along its length,
would it be safe to use this sling - and why?

4. Why would a belt sling be used instead of a

wire-rope sling?

5. When inspecting a belt sling you see red yarn

showing through, what does this suggest?

Module 3.2 39
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Part 2
Directions: Your instructor will hand out various types of
slings. You must perform a pre-use inspection on these
slings to determine if they are safe to use. If you feel the
strap is unsafe, you must state why it must not be used.

Your instructor will tell you how he wishes you to record

your inspection results.

40 Metals Mechanic III