Mejia Cement Plant
The rigging system
Know How to Do It Right!
Then Do It Right!
The Rigger
Must apply intelligence, common sense and experience.
Anticipate what will happen when the load is moved.
Thought process must take place before the work is started.
Questions that must be answered by rigger ??????????????
1. What is to be done with the load?
2. What tools are needed?
3. Do the tools have the capacity to handle the loads and forces involved?
4. How can the hookup be made?
5. What will happen when the load is first moved?
6. What will be the travel path of the load to reach the desired location?
7. How will the load be set down at the desired location?
8. What other factors are involved (weather, electrical wires, sloping grades, visibility)?
9. Are additional personnel needed to control the load safely during the process?
C.G of Load
The shape of a load normally determines its center of gravity. The shape of a load may be
symmetrical or asymmetrical. A symmetrical load is a load in which one-half of the load is a
mirror image of the other half. Symmetrical loads include straight pipe sections, motors,
paper rolls, and sheet metal.
C.G of Load
A load may be lifted without chance of tipping or toppling once the center of gravity is
determined (balanced load). Load tipping occurs when a load is unsteady, unbalanced, or
unstable.
C.G of Load
In addition to the vertical center of gravity, the horizontal weight center (horizontal center
of gravity) of a load must also be determined. The horizontal weight center is a weight mass
above a pivot point that causes a load to topple because it is top heavy. The lifting
equipment must not be attached to the load at any point lower than the horizontal weight
center. A load may be unstable and subject to toppling if lifting equipment is placed below
the horizontal weight center of a load.
Sling
A sling is a line consisting of a strap, chain, or rope used to lift, lower, or carry a load. Slings
used to lift loads are made of various components. The main sling components lift the load.
Main sling components include wire rope, fiber rope, chain, webbing, and round sling.
Attachments
Other sling components include rigging hardware attachments such as clips, hooks,
eyebolts, shackles, sockets, wedge sockets, triangle choker fittings, and master links.
Main Components
A sling consists of a section of the main component (rope, chain, etc.) with a loop at both
ends. Basic slings include vertical (single-leg), choker, U, basket, and bridle. Tables are used
to determine the safe load capacities of specific rigging components such as rope, webbing,
chain, etc., and may also rate their attachments.
Sling Angles
Angular lifting tension increases and load capacity decreases as the sling angle decreases.
The sling angle decreases as the lifted load widens
Checking the Dimensions
The diameter of wire rope is determined by the largest possible outside dimension. The outside
dimension (diameter) is the circle that fully encircles the rope. The rope is measured from the high spot
on one side of the rope to the high spot on the opposite side using vernier calipers. New ropes are
normally slightly larger in diameter than the specifications indicate.
Conditions affecting rope
A rope loses strength during use due to moisture, temperature, chemical activity, and
bending
Design of the Wire pattern
Wire rope is also classified by the design of the wire pattern. While many pattern variations
exist, the most common wire ropes used for basic rigging are filler wire, Warrington, Seale,
and Warrington-Seale. Each type uses wires of different sizes and offers more or less
flexibility and wear than the others
Strength Capacity
Once the proper wire rope size is determined, the load capacity of choker, basket, or bridle
slings used to lift the load are determined.
Seizing
The ends of wire rope must be secured by binding (seizing) to prevent raveling, unsafe loose
wires, or strength reduction before cutting a wire rope. Seizing is the wrapping placed
around all strands of a rope near the area where the rope is cut. Seizing holds the strands
firmly in place by the tight turning of seizing wire. This must be done twice to both ends
before the cut.
Wire rope terminations
Wire rope ends (terminations) are fastened to fittings or spliced into loops when wire rope
is attached to a load. Common wire rope terminations include thimbles and sockets.
Fittings, loops, or other attachments may not have the strength of the rope and may reduce
the sling efficiency
Grips Required for fastening wire rope ends
In a looped rope, the loose end is the dead end, and the load-lifting portion is the live end. Loops are
secured using a U-bolt clip (clamp). A U-bolt clip consists of a saddle, threaded U-section, and two nuts.
The clip should be assembled with the threaded U-section contacting the dead-end section of the rope for
maximum rope strength and to prevent damage to the live end of the thimble and clip assembly. Clip
connections must be arranged, spaced, and assembled properly to maintain the strength of the rope.
Diameter of wire rope Minimum number
(mm) of
Bulldog clamps
Up to and including 20 3
Over 20, up to and
4
including 32
Over 32, up to and
5
including 38
Over 38, up to and
6
including 44
Over 44 7
Fiber Rope
Fiber rope is constructed by twisting fibers into yarn,
yarn into strands,
and strands into rope.
Yarn is a continuous strand of two or more fibers
twisted together.
A strand is several pieces of yarn helically laid
about an axis.
A helix is a spiral or screw shape form.
Strands are twisted (laid) to form the rope.
Wire rope is constructed by twisting wires into strands
around a wire core.
The strands are laid to form the wire rope.
The strands are often laid around a fiber core.
Fiber Rope
Fiber rope is constructed by twisting fibers into yarn, yarn into strands, and strands into rope. The first
step in making fiber rope is to create a yarn by twisting the fibers in one direction. The yarn is twisted
together in the opposite direction to create a strand. Strands are twisted (laid) in the reverse direction to
create the rope. Reversing the twist of each step prevents the rope from unwinding
Web Sling
Webbing is a fabric of high-tenacity synthetic yarns woven into flat narrow straps. See Figure . A synthetic
yarn is yarn made of twisted, manufactured fibers such as nylon or polyester. Webbing is constructed in
one to four plies, with protected edges and red warning cores to indicate wear or damage. Webbing for
rigging purposes is normally used when maximum load damage protection is required. The softness of
the webbing material, along with its wide and flat design, offers excellent protection for glass and
polished or painted loads.
Web Slings - Loading
Consideration must be given to the kind of load, its weight, and its center of gravity when
selecting a web sling. The type of web sling selected and its use must be made with safety
as the main consideration. For example, basket and choker hitches are used with web
slings.
Sling Chains
Alloy material is chosen for sling chain to reduce the occurrence of fracturing of the metal. A
fracture is a small crack in metal caused by the stress or fatigue of repeated pulling or bending
forces. Through the combination of alloy metals and tempering, sling chain is capable of 15% to
30% elongation before breaking. This is a safety specification requirement for sling chain and is
not to be used as a determination for replacement.
Chain should be
removed from service if
the measurement of
used chain exceeds 1
&1/2% elongation from
that of new chain.
Sling Chains
The four main types of chain are binding chain, rigging chain, lifting
chain, and hoist apparatus chain. Each chain, except for hoist
apparatus chain, has a periodic embossing of a grade number or letter,
indicating its capability.
* 1 pound (in lb) = 0.453 Kg.
Shackle
A shackle is a U-shaped metal link with the ends drilled to receive a pin or bolt. The removal
of the pin or bolt allows an opening for one or more loop eyes that can be attached to
complete a sling. Shackles are made in a straight-U design (chain shackle) or a curved-U
design (anchor shackle). A shackle may be used to make the connection between the
rigging assembly and the hoisting hook. Shackle strength varies to conform to load weight.
Hook
The WLL of the weakest component should be the working load limit of the entire sling
assembly if a sling is required to be assembled using attachments with different working
load limits. Do not use makeshift hooks, links, or fasteners fashioned from bolts, rods, or
other materials. The hook is a major link between the rigged load and the hoisting
equipment. A hook is a curved or bent implement for holding, pulling, or connecting
another implement.
Hoisting Hook
A hoisting hook is a steel alloy hook used for overhead lifting and is
connected directly to the piece being lifted.
Sling and Rigging Inspection
Besides the pre-use or daily inspections, monthly and annual inspections by a
competent person are required
A thorough examination must be performed monthly and documented at least
once every 12 months.
A record shall be made of the annual inspection stating the number of Lifting
Tools & Tackles inspected, who conducted the inspection, the date of inspection,
and whether any lifting tools & tackles were found in a state requiring removal of
service. These inspections are to be conducted, documented and files
maintained at the plant Level.
Inspection & Defects
Kinking, core protrusion, and bird caging may be en-countered when inspecting wire rope.
Kinking is a sharp permanent bending. Kinking is normally caused by improper removal of
wire rope from a spool or improper storage. Kinking weakens a wire rope and in many
cases makes it useless.
Inspection & Defects
Fiber rope inspection is used to remove a rope from service before the ropes condition
poses a hazard with continued operation. Fiber rope should be inspected monthly.
Inspection & Defects
Webbing should be inspected at least annually and round slings should be inspected
monthly.
Inspection & Defects
Chain should be inspected annually. Repairs to rigging and hoisting chain should only be
made and tested by the chain manufacturer. Never use mechanical coupling links or repair
links to repair any sub-standard rigging or hoisting chain.
Any Questions?
If the student
hasnt learned,
the instructor
hasnt taught!
Lafarge India | Training | 2014 July 5, 2017 33
