Crane Rigging Basic Safety

Crane Rigging Basic Safety

How to Use this Presentation
Introduction How to Use this Presentation DISCLAIMER This training material presents very important, pertinent information. It should not be assumed, however, that this program satisfies every legal requirement of every state. Some states require the training be developed and delivered by an individual with specific training and experience. This training is AWARENESS LEVEL and does not authorize any person to perform work or validate their level of competency; it must be supplemented with operation and process- specific assessments and training, as well as management oversight, to assure that all training is understood and followed. Your organization must do an evaluation of all exposures and applicable codes and regulations. In addition, establish proper controls, training, and protective measures to effectively control exposures and assure compliance. This program is neither a determination that the conditions and practices of your organization are safe, nor a warranty that reliance upon this program will prevent accidents and losses or satisfy local, state, or federal regulations. This presentation contains base material for use in an instructor-led training setting. You may modify this presentation to satisfy the specific training needs of your organization. On some slides, the display text is supplemented with additional material in the slide notes. This content is licensed for modification and use in a classroom setting. You may not redistribute this material in any form.

Introduction Safety from the Ground Up
The safety of a rigging project depends on the proper preparation of the necessary components at each stage of the lift, from the sling, attachments, and lifting device, to the riggers, crane operators, and other personnel involved. Course topics: General rigging equipment and safety Various sling types Steel erection rigging operations The safety of a rigging project depends on the proper preparation of the necessary components at each stage of the lift, from the sling, its attachments, and the lifting device, to the riggers, crane operators, and other personnel involved. This course will provide an introduction to general rigging equipment and safety, an outline of various sling types and their capacities and characteristics, and an overview of steel erection rigging operations, including hand signals for crane operations.

Course Overview General Rigging Safety Alloy Steel Chain Slings
Introduction Course Overview General Rigging Safety Alloy Steel Chain Slings Wire Rope Slings Metal Mesh Slings Natural and Synthetic Fiber Rope Synthetic Web Slings Steel Erection Rigging Hand Signals

General Rigging Safety
1 General Rigging Safety What you need to know: General safety practices Inspection requirements Proper identification of equipment limits Proper storage of equipment Hitches and slings The dangers of rigging work are greatly amplified for those who are unfamiliar with the basics of rigging safety. This chapter will familiarize you with general safety practices, inspection requirements, proper identification of equipment limits, proper storage of equipment, and an introduction to the different hitches and slings you’ll use.

Sling Types Alloy steel chain Wire rope Metal mesh Fiber rope
1 General Rigging Safety Sling Types Alloy steel chain Wire rope Metal mesh Fiber rope Synthetic web

1 General Rigging Safety
Vertical Hitches Under normal conditions, a sling in a vertical (90°) hitch will be able to lift its maximum rated capacity.

Choker Hitches Choker hitches will tighten on a load when lifted, but will not provide full 360˚ contact with the load unless the line is wrapped around the load twice (creating a double choker hitch). Additionally, the capacity of a sling in a choker hitch is 75 – 80% of the sling’s maximum rated capacity. Safe use: Do not use a choker hitch to lift loose bundles. Do not use slings made with wire rope clips in a choker hitch. Do not use wire rope slings with ferrules in choker hitches. If using a hitch where the angle of choke is less than 120˚, make sure to adjust the sling’s capacity accordingly. (This will be covered in greater detail later in the course.)

Basket Hitches Basket hitches allow loads to be easily controlled. They minimize a load’s tendency to twist. Basket hitches can either be connected to a single hook or in a “U” configuration with each leg connected vertically to a spreader bar. The vertical “U” configuration allows the sling to carry the full rated capacity on each leg, as long as the D/d ratio is at least 25/1. Safe use: Do not use basket hitches on hard-to-balance loads.

Bridle Hitches Bridle hitches connect 2 – 4 sling legs to a load via lifting attachments (e.g., lugs). Safe practices: Make sure the load is balanced by placing the hook point over its center of gravity and adjusting the leg lengths to keep the load level. Prior to connecting to your load, determine the working load limit for multi-legged slings. If using a 4-legged sling, calculate the working load limit as you would if only using 3 legs. This allows the load’s weight to be evenly distributed while also leaving a leg free for stability.

Safe Operating Practices
1 General Rigging Safety Safe Operating Practices Practices for hoisting: Securely attach slings to their loads. Pad or protect slings from loads’ sharp edges. Keep clear of suspended loads and loads about to be lifted. Keep your hands or fingers clear of the space between a sling and the load when the sling is being tightened. Housekeeping: When rigging equipment is not in use, remove it from the immediate work area to assure that it does not present a hazard.

Sling Safety Restrictions
1 General Rigging Safety Sling Safety Restrictions Never: Load slings in excess of their rated capacities. Use damaged or defective slings. Use slings that are shortened with knots, bolts, or other makeshift devices or slings with kinked legs. Rest a load on a sling. (However, if a load does rest on a sling, do not pull the sling out from under the load.) Ride on the sling or the load, unless the load is specifically designed and tested for carrying personnel. Shock load, which is allowing the load to free fall, changing the load’s center of gravity during hoisting, or both.

Inspections Prior to use on each shift, a competent person must thoroughly inspect rigging equipment for damage or defects. During use, as needed and where service conditions allow, slings and rigging equipment are subject to additional inspection. Defective rigging equipment, slings, or fastenings must be removed from service immediately.

Rating and Identification
1 General Rigging Safety Rating and Identification Identification markings are required on all rigging equipment. Identification marking requirements: Permanently affixed Legible Approved by the manufacturer Marked with the safe working load. * Do not use equipment without identification markings. ! Never load equipment in excess of the safe working load.

Sling Attachments and Custom Equipment
1 General Rigging Safety Sling Attachments and Custom Equipment Capacity requirements: Sling attachments should have a rated capacity greater than or equal to that of the chain in use. If you must use attachments with a lower capacity than the sling, do not use the sling beyond the rated capacity of the weakest attachment. Common sling attachments include: Custom equipment: Any special custom equipment (e.g., grabs, hooks, etc.) must also be marked with its safe working load, as well as proof-tested prior to use at 125% of the rated load. Clips Eyebolts Fittings Hooks Master links Shackles Sockets Triangles * Do not use clips to fabricate wire rope slings.

Hooks Sling legs must only contact the hook within 45˚of the centerline. Do not connect loads using the hook’s tip. When connecting hooks to a load in a bridle hitch, the hook tips must be pointing out or up. Inspections and removal from service: Immediately remove from service any hooks that display: Cracks Deformation Nicks Gouges Missing latch facility Wear of 5% at the narrowest point or 10% of the profile or depth * Watch for wear at these points.

Center of Gravity (horizontal)
1 General Rigging Safety Center of Gravity (horizontal) Loads can be either symmetrical or asymmetrical. Either way, connect the load above their horizontal center of gravity. Symmetrical Load Asymmetrical Load The center of gravity is along the centerline. The center of gravity is not along the centerline.

Center of Gravity (horizontal)
1 General Rigging Safety Center of Gravity (horizontal) Loads not rigged at the horizontal center of gravity may tip or fall off the sling. In addition to the risks of falling objects and damage to the load, slipping or falling loads can cause shock stress on the rigging and hoisting equipment, weakening it for future use. Balanced Asymmetrical Load Unbalanced Asymmetrical Load

Center of Gravity (vertical)
1 General Rigging Safety Center of Gravity (vertical) In addition to the horizontal center of gravity, consider the load’s vertical center of gravity. Connect loads at or above the vertical center of gravity. Loads connected below their horizontal center of gravity may be at risk of toppling. Load is stable. Load is unstable.

Environmental Conditions
1 General Rigging Safety Environmental Conditions Be aware of environmental conditions that may affect the capacity of the sling or other components. Weather: Wind Precipitation Temperature Visibility Worksite features: Power lines or other overhead obstructions Uneven or unstable surfaces Reactive substances: Chemicals which may damage slings, other rigging components, or personnel * If any of these conditions are present, follow the manufacturer recommendations.

Sling-to-Load Angles The sling-to-load angle is the angle between a sling’s legs and the load’s horizontal plane. The lower the sling leg angle, the greater the tension on the sling. This tension increases the sling’s actual load. The sling angle is not a concern for vertical hitches because they are not affected by angle loss factors. However, for basket, bridle, and choker hitches, knowing this angle is critical to planning a lift. You must calculate how much the angle reduces the load capacity. Never use angles that are less than 30˚without approval from a qualified person.

Sling Angle Loss Factor
1 General Rigging Safety Sling Angle Loss Factor Sling Angle Loss Factors The sling angle loss factor allows you to calculate how much the angle reduces the overall load capacity. To obtain the loss factor, refer to a sling angle loss factor table. (See the adjacent example.) To use the loss factor: Multiply the loss factor by the load capacity to obtain the reduced load capacity. (A low angle equals a lower loss factor, creating a lower reduced load capacity.) Angle from Horizontal (degrees) Loss Factor 90 1.000 85 .9962 80 .9848 75 .9659 70 .9397 65 .9063 60 .8660 55 .8192 50 .7660 45 .7071 40 .6428 35 .5736 * If the reduced load capacity is less than the load weight, the hitch is not strong enough to perform the lift.

Activity: Sling Angle Loss Factor
1 General Rigging Safety Activity: Sling Angle Loss Factor Reduced Load Method The reduced load method uses the sling-to-load angle to determine the reduced load limit. Actual Load Method The actual load method uses inverse proportions to determine the actual load for each sling leg. There are a couple of different methods to determine how your working load limit is affected by the sling’s angle.

1 General Rigging Safety Activity: Sling Angle Loss Factor Reduced Load Method Use the reduced work load method to confirm the adequate sling strength to carry this load in a bridle hitch. The Reduced Work Load method looks directly at the angle to determine the reduced work load on the sling.

1 General Rigging Safety Activity: Sling Angle Loss Factor 4,200 lbs Step 1: Establish the weight of the load. Load: 4,200 lbs Start by verifying the total weight of the load. In this example, the load is 4,200 pounds.

1 General Rigging Safety Activity: Sling Angle Loss Factor 4,200 lbs Step 2: Find the vertical load capacity of the sling. 1. Load: 4,200 lbs 2. Vertical load capacity (single leg): 2,800 lbs Next, find the vertical load capacity of the sling. This should be clearly indicated on the sling’s identification tag. The sling in this example is rated for 2,800 pounds for a vertical hitch.

1 General Rigging Safety Activity: Sling Angle Loss Factor 4,200 lbs Step 3: Account for the capacity of both legs. (Multiply the vertical load capacity by 2.) 1. Load: 4,200 lbs 2. Vertical load capacity (single leg): 2,800 lbs 3. Vertical load capacity (two legs): 5,600 lbs (2,800 x 2) To account for the capacity of both legs of the sling, multiply the sling’s vertical load capacity by two. The resulting capacity is 5,600 pounds.

1 General Rigging Safety Activity: Sling Angle Loss Factor 4,200 lbs Step 4: Determine the angle of your sling legs. 1. Load: 4,200 lbs 2. Vertical load capacity (single leg): 2,800 lbs 3. Vertical load capacity (two legs): 5,600 lbs (2,800 x 2) 4. Sling angle (both legs): 60˚ The load capacity assumes that the sling is in a vertical hitch. Since you will be using it in a bridle hitch, you need to calculate the actual capacity of the sling in this configuration. Start by determining the angle of your sling legs. In this case, the sling-to-load angle is sixty degrees.

1 General Rigging Safety Activity: Sling Angle Loss Factor Sling Angle Loss Factors Angle from Horizontal (degrees) Loss Factor 90 1.000 85 .9962 80 .9848 75 .9659 70 .9397 65 .9063 60 .8660 55 .8192 50 .7660 45 .7071 40 .6428 35 .5736 4,200 lbs Step 5: Determine your loss factor. 1. Load: 4,200 lbs 2. Vertical load capacity (single leg): 2,800 lbs 3. Vertical load capacity (two legs): 5,600 lbs (2,800 x 2) 4. Sling angle (both legs): 60˚ 5. Loss factor: .866 Refer to the table to find your loss factor. A sixty-degree sling-to-load angle results in a loss factor of .866.

1 General Rigging Safety Activity: Sling Angle Loss Factor Step 6: Determine the reduced load capacity of your hitch. 1. Load: 4,200 lbs 2. Vertical load capacity (single leg): 2,800 lbs 3. Vertical load capacity (two legs): 5,600 lbs (2,800 x 2) 4. Sling angle (both legs): 60˚ 5. Loss factor: .866 Populate the fields below with the corresponding figures above to calculate the full load capacity of your hitch. 4,200 lbs x = Full 2-Leg Vertical Load Capacity (lbs) 60˚ Sling Angle Loss Factor Reduced Load Capacity (lbs) Next, determine the reduced load capacity of the hitch by multiplying the full two-leg vertical load capacity by the loss factor. Populate the fields below with the correct vertical load capacity and the loss factor, using the numbers above in order to calculate the reduced load capacity. 5,600 x .866 =

1 General Rigging Safety Activity: Sling Angle Loss Factor Step 7: Confirm that your hitch can carry your load. 1. Load: 4,200 lbs 2. Vertical load capacity (single leg): 2,800 lbs 3. Vertical load capacity (two legs): 5,600 lbs (2,800 x 2) 4. Sling angle (both legs): 60˚ 5. Loss factor: .866 6. Reduced load capacity: 4,849.6 lbs Based on the figures above, is your reduced hitch load capacity adequate to lift this load? 4,200 lbs Based on the figures above, is your reduced hitch load capacity adequate to lift this load? The reduced load capacity is 4,849.6 pounds. This exceeds the load weight of four-thousand, 4,200 pounds. The correct answer is yes: the hitch will be able to lift the load. Yes No

1 General Rigging Safety Activity: Sling Angle Loss Factor Actual Load Method We will now use the actual load method to calculate a two-leg bridle hitch load that allows for a tight vertical clearance. The Actual Load method determines the actual load per sling leg using inverse proportions. The Actual Load method may be easier for determining the required sling capacity in preparation for the lift, or for “on-the-fly” calculations if necessary.

1 General Rigging Safety Activity: Sling Angle Loss Factor 5,200 lbs Step 1: Establish the weight of the load. 1. Load weight: 5,200 lbs Start by verifying the weight of your load. Our example here is 5,200 pounds.

1 General Rigging Safety Activity: Sling Angle Loss Factor 3.2 ft Step 2: Determine the vertical height of your hitch. Load weight: 5,200 lbs Vertical hitch height: 3.2 ft Next, determine the vertical height of your hitch. Here, we have 3.2 feet of clearance between the load and the hook.

1 General Rigging Safety Activity: Sling Angle Loss Factor 4 ft Step 3: Establish the length of your sling legs. Load weight: 5,200 lbs Vertical hitch height: 3.2 ft Sling leg length: 4 ft Now, establish the length of your sling legs. In this configuration, our sling legs are each four feet long.

1 General Rigging Safety Activity: Sling Angle Loss Factor Step 4: Establish the proportional tension factor. (Divide the sling leg length by the vertical height.) Load weight: 5,200 lbs Vertical hitch height: 3.2 ft Sling leg length: 4 ft 4 3.2 Populate the fields below with the corresponding figures above. ÷ = Sling Leg Length Vertical Hitch Height Now that we know the vertical height and sling leg length, we can determine the proportional tension factor. Divide the sling leg length by the vertical height. 4 ÷ 3.2 = 1.25

1 General Rigging Safety Activity: Sling Angle Loss Factor Step 5: Determine the vertical load on each of the two legs. 1: Load weight: 5,200 lbs 2. Vertical hitch height: 3.2 ft 3. Sling leg length: 4 ft 4. Tension factor: 1.25 ? ? 5, ÷ = ,600 Determine the vertical load on each leg by dividing the load’s total weight by the number of legs in the sling. 5,300 ÷ 2 = 2,600 Load Weight (lbs) Number of Sling Legs Vertical Load for Single Leg

1 General Rigging Safety Activity: Sling Angle Loss Factor Step 6: Determine the actual load on each sling leg. 1: Load weight: 5,200 lbs 2. Vertical hitch height: 3.2 ft 3. Sling leg length: 4 ft 4. Tension factor: 1.25 5. Vertical load on each sling leg: 2,600 lbs Populate the fields below with the corresponding figures above. x = ,250 Once we know the tension factor and vertical load on each sling leg, we can determine the actual load per leg. Multiply the vertical load on each leg by the tension factor. 2,600 times 1.25 gives us 3,250 pounds. Vertical Load on Each Sling Leg (lbs) Tension Factor Actual Load For Each Sling Leg

1 General Rigging Safety Activity: Sling Angle Loss Factor Step 7: Verify your vertical sling load capacity. 1: Load weight: 5,200 lbs 2. Vertical hitch height: 3.2 ft 3. Sling leg length: 4 ft 4. Tension factor: 1.25 5. Vertical load on each sling leg: 2,600 lbs 6. Actual load on each sling leg: 3,250 lbs 7. Vertical load capacity: 2,800 lbs The last step is to double-check the sling’s rated vertical load capacity. This sling is rated for 2,800 pounds per leg.

1 General Rigging Safety Activity: Sling Angle Loss Factor Step 8: Verify your vertical sling load capacity. 1: Load weight: 5,200 lbs 2. Vertical hitch height: 3.2 ft 3. Sling leg length: 4 ft 4. Tension factor: 1.25 5. Vertical load on each sling leg: 2,600 lbs 6. Actual load on each sling leg: 3,250 lbs 7. Vertical load capacity: 2,800 lbs Based on the actual load on each sling leg and the vertical load capacity, is your actual sling load capacity adequate to lift this load? Based on the figures above, is your load capacity adequate to lift this load? The actual load on each leg exceeds the sling’s rated vertical capacity, so no, you will not be able to lift the load using this sling. Answer: No Yes No

Sling-to-Load Angle—Choker Hitch
1 General Rigging Safety Sling-to-Load Angle—Choker Hitch A sling’s capacity in a choker hitch assumes that the angle of choke is at or above 120˚. If the angle of choke is less than 120˚, the sling’s capacity will be further reduced.

Sling Angle Loss Factor—Choker Hitch
1 General Rigging Safety Sling Angle Loss Factor—Choker Hitch Choker hitches: The use of choker hitches reduce a sling’s load limit. The angle of choke can reduce the load limit further. Once your angle of choke has been determined, multiply the appropriate loss factor to your sling’s capacity to determine the reduced load limit. (See the adjacent table.) The total load weight must not exceed the reduced load limit. Sling Angle Loss Factors Angle of Choke (degrees) Loss Factor 121+ 1.000 90 – 120 .870 60 – 89 .740 30 – 59 .620 0 – 29 .490

Activity: Sling Angle Loss Factor—Choker Hitch
1 General Rigging Safety Activity: Sling Angle Loss Factor—Choker Hitch This activity will focus on determining the loss factor for choker hitches, which is similar to determining the loss factor for basket and bridle hitches but uses some different numbers. As with the previous activity, you’ll determine if the sling is safe to use for the lift using the provided parameters. Confirm the adequate sling strength to carry this load in a choker hitch.

1 General Rigging Safety Activity: Sling Angle Loss Factor—Choker Hitch Step 1: Establish the weight of the load. 1. Load: 1,650 lbs 1,650 lbs Start by verifying the total weight of the load. In this example, the load is 1,650 pounds.

1 General Rigging Safety Activity: Sling Angle Loss Factor—Choker Hitch Step 2: Establish the choker load capacity of your sling. 1. Load: 1,650 lbs 2. Choker load capacity: 2,200 lbs 1,650 lbs Next, establish the load capacity of your sling for use in a choker hitch. In this hitch, the sling is rated for 2,200 pounds.

1 General Rigging Safety Activity: Sling Angle Loss Factor—Choker Hitch Step 3: Determine the choke angle. 1. Load: 1,650 lbs 2. Choker load capacity: 2,200 lbs 3. Choke angle: 80˚ 1,650 lbs In order to determine the loss factor, you will need to know the choke angle of the hitch. In this case, we’re looking at an eighty-degree choke angle.

1 General Rigging Safety Activity: Sling Angle Loss Factor—Choker Hitch Step 4: Determine your loss factor. 1. Load: 1,650 lbs 2. Choker load capacity: 2,200 lbs 3. Choke angle: 80˚ 4. Loss factor: .74 Angle of Choke (degrees) Loss Factor 121+ 1.000 90 – 120 .870 60 – 89 .740 30 – 59 .620 0 – 29 .490 1,650 lbs Refer to the table to find your loss factor. If the choke angle falls between sixty and eighty-nine degrees, the loss factor is point-seven-four (.74).

1 General Rigging Safety Activity: Sling Angle Loss Factor—Choker Hitch Step 6: Determine the reduced load capacity of your hitch. 1. Load: 1,650 lbs 2. Choker load capacity: 2,200 lbs 3. Choke angle: 80˚ 4. Loss factor: .74 Populate the fields below with the corresponding figures above to calculate the reduced load capacity of your choker hitch. 5600 Choker Load Capacity (lbs) x ˚ Choke Angle Loss Factor = Load Capacity (lbs) 1,650 lbs Next, determine the reduced load capacity for your sling by multiplying the choker load capacity by the loss factor. Populate the fields below with the correct choker load capacity and loss factor, using the numbers above in order to calculate the reduced load capacity. 2,200 x .74 = 1,628

1 General Rigging Safety Activity: Sling Angle Loss Factor—Choker Hitch Step 6: Confirm that your hitch can carry the load. 1: Load: 1,650 lbs 2. Choker load capacity: 2,200 lbs 3. Choke angle: 80˚ 4. Loss factor: .74 5. Reduced load capacity: 1,628 lbs Based on the figures above, is your reduced hitch load capacity adequate to lift this load? 1,650 lbs Yes No Based on the figures above, is your reduced hitch load capacity adequate to lift this load? Answer: No The reduced load capacity is one-thousand, one-hundred-twenty-eight (1,628) pounds. This amount is lower than the load weight of one-thousand, six-hundred-fifty (1,650) pounds. Therefore, the sling is not capable of lifting this load.

Alloy Steel Chain Slings
2 Alloy Steel Chain Slings What you need to know: How to identify size, grade, and capacity specifications Additional inspection criteria specific to alloy steel chain Deficiencies that require repair or removal of the sling from service Alloy steel chains are commonly used due to their versatility: they are strong and durable, resistant to abrasions and high temperatures, and able to conform to the shape of their loads. In the following slides, you’ll learn how to identify an alloy steel chain’s size, grade, and capacity specifications, additional inspection criteria specific to alloy steel chain, and deficiencies that require repair or removal of the sling from service.

2 Alloy Steel Chain Slings
Identification Alloy steel chain identification markings must indicate the following: Size Grade Rated capacity Reach Manufacturer or fabricator Date of manufacture or fabrication This durable steel tag is ideal for chain identification. A built-in RFID tag enables the specifications to be read with a mobile device. ! Do not use alloy steel chain slings for loads in excess of their rated capacities (i.e., working load limits).

Attachments Attachments should have a rated capacity at least equal to that of the chain in use. Otherwise, the sling must not be used beyond the rated capacity of the weakest attachment. ! Do not use makeshift links, fasteners formed from bolts or rods, or other such attachments. * Slings for use in overhead lifting must be at least Grade 8.

Inspection Inspect for the following:
2 Alloy Steel Chain Slings Inspection Inspect for the following: All items listed in the general inspection requirements Wear Defective welds Deformation Increase in length Evidence of heat damage (e.g., discoloration) Frequency: Inspect slings at least once every 12 months. The frequency is determined by the following: How often it is used The severity of service conditions The type of lifts being made Knowledge gained from the service life of other slings used in similar conditions Records: The employer must keep and maintain a record of the most recent inspection for each alloy steel chain sling, which must be made available for examination if required.

Safe Operating Temperatures
2 Alloy Steel Chain Slings Safe Operating Temperatures Service limit: When a sling is exposed to service temperatures greater than 600˚F, employers must reduce its maximum working load limit according to the manufacturer’s recommendations. Remove from service threshold: Any alloy steel chain slings that have been heated above 1,000˚F must be permanently removed from service.

Repair and Reconditioning
2 Alloy Steel Chain Slings Repair and Reconditioning Worn or damaged slings: Worn or damaged alloy steel chain slings or attachments are not to be used until repaired. If welding or heat testing is performed, slings must also be reconditioned and proof-tested by the sling manufacturer or equivalent entity prior to re-entering service. Broken chain: Do not use low carbon steel repair links, construction links, or mechanical coupling links to repair broken lengths of chain. This is a rare example of a broken weld point on a chain link. Never use a chain with broken welds.

Proof-Testing Testing before use: Any new, repaired, or reconditioned alloy steel chain slings, including all welded components in the sling assembly, must be proof-tested before use by the sling manufacturer or equivalent entity. The employer must assure that proper testing is performed and keep a certificate of the proof test, which is to be made available for examination if required. A proof-testing machine capable of applying extreme tensile forces to sling and attachment materials

Minimum Allowable Chain Size
2 Alloy Steel Chain Slings Effect of Wear Chains are prone to extreme wear during lifts. Remove chains from service if the chain size at any point of the link is less than the size stated in the adjacent table. Minimum Allowable Chain Size Rated chain size (inches) Minimum allowable chain size at any point (inches) 13 64 ⅜ 19 64 25 64 ⅝ 31 64 19 32 ⅞ 45 64 1 13 16 1 ⅛ 29 32 1 ¼ 1 ⅜ 1 ½ 1 ¾

Removal from Service Alloy steel chain slings displaying cracks or deformation in any master links, coupling links, hooks, or any other components must be immediately removed from service. A hook with a stretched throat opening

3 Wire Rope Slings What you need to know:
How to identify size, grade, and capacity specifications Additional inspection criteria specific to wire rope Deficiencies that require repair or removal of the sling from service Wire rope slings share many characteristics with alloy steel chain regarding strength and durability, though their pliability and resistance to heat and abrasions is dependent on the components of the rope’s construction. In the following slides, you’ll learn how to identify wire ropes’ size, grade, and capacity specifications, additional inspection criteria specific to wire rope, and deficiencies that require repair or removal of the sling from service.

3 Wire Rope Slings Identification Wire rope identification markings must indicate the following: Recommended safe working load for the types of hitches used The angle that was used to calculate the safe working load, if applicable The number of legs ! Do not use wire rope slings for loads in excess of their rated capacities (i.e., working load limits).

Wire Rope Construction
3 Wire Rope Slings Wire Rope Construction Prior to use or inspection, verify the sling’s construction, including the following: Core material Lay Fabrication 6x19 ! Never use wire rope slings in ways that are not specified by the manufacturer’s recommendations. 18x7 8x19

3 Wire Rope Slings Attachments Most end attachments must be proof-tested by the manufacturer or equivalent entity at twice their rated capacity prior to their initial use. The employer must keep a certificate of the proof test, which is to be made available for examination if required. Refer to the manufacturer’s recommendations to verify if your end attachments require proof-testing. A spelter socket

Attachments: Choker Hitch Shackle
3 Wire Rope Slings Attachments: Choker Hitch Shackle Safe shackle attachment: The eye-splice loop is secured around the shackle bolt. Hazardous shackle attachment: Movement of the sling’s leg may unscrew the bolt during the lift.

3 Wire Rope Slings Minimum Lengths Wire rope is subject to minimum lengths between splices, sleeves, loops, or end fittings. Sling type Minimum length Cable laid slings, 6x19 slings, and 6x37 slings 30 times the component rope diameter between splices, sleeves, or end fittings Braided slings 40 times the component rope diameter between loops or end fittings Cable laid grommets, strand laid grommets, and endless slings Circumferential length of 96 times the sling’s diameter

Inspections: Wire Conditions
3 Wire Rope Slings Inspections: Wire Conditions In addition to the general inspection requirements, wire rope must be inspected for the following conditions: Faulty sling construction: Wire rope slings used in hoisting, lowering, or pulling loads must be constructed from a single continuous piece without knots or splices, except for eye splices in the ends of wires and other endless rope slings. Knots: Do not secure wire rope with knots, except for haul back lines on scrapers. Broken wires: Do not use wire rope slings if the total number of visible broken wires in any length of 8 diameters exceeds 10% of the total number of wires or if the rope shows any other signs of excessive wear, corrosion, or defect. Do not inspect a sling by passing bare hands over the wire rope body. Broken wires, if present, may puncture the hands. Broken wire rope is hazardous to handle because of sharp loose wires.

Inspections: Splices and Swages
3 Wire Rope Slings Inspections: Splices and Swages Proper splices: Cover or blunt any protruding ends of strands in splices on slings and bridles. Eye splices in any wire rope must have at least three full tucks. Please note that this requirement does not prohibit the use of other approved splices or connections which are proven to be as efficient. Swages: Check that any swaged fittings are secure and that no wires are broken at the fitting.

Inspections: Eye Formation
3 Wire Rope Slings Inspections: Eye Formation Eye formation: Do not use wire rope clips or knots to form eyes in rope bridles, slings, or bull wires. U-bolts: When U-bolt wire rope clips are used to form eyes, refer to the adjacent table to determine the number and spacing of clips. Number and Spacing of U-Bolt Wire Rope Clips Improved Plow Steel Rope Diameter (inches) Number of Clips Minimum spacing (inches) Drop Forged Other Material 3 4 ⅝ 3 ¾ 5 4 ½ ⅞ 5 ¼ 1 6 1 ⅛ 6 ¾ 1 ¼ 7 7 ½ 1 ⅜ 8 ¼ 1 ½ 8 9 * When used for eye splices, apply the U-bolt clip so that the “U” section is contacting the dead end of the rope.

3 Wire Rope Slings Safe Operating Temperatures Fiber Core All fiber core wire rope slings that have been exposed to temperatures above 200˚F must be permanently removed from service. Non-Fiber Core Non-fiber core wire rope slings may be used in temperatures ranging from -60˚F to 400˚F without decreasing the working load limit. ! ! If operating outside this temperature range, follow the manufacturer’s recommendations. If operating outside this temperature range, follow the manufacturer’s recommendations.

3 Wire Rope Slings Removal from Service Damage to wire rope: Wire rope slings displaying any of the following characteristics must be immediately removed from service: Damage to hooks: Hooks displaying any cracks or deformation must be immediately removed from service. 10 randomly distributed broken wires in one rope lay 5 broken wires in one strand of one rope lay Wear or scraping of ⅓ of the original diameter of outside individual wires Kinking, crushing, bird caging, or any other damage-causing distortion of the wire rope’s structure Proof of heat damage Ropes or end attachments showing corrosion, cracks, deformation, or wear

4 Metal Mesh Slings What you need to know:
How to identify size, grade, and capacity specifications Requirements for testing new and repaired metal mesh slings Deficiencies that require repair or removal of the sling from service Metal mesh slings see extensive use in industries where hot, abrasive, or sharp loads are common. They are more resistant to cutting than other slings, and are able to secure loads with minimal stretching. In the following slides, you’ll learn how to identify metal mesh slings’ size, grade, and capacity specifications, requirements for testing new and repaired metal mesh slings, and deficiencies that require repair or removal of the sling from service.

4 Metal Mesh Slings Identification Metal mesh identification markings must indicate the sling’s rated capacity for vertical basket hitch and choker hitch loadings. ! Do not use metal mesh slings for loads in excess of their rated capacities (i.e., working load limits). ! Do not apply coatings to metal mesh slings that diminish its rated capacity.

4 Metal Mesh Slings Attachments Handles or other attachments must have a rated capacity at least equal to that of the metal mesh sling and must not exhibit any deformation after proof- testing. Make sure that: Handles are attached to the sling in a way that does not reduce the sling’s rated capacity. The load is evenly distributed across the width of the fabric. Sharp edges do not damage the fabric. All attachments are rated for the temperature in your lifting environment.

Repair and Reconditioning
4 Metal Mesh Slings Repair and Reconditioning Manufacturer Repairs Do not use repaired metal mesh slings unless the repairs were performed by the sling’s manufacturer or an equivalent entity. Any repairs must be indicated either by permanently marking or tagging the sling or keeping a written record detailing the date and nature of the repairs and the person or organization that performed the repairs. Any records are to be made available for examination if required. Manufacturer Proof-Testing Do not use any new or repaired metal mesh slings, including handles or other attachments, until they have been proof-tested by the manufacturer or equivalent entity to at least 1 ½ times their rated capacity. Proof-testing must be performed on elastomer impregnated slings prior to coating.

4 Metal Mesh Slings Safe Operating Temperatures Non-elastomer impregnated metal mesh or metal mesh that is not impregnated: Allowable temperature range: -20˚F to 550˚F Polyvinyl chloride or neoprene impregnated metal mesh: Allowable temperature range: 0˚F to 200˚F ! Follow the manufacturer’s recommendations if operating outside these temperature ranges, or using metal mesh slings impregnated with other materials.

4 Metal Mesh Slings Removal from Service Metal mesh slings are to be immediately removed from service if any of the following are discovered: A broken weld or broken brazed joint along the sling edge Reduction in the wire’s diameter of 25% due to abrasion or of 15% due to corrosion Lack of flexibility caused by distortion of the fabric Distortion of the female handle so that the slot’s depth is increased by more than 10% Distortion of either handle so that the width of the eye is decreased by more than 10% A 15% reduction of the original cross sectional area of metal at any point around the handle’s eye Distortion of either handle out of its plane

Natural and Synthetic Fiber Rope
5 Natural and Synthetic Fiber Rope What you need to know: How to identify size, grade, and capacity specifications Proper splicing requirements Deficiencies that require repair or removal of the sling from service Unlike the metal options we’ve covered so far, natural and synthetic fiber rope slings are primarily used in temporary jobs, such as painting or construction, and in marine environments. Fiber ropes are flexible, non-marring, and can maintain a firm hold on loads. In the following slides, you’ll learn how to identify fiber ropes’ size, grade, and capacity specifications, proper splicing requirements, and deficiencies that require repair or removal of the sling from service.

Identification and Attachments
5 Natural and Synthetic Fiber Rope Identification and Attachments Identification: Fiber rope identification markings must indicate the following: The stated capacity for the types of hitches used and the angle upon which it is based The type of fiber material The number of legs (if more than one) ! Do not use fiber rope slings for loads in excess of their rated capacities (i.e., working load limits). ! Do not use fiber rope slings if the end attachments in contact with the rope have sharp edges or projections.

5 Natural and Synthetic Fiber Rope
Splicing Use spliced fiber rope slings only if they meet the following minimum requirements, along with any additional manufacturer recommendations: Tucks: Rope Type Eye Splices (minimum full tucks) Short Splices (minimum full tucks) Manila Rope 3 6 (3 per side of the center line) Synthetic Fiber Rope 4 8 (4 per side of the center line) Tail ends: Do not trim strand tail ends flush with the surface of the rope immediately adjacent to the full tucks. This requirement applies to all types of fiber rope and both eye and short splices. Rope Diameter Minimum Tail Length beyond the last full tuck Under 1” diameter 6 rope diameters 1” diameter and larger 6 inches In cases where a projecting tail interferes with the sling’s use, taper the tail and splice it into the body of the rope using at least two additional tucks, leaving a tail length of approximately 6 rope diameters beyond the last full tuck.

Splicing Minimum clear length: The required minimum clear length of rope between eye splices is equal to 10 times the rope’s diameter. Knots: Do not use knots in place of splices. Specialized clamps: Only use clamps specifically designed for fiber ropes and splicing. Proper splice sizing: For all eye splices, make sure that the eye is appropriately sized so that it provides an included angle of 60° or less at the splice when the eye is placed over the load or support. Fiber rope eye splice

Safe Operating Temperatures and Repairs
5 Natural and Synthetic Fiber Rope Safe Operating Temperatures and Repairs Safe Operating Temperatures Fiber rope slings may be used in temperatures ranging from -20˚F to 180˚F without decreasing working load limits. If operating outside this temperature range or if dealing with wet frozen slings, follow the manufacturer’s recommendations. Repairs Only fiber rope slings made from new rope may be used. ! Never use repaired or reconditioned fiber rope slings under any circumstances.

Removal from Service Natural and synthetic fiber rope slings are to be immediately removed from service if any of the following criteria are met: Abnormal wear Powdered fiber between strands Broken or cut fibers Variations in the size or roundness of strands Discoloration or rotting Distortion of hardware in the sling

6 Synthetic Web Slings What you need to know:
How to identify size, grade, and capacity specifications Necessary precautions to be taken in specific environmental conditions Deficiencies that require repair or removal of the sling from service The properties and applications of synthetic web slings vary depending on the synthetic material used in its construction. However, all synthetic web slings are strong and non-marring in addition to being easy-to-use and economical. In the following slides, you’ll learn how to identify synthetic web slings’ size, grade, and capacity specifications, necessary precautions to be taken in specific environmental conditions, and deficiencies that require repair or removal of the sling from service.

6 Synthetic Web Slings Identification Synthetic web identification markings must indicate the following information: Name or trademark of manufacturer Rated capacities for each type of hitch Type of synthetic web material ! Do not use synthetic web slings for loads in excess of their rated capacities (i.e., working load limits).

6 Synthetic Web Slings Sling Construction Synthetic web slings must be of uniform thickness and width. Selvage edges must not be split from the webbing’s width. Fittings must have a minimum breaking strength equal to the sling’s and must be free of any sharp edges that could damage the sling. Synthetic web sling with uniform thickness

6 Synthetic Web Slings Attachments End fittings and eyes may only be attached or formed via stitching. When attaching fittings or forming eyes, the thread must be applied in an even pattern and contain a sufficient number of stitches to reach the full breaking strength of the sling. Synthetic web sling strap with attached fitting

Environmental Conditions
6 Synthetic Web Slings Environmental Conditions Certain synthetic web slings may not be used if specific environmental conditions are present. Nylon web slings are not to be used where fumes, vapors, sprays, mists, or liquids of acids or phenols are present. Polyester and polypropylene web slings, or any sling with aluminum fittings, are not to be used where fumes, vapors, sprays, mists, or liquids of caustics are present.

6 Synthetic Web Slings Safe Operating Temperatures Polyester and Nylon Never use synthetic web slings at temperatures above 180˚F. Polypropylene Never use web slings at temperatures above 200˚F.

6 Synthetic Web Slings Repairs Do not use repaired synthetic web slings if any part of the sling (including webbing and fittings) has been repaired in a temporary manner. Only use repaired synthetic web slings if the repairs were performed by the sling manufacturer or equivalent entity. In addition, all repaired slings must be proof-tested by the manufacturer or equivalent entity to twice its rated capacity before returning to service. The employer must keep a certificate of the proof test, which is to be made available for examination if required.

6 Synthetic Web Slings Removal from Service Synthetic web slings shall be immediately removed from service if any of the following are discovered: Acid or caustic burns Melting or charring of any part of the sling surface Snags, punctures, tears, or cuts Broken or worn stitches Distortion of fittings

Steel Erection Rigging
7 Steel Erection Rigging What you need to know: Pre-shift inspection requirements for cranes and rigging Basic safety requirements during crane operations Additional safe practices in specific scenarios In the following slides, you’ll learn about: pre-shift inspection requirements for cranes and rigging basic safety requirements during crane operations additional safe practices for specific scenarios that you may encounter, such as working under loads and multiple lift rigging.

Pre-Shift Visual Inspection of Cranes
7 Steel Erection Rigging Pre-Shift Visual Inspection of Cranes Prior to each shift, a competent person must inspect any cranes used in steel erection activities for deficiencies during operation. The following components must be included in the inspection: Control mechanisms: Check all control mechanisms for maladjustments, and check the control and drive mechanism for excessive wear of components and contamination by lubricants, water, or other foreign matter. Safety devices: Check safety devices, including boom angle indicators, boom stops, boom kick out devices, anti two-block devices, and load movement indicators where required. Tires: Check for proper inflation and condition. Pressurized lines: Check air, hydraulic, and other pressurized lines for deterioration or leakage, particularly those with flex in normal operation. Ground conditions: Check ground conditions around the hoisting equipment for proper support, including ground settling under and around outriggers, ground water accumulation, or similar conditions. Electrical apparatuses: Check for malfunctioning, signs of excessive deterioration, dirt, or moisture. Hydraulic systems: Check for proper fluid levels.

Pre-Shift Visual Inspection of Hoist and Rigging Equipment
7 Steel Erection Rigging Pre-Shift Visual Inspection of Hoist and Rigging Equipment Prior to each shift, a competent person must inspect any crane hoists and rigging equipment for deficiencies during operation. The following components must be included in the inspection: Hoisting equipment: Inspect hoisting equipment, prior to use as well as after each move and setup to assure that the load is level. If any deficiencies are identified, the inspector must immediately determine whether the deficiencies constitute a hazard. If so, the hoisting equipment is to be removed from service until all deficiencies have been corrected. Rigging inspection: Additionally, prior to each shift the rigging must be inspected by a qualified rigger (meaning a rigger who is also a qualified person).

7 Steel Erection Rigging
Operation Operator control: Licensed operators are responsible for all operations under their direct control. If concerns regarding safety arise, operators are authorized to stop and refuse to handle loads until safety has been assured. Hoist riding: Use of the headache ball, hook, or load to transport personnel is strictly prohibited unless the employer demonstrates that the erection, use, and dismantling of conventional means of reaching the work area (e.g., personnel hoists, ladders, scaffolds, aerial lifts, etc.) would be more hazardous or impossible due to the project’s structural design or worksite conditions. Never remove the safety latch. Safety latches: Safety latches on hooks are not to be deactivated or made inoperable unless a qualified rigger has determined that the hoisting and placing of purlins and single joists can be performed more safely by doing so or that equivalent protection is provided in a site-specific erection plan.

Working Under Loads Pre-plan your routes.
7 Steel Erection Rigging Working Under Loads Pre-plan your routes. Organize routes for suspended loads to assure that no employees are required to work directly below a suspended load, except for employees who are necessary for the initial connection, hooking, or unhooking of the load. When working under suspended loads is necessary, the following conditions must be met: Proper rigging: All rigging materials, assemblies, and loads being hoisted must be properly rigged by a qualified rigger to prevent unintentional displacement. Safety latch hooks: Use only hooks with self-closing safety latches or their equivalents to prevent components from slipping out of the hook.

7 Steel Erection Rigging
Multiple Lift Rigging Multiple lifts are only allowed if the following conditions are met: A multiple lift rigging assembly is used. A maximum of five members are hoisted per lift. Only beams and similar structures are lifted. All employees engaged in the lift have received proper training. Cranes and hoisting equipment are used in compliance with the manufacturer’s specifications and limitations. Controlled load lowering is used whenever the load is over the connectors.

Multiple Lift Rigging: Calculating 5-to-1 Safety Factor
7 Steel Erection Rigging Multiple Lift Rigging: Calculating 5-to-1 Safety Factor 5-to-1 safety factor: All components of the multiple lift rigging assembly must be specifically designed and assembled with a maximum capacity for the total assembly and for each individual attachment point. The capacity will be based on the manufacturer’s specifications with a 5-to-1 safety design factor for all components, and must be certified by a manufacturer or qualified rigger. Formula: Minimum breaking strength Safety factor Permissible Working Load = Example: 20,000 lbs (Minimum breaking strength) 5 (Safety factor) 4,000 lbs (Permissible Working Load) =

Multiple Lift Rigging: Sling Assembly
7 Steel Erection Rigging Multiple Lift Rigging: Sling Assembly Make sure that: The total load does not exceed the rated capacities of either the hoisting equipment or the rigging, as specified in the appropriate load and rigging rating charts. All members on the multiple lift assembly are set from the bottom up. All members that are rigged in the multiple lift assembly are: Attached at their center of gravity. Staying reasonably level. Rigged from the top down. Rigged at least seven feet (2.1 m) apart.

8 Hand Signals What you need to know:
How to recognize and perform standard hand signals for crane direction While crane operators are in control of the load, they must rely on a signaler on the ground to relay directions and monitor their movement. In the following slides, you’ll learn how to recognize and perform the standard hand signals for crane direction.

8 Hand Signals Hoist and Lower Hoist Move your hand in a circular motion with your forearm vertical and your forefinger pointing up. Lower Move your hand in a circular motion with your forearm extended downward and your forefinger pointing down.

Stop and Emergency Stop
8 Hand Signals Stop and Emergency Stop Stop Extend your arm outward with the palm facing down, and rapidly move your hand back and forth. Emergency Stop Extend both arms outward with your palms facing down, and rapidly move your hands back and forth.

Trolley Travel and Tower Travel
8 Hand Signals Trolley Travel and Tower Travel Trolley Travel Raise your hand with the palm facing up, the fingers closed, and the thumb pointing in the direction of travel. Tower Travel Extend your arm forward with the hand open and slightly raised, and make a pushing motion in the direction of travel.

8 Hand Signals Swing and Move Slowly Swing Extend your arm outward and point with a finger in direction of the boom’s swing. Move Slowly Place a motionless hand behind your signal hand.

8 Hand Signals Dog Everything Dog (Hold) Everything Clasp hands in front of your body.

Crane Rigging Basic Safety

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