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SAMSUNG ENGINEERING

Crane And Rigging Safety

Course Outline
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. Crane Pre-start Checks Crane Set Up Crane Operation Crane Accidents Rigging and Lifting Duties and Responsibilities Rigging Selection Types of Rigging & Lifting Equipment How to use rigging and lifting equipment effectively and safely. Safety Methods for Handling Loads of Various Sizes, Shapes and Weights How to Prevent Damage to the Load and Equipment. Safe Ways of Hitching, Lifting and Blocking Loads.

11. 12.

Pre-Start Crane Checks


Check for:
loose objects; grease and oil spills; low oil, fuel and lubricant levels; damage and structural weakness;

drum guards damaged or removed


rollers, drums and sheaves not rotating freely.

+
NO! WHEELS ARE CARRYING LOAD

CRANE SET-UP
There is Only One Way to Set-up a Crane The Right Way Check that the

1. 2. 3.
NO! NO! ALL ALL BEAMS BEAMS MUST TO BE BEFULLY FULLY EXTENDED EXTEDED

The ground is level. The ground will support the crane. The crane area is clear of obstacles. There are no under ground services in crane area. There is sufficient room to operate the crane. The crane can work within its safely working load. You have the correct size crane mats.

4. 5. 6. 7.

YES YES PROPER OUTRIGGER SETUP CORRECT OUTRIGGER SET-UP

8.

The crane is set-up level.

Before backing up make sure no one is behind the crane. Assign a flagman

Do not jump down from the machine step down

Cranes should be grounded

10 ft up to 125,000 Volts
15 ft 125,000 volts to 250,000 volts 25 ft above 250,000 volts
It is extremely dangerous to move and operate near overhead high tension lines

Must have signal because load line can reach power lines if cranes swings.

The Principles of Crane Operation


As the person in charge of a lift, you will need to understand: that only one person is in overall control of all activities; how the crane operates; the slew and travel speed; and that the manufacturers specifications are to be observed at all times.

Hydraulic mobile crane

Never allow anyone to ride on the crane

Never use more boom than necessary

Always use the shortest boom possible.

Mark the location of all underground services that could be crushed by the weight of the crane

Keep Unauthorized personnel out the Area

Measure the load radius before making capacity lifts.

Know the weight of the load before they are lifted or use a load indicator.

Never rely on crane stability to determine load capacity

Never attempt to use another equipment to increase stability of crane

Unattended Machinery

Do NOT leave the controls of a lifting machine unattended when a load is being suspended

Hydraulic Crane Operators who waits for signs of tipping to warn him of an overloaded condition will often the boom exceed the pressure limits or cause severe damage to his machine before any signs of tipping occur.

Too much counterweight Tip back

Too little counterweight Tip forward

The Counter weight must be correct for the machine, the boom length and for the load

CRANE ACCIDENTS

Incident at a shipyard in Malaysia


June 30, 2005

This incident happened due to unsafe rigging: one sling held the load at the end and one sling in the middle of the pipe.

Fortunately there were no fatalities.

Lesson learned:

Rigging study?

Never drag a load

Keep the load directly below the boom. The hoist line must be plumb at all times

A Boom could topple backward if the swing stopped suddenly.

Rigging
the connecting of a load to a source of power so that it can be lifted and moved safely and predictably.

Duties you must perform if you are in charge of a lifting operation


If you are in charge of a lifting operation, you must be trained and experienced enough to be able to:
Make an assessment of the lifting requirements;

Plan the operation; Select the most suitable lifting


equipment; Implement adequate inspection and maintenance procedures on the equipment planned to be used

Coordinate the lifting operations.

Rigging Selection
Very rarely does the average worker on a construction site get the opportunity to actually pick the rigging. It is normally purchased by a supervisor, the Company Purchasing Department or it is sent out from another project. This itself can create serious problems.

Rigging Selection
The rigging capacity and the material to be lifted must match. Using too small capacity rigging or components is just asking for an accident to happen.

Rigging Selection
Are there any Unusual Loading or Environmental Conditions? a. Wind?
Wind shifts loads The effect of the wind on a load can be severe

b.
c. d.

Temperature?
Surfaces?(Water) Unstable Object(s)?

Is the Equipment in Acceptable Condition? Appropriate Type? Proper Identification?

Properly Inspected?

Are the Working Load Limits Adequate?


a. What is the weight of the load?

b. Where is the center of gravity?

c. What is the sling angle?

d. Will there be side loading?

e. Capacity of the gear?

Checking Chain and Wire Slings


Check chain slings for: cracks or nicks; spread or worn links; and corrosion. Check wire slings for: kinking, distortion or stretching; flattening of diameter; broken or sheared fibres; and bird caging.

The Lifting Plan Checklist


Things that must be checked before commencing a lift are: the weight of the load; the shape and substance of the load; the maintenance of the slings and lifting gear; the communication systems; the working radius established and marked; and the weather conditions.

Checking The Load


Weight - safe working load of the slings and lifting gear.

Shape and size - attachment points and position of slings. Never lift a load without knowing its weight. Type of material - type of sling and method of attachment.

Selecting the Lifting Gear


Some things that will determine which gear you may have to use include: the weight of the load; the shape of the load; the type of material the load is made from, (to avoid damage to the load);

the height of the lift; and


the visibility of the load throughout the operation.

Synthetic Fibre Slings, Shackles and Eye-bolts


Check synthetic fibre slings for: broken stitching; stretching; frayed fabric; and chemical damage.

Check shackles and eye-bolts for: stretching or distortion; and

excessive crown or pin wear on shackles.

SHACKLES

Chain Hoists/Chain Blocks

Chain hoists are used in many different industries were lifting of equipment is required to move various equipment and machinery. They come in sizes from 250Kg to 25 tons safe working load and with various lengths. Very little effort is need to lift a load, with this device a man can lift ten tons on his own. Chain hoists are made of steel and very durable but can be damaged very Easley so care must be taken when handling the. Before using them check that the 1. It is of the correct safe working load for the job. 2. It has been certified by a third party inspector. 3. Hoist body has no cracks, or broken castings (Some have aluminum body's) 4. Hook is not deformed and is fitted with a safety Latch. 5. Anchor pins are in place and are of the correct type. 6. Chain is in good condition. 7. Operating mechanism is in good working order 8. The Safe Working Load is clearly marked on the hoist block

LEVER HOIST

Lever hoists are basically the same type of lifting appliance as a chain hoist with a different way of operating. With a lever to hoist and lower the load.A lever hoist can also used for pulling loads. Care and maintenance is the same as for a chain hoist. Inspection is basically the same as a chain hoist.

TIRFOR
A tirfor is a mechanical device with a lever handle to operate the tirfor Tirfors are generally used for pulling and as a tensioning device. Tirfors can also be used for lifting using a series of blocks. Before using a tirfor be sure to check both the tirfor and tirfor wire for damage

PLATE CLAMPS

NEVER EXCEED THE RATED CAPACITY OF THE CLAMP When using a plate clamp ensure that the clamp is fitted correctly be fore lifting. Plate clamps should be checked before and after use for any damage Some types of plate clamps are fitted with a manual lock ensure that that the lock is engaged before lifting. When lifting plate from one side with the plate on edge a spreader beam must be used. When lifting plate in the horizontal four clamps to be used with a spreader beam. Never lift a plate with one clamp

Wire Ropes for lifting loads

Before using wire ropes examine carefully for breakage, deformity, corrosion or other defects

Chain Slings
Used to lift very heavy loads.
Do not wrap chain slings around a load. Attach chain slings directly to the load using hooks and shackles. Chain slings can withstand higher temperatures than wire rope or synthetic fibre slings. Chain links can stretch, deform and break if the safe working load is exceeded.

Chain links can fracture when the chain is kinked, crossed over or knotted.

Wire Rope Slings


Overstressing the sling causes the wires to stretch, flatten and break.
Thimble
Mechanical splice Reeving Thimble Thimble Thimble

Used for lifting loads that do not have fixed lifting points to attach hooks onto.

Soft eye

Thimble

Soft eye

Soft eye

Easily damaged through corrosion, kinking, crushing and abrasion.

Endless

The flexibility of the wire rope allows the sling to be wrapped around the load.

Synthetic Fibre Slings


Do not expose to extreme heat or naked flames. Available in round, flat belt or flat web form and made from nylon or polyester. Used for lifting loads that need their surfaces protected by a soft substance that will not scratch or mark.

Fibres will rot if exposed to acids or alkalis.

Easily cut by sharp edges.

Attaching Slings
Make sure all slings, shackles and lifting gear have a Safe Working Load (SWL) or Working Load Limit (WLL) greater than the load to be lifted.
Use packing to prevent wire rope slings being cut by sharp edges. Wear gloves, safety boots and a hard hat when slinging loads.

Always use shackles to attach chain sling hooks to eye-bolts and lifting lugs.

Always position slings so the crane hook can be positioned over the loads centre of gravity.

Multiple Leg Slings


Select a sling so that all of the sling legs are used. Use an approved chain shortener to shorten the length of sling legs. Never allow the angle between the legs of a sling to exceed 90 degrees. If a load of 1000 kg is lifted at an angle of 90 degrees the strain on each leg is 707 kg.

Use a spreader bar if a wide spacing between lifting points prevents you keeping the included angle below 90 degrees. At 120 degrees the strain on each leg is 1000 kg.

Hitch Basket - loading with the sling passed under the load and both ends on the hook or a single master link.

Hitch Choker loading with the sling passed through one eye and suspended by the other.

Hitch Vertical loading with the the load suspended vertically on a single part or leg of the sling.

Master link a steel link or ring used to support all legs of a chain or wire rope sling.

Mousing lashing between the neck and the tip of a hook to prevent the load coming off. Rated capacity the maximum allowable working load.

Wire rope consists of many individual wires laid into a


number of strands which are in turn, laid around a center core.

Types of Wire, Wire Rope, Slings

Wire Rope Construction


BENEFIT OF FEWER OUTSIDE WIRES PER STRAND BENEFIT OF MORE OUTSIDE WIRES PER STRAND

ABRASION RESISTANCE
Increases with larger wires Decreases wit h smaller wires

FATIGUE RESISTANCE
Decreases with larger wires Increases with smaller wires

Wire Rope Capacities


SLING CAPACITY DECREASES AS THE ANGLE INCREASES

A sling capable of lifting 100lbs in a 30 degree vertical basket hitch can only left 856 lbs at a 30 degree angle, 707 lbs at a 45 degree angle and 500 lbs at a 60 degree angle.

Type of Wire Rope Sling Damage

Birdcage damage

Type of Wire Wire Rope Sling Damage

Damage as a result of a kink in the wire rope

Rigging Protection From cutting or Slipping


Softeners, padding or use of blocking..

Wire Rope Capacities

Inspecting Lifting Gear


When inspecting lifting equipment you should look for the following: the SWL mark (Safe Working Load Limit); kinks, especially in wire ropes; cuts in a rope; loose strands; mildew; chemical attack;

exposure to high heat; and


broken wires.

Slinging a Load
You should consider the:
weight of the load; size and shape of load;

location of the lifting points;


centre of gravity; need for tag lines; and use of quick release shackles.

Different ways of lifting loads


Double wrap sling grips the load and helps prevent the load from slipping sideways

Nylon used slings to lift loads

Cradle sling used to lift loads

Doing a Trial Lift


With the load off the ground, check if the :
load slips; load is out of balance; hoist brake system slips or fails; and load can be raised without catching or hitting anything.

Never allow personnel to ride the load

Stand away from loads when the slings are being pulled out from under them

Weight of Loads
Do NOT guess the weight of the load to be lifted

Determining the Load Mass


The weight of a load can be determined by: using calculations;

measuring the load; load cells (confirm with the

crane before lifting);


the shape of the load; weighbridge dockets;

drawings;
standard section tables;

and delivery dockets.

Suspended Loads

Do NOT stand or pass under a suspended load

Suspended Loads

Make Sure the Path is clear before moving the Load

When loading or unloading trucks always work over the rear and ensure that the driver leaves the cab.

Moving a Load Correctly


You should:
raise the load slowly and smoothly; check lifting gear and load are clear before moving load horizontally; keep the load clear of all personnel;

maintain the rope tension when landing the load; and


keep the load or your signal person in view at all times.

Unslinging a Load
Rest the load on bearers if wire rope or synthetic fibre slings are wrapped around the load. Never pull a sling out from under a load that is resting on it.

Never leave unused slings attached to a crane hook.

Never try to release a load that is still under tension or while the load is still suspended.

Allow the load to come to a full rest and check that all tension has been released before removing slings.

Use of Hand Signals


When you do not have a clear view of the load, or if you cant maintain verbal contact, then you must use hand signals. Use a person who is competent in using standard crane signals. The person signalling to the crane operator must be the only person giving signals. Use only one hand to give signals.

The signalman must position himself in full view of the operation and if using hand signals close enough to be seen clearly. His position must give him a full view of the load and equipment at all times.

When acting as a signalman / rigger, stand where you can see the load and can be seen by the operator.

Only One Person to Give Crane Signals


Only one person shall give signals to the crane operator. The signal man shall wear a green reflective vest when giving the crane signals. Should the crane operator see a seconded person giving signals he is to stop crane operations and inform the signal man. The exception to this rule is an emergency stop signal the crane operator will accept this signal from anyone on the job.

Pinch points

One of the most common injury to riggers and Slingers are hand injuries caused by hands being trapped. Riggers must avoid pinch points such as when tensioning slings, and when placing the loads. Similarly, when loads are moved on rollers, it is al to easy for a careless person to get a hand or foot caught underneath a roller. Good practice is to look and notice were pinch points are and keep away from them.

Wait Until After Work to have Fun and Games


Horseplay and fooling around on the job can be dangerous cause injuries and death. Workers can ensure their own safety only when their attention is focused on the work at hand. When heavy loads are being moved, games and practical jokes are not worth the risks involved. Any person found hose playing or fooling around will be removed from the site immediately.

Keep all Parts of the Body away from Under the Load
When ever a load is lifted above floor level, the Possibility exists that it may fall. For this reason, It is important to riggers and others in the area to Avoid walking below a suspended load. Often, These areas where rigging is taking place are Blocked of with safety barriers to warn passersby And to keep them out of the area. Riggers have to be careful to keep ALL parts of Their bodies including hands and feet out From under suspended loads.

Any Questions?????

THANK YOU VERY MUCH FOR YOUR KIND ATTENTION.

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