Material Handling and Hand Rigging

1. Material HandlingandHand Rigging Contren learning series # 40111-07

2. 1.0.0 Introduction • Moving and placing heavy objects is a frequent occurrence in the industrial maintenance profession. • Everyone in this profession needs a knowledge of how to place rigging on a load to safely lift, move, and sit heavy objects. • Everyone will not be the crane operator, but everyone must know how to signal the operator.

3. 2.0.0 Rigging Hardware • Only hardware designed for lifting should be used. • We will discuss: • Hooks • Shackles • Eyebolts • Lifting Lugs • Turnbuckles • Beam Clamps • Plate Clamps • Rigging Plates and Links • Spreader and Equalizer Beams

4. 2.1.0 Hooks • Used to attach to a sling or load. • Always inspect hook before use. • Replace if: • Throat is opened 15% over the original width. • Body is twisted 10 degrees from original plane.

5. 2.2.0 Shackles (Clevis) • Used to attach an item to a load or to attach slings or wire ropes together. • Important safety information: • The shackle pin (not the body) must always be hung on the hook. • Pin wear of 10% or more must be replaced. • Shackles pulled at an angle has reduced capacity. • Never use a shackle in a manner that allows the pin to be rolled under a load.

6. 2.3.0 Eyebolts • Attached to heavy equipment to give connection points for lifting. • Shoulder-less eyebolts can only be used for vertical lifting. • Use shoulder eyebolts for angled lifting connections. • Position the ring so that the lifting force is applied to the ring.

7. 2.4.0 Lifting Lugs • Custom-built for a specific machine for proper lifting. • May be welded, bolted, or pinned to the machine.

8. 2.5.0 Turnbuckles • Used to adjust the length of rigging connections. • Typical ends: Eye, jaw, hook. • Hook ends have less load capacity than others. • Important safety information: • Do not weld on a turnbuckle. • Only one turnbuckle per leg. • Do not use jam nuts (unless supplied by factory). • Do not over-tighten. Use correct wrench size only. • Not for angular loading unless factory-specified.

9. 2.6.0 Beam Clamps • Used to connect lifting devices to structural beams so they can be lifted and positioned. • Two clamps may be used as long as the bridle sling angle does not exceed 25 degrees from vertical. • Replace clamp if jaws open more than 15% of original.

10. 2.7.0 Plate Clamps • Used to grip structural plate steel for attachment to lifting devises. • Screw plate clamps are considered to be the safer than the cam plate clamps. • Grip and lift only one sheet at a time. • Replace if evidence of any wear or deformation to body or teeth is seen.

11. 2.8.0 Rigging Plates and Links • Plates and links that are custom built for a specific component to be lifted.

12. 2.9.0 Spreader and Equalizer Beams • Used to support long loads during the lifting operation. • Tested at 125% of the rated capacity.

13. 3.0.0 Slings • Common Sling Types: • Wire Rope • Synthetic Web and Round • Metal Mesh

14. 3.1.0 Sling Capacity • Capacity depends on: • Sling material and type • Hitch configuration and quality

15. 3.2.0 Sling Care and Storage • Store slings on a rack off the ground. • Do not drive or walk over slings. • Thoroughly inspect slings before each use.

16. 3.2.1 Wire Rope Slings • Inspect for: • Broken wires • Diameter reduction • Heat damage • Corrosion • Damaged ends and fittings • Rope distortion • Core protrusion • Unlaying of a splice • Discard if wear exceeds one-third of original diameter. • The D/d ratio affects the capacity of wire rope slings. • There are charts that give you the efficiency based on D/d. ------------D------------ - --d

17. 3.2.2 Synthetic Web and Round Slings • Inspect for: • Chemical burns • Melting • Holes, cuts tears, snags • Broken stitches in splices • Abrasion • Knots • Damaged fittings • Missing or illegible tag

18. 3.2.3 Metal Mesh Slings • Inspect for: • Broken weld joints • Broken wires • wire diameter reduction • Discard if: • Wire diameter reduction is • 25% - abrasion • 15% - corrosion • 10% increase in choker slot • 10% increase in eye openings • 15% reduction in web cross-section

19. 3.3.0 Chain Slings • Recommended for: • Rough objects (ie: castings) • High temperatures • Not recommended for routine lifting • A chain link is a single bar of steel. • If one link breaks, the load falls, • Usually without warning. • If any portion is worn 15%, remove from service. • Chains must be annealed every 1-2 years. • After being annealed 6 times, destroy chain. • Use only Grade 8, or higher, chain.

20. 3.3.1 Chain Sling Storage • Store chains on a rack off the ground. • Do not drive or walk over chains. • Thoroughly inspect chains before each use. • Lubrication of chains can be dangerous. • Slippery when handling. • Lubricates attract dust, causing abrasion. • Sometimes lubrication is necessary for storage in exposed environments.

21. 3.3.2 Chain Sling Care and Inspection • Inspect before each use. • Annual inspection (replace if:) • Wear – 15%, or more, anywhere • Stretch – 5% longer than original • Links – twisted, bent, cut, gouged, or nicked • Cracks – in any part of chain • Link Welds – any deformation • End Fittings – stretch, wear, twist, cut, opening • Capacity Tag – missing or illegible

22. 4.0.0 Tag Lines • Typically are natural fiber or synthetic rope • Hand- held to keep load from swinging or twisting

23. 5.0.0 Block and Tackle • Basic lifting device used for light loads • Capacity of simple b&t is equal to the load line (tackle) • Capacity of compound b&t is higher due to more sheaves; thus, multiple load lines Compound Simple

24. 6.0.0 Chain Hoists • Lifting device for lifting light loads • Sometimes referred to as chain falls • For straight vertical lifting only • Never wrap the chain around the load • Always attach a choker to the chain

25. 6.1.0 Spur-Geared Chain Hoists • Lifting device for lifting light loads • For straight vertical lifting only • Most efficient type of manual hoist • Most commonly used

26. 6.2.0 Electric Chain Hoists • Works just like a spur-gear hoist • Except than an electric motor is used instead of a pull chain

27. 6.3.0 Care of Chain Hoists • Inspect before each use. • Check for adequate capacity. • Inspect load chain and hook. • Inspect sheaves. • Check for proper lubrication. • Assure that hoist is securely hung.

28. 7.0.0 Ratchet-Lever Hoists and Come-Alongs • Used for short pulls. • Ratchet-Lever Hoist • Uses a chain for load suspension • Vertical lifts only. • Not the same as a chain hoist. • Come-Alongs • Uses a cable for load handling • Horizontal pulling only Fast Wind Handle For spooling of chain Ratchet Handle For load handling

29. 8.0.0 Jacks • Used to raise or lower equipment. • Short movements with good control. • Three types: • Ratchet jack • Screw jack • Hydraulic jack

30. 8.1.0 Ratchet Jacks • Raises and lowers loads under 25 tons • Uses the lever-and-fulcrum principle • Raises or lowers one notch at a time • A pawl locks the load between lift strokes

31. 8.2.0 Screw Jacks • Can raise or lower loads heavier than the ratchet jack • Uses the screw-and-nut principle • Turning the screw raises or lowers the load

32. 8.3.0 Hydraulic Jacks • Most useful general purpose jack • Uses hydraulic pressure • Slow, but very precise movements

33. 8.4.0 Inspecting and Using Jacks • Inspect before each use • Use the proper jack handle (no extensions) • Remove the jack handle when not using • Place on solid footing • Assure vertical lifting • Block and crib load as it is raised or lowered • Never exceed jack capacity

34. 9.0.0 Tuggers • Electric or pneumatic wenches • Used for lifting, lowering, and pulling • Assure adequate capacity • Assure secure anchoring

35. 10.0.0 Cranes • Cranes are a valuable resource for handling heavy equipment and structural components. • Overhead cranes • Gantry cranes • Mobile cranes

36. Overhead Girder Crane

37. Gantry Crane

38. Jib Crane

39. Mobile Crane

40. Job-Site Safety ?

41. Crane Operations

42. 10.1.0 Verbal Modes of Communication • Type of communication depends on the requirements of the situation: • Portable radio (walkie-talkie) • Frequency noise or crowding can be disruptive • Background noise can interfere

43. 10.2.0 Non-Verbal Modes of Communication • Flags and whistles have been used. • Hand signals are the most common form of crane communication. • ASME B30.5 Consensus Standard of Hand Signals

44. 10.2.0 Non-Verbal Modes of Communication • If a mobile crane is being moved without the direction of a rigger, the operator must use the crane’s horn to signal: • STOP – one (1) audible signal • FORWARD – two (2) audible signals • REVERSE – three (3) audible signals

45. 11.0.0 General Rigging Safety • The rigger must be aware of all hazards, including those that are unavoidable: • Weather – wind, rain, snow, etc. • Slippery surfaces • Unguarded areas (adjacent to worksite) • Remember that most accidents result from human error.

46. 11.1.0 Personal Protection • Hard hats • Safety glasses • Ear plugs • Gloves • Steel toe boots • Barricades

47. 11.2.0 Equipment and Supervision • Employer is responsible for ensuring that all hoisting equipment is operated by experienced and trained personnel. • As a rigger, you are responsible for selecting the correct rigging and lifting equipment, using it correctly, and directing the crane movements safely and effectively.

48. 11.3.0 Basic Rigging Precautions • Determine the weight of the load and rigging. • Verify load limits for hoisting equipment. • Examine all equipment and rigging. • Discard, and report, all defective equipment. • Stay weather-conscience; be prepared to stop. • Be alert for factors that can reduce equipment capacity. • Keep loads plumb if at all possible. • Avoid sudden snatching, swinging, and stopping. • Avoid rapid acceleration and deceleration.

49. 11.4.0 Barricades • Always use barricades to isolate the swing area of a lift. • Be sure you understand your company’s barricading policy before you start.

50. 11.5.0 Load-Handling Safety • As a rigger, you are the ‘eyes’ of the crane operator. • Be confident of the full path of the lift before you start. • Watch area outside the swing. • Watch the path of the rear (counterweight) area of the crane.