Professional Documents
Culture Documents
Lifting Accessories
Safety
ISBN 978-952-479-064-2
ISSN 1456-3614
Multiprint Oy, Tampere 2007
Table of Contents
INTRODUCTION .........................................................................................................5
General requirements for lifting accessories ................................................................6
Structure ....................................................................................................................6
Safety factor ...............................................................................................................6
Machinery Decision requirements apply also to lifting accessories
custom-built for individual uses ...................................................................................6
Use and inspection ....................................................................................................7
Procurement ..............................................................................................................8
Lift planning .............................................................................................................8
GUIDANCE AND TRAINING .......................................................................................9
MARKINGS AND LOAD TABLES ...................................................................................9
FACTORS TO OBSERVE DURING LIFTING ...................................................................11
CHAIN SLINGS .........................................................................................................12
Structure ..................................................................................................................12
Chain ......................................................................................................................12
Equipment ...............................................................................................................13
Inspection and rejection criteria for chain slings ........................................................15
WIRE ROPE SLINGS ..................................................................................................15
General ................................................................................................................... 15
Inspection and rejection criteria for wire rope slings ..................................................16
Synthetic round slings and lifting belts ......................................................................17
Material ..................................................................................................................17
Markings .................................................................................................................18
Working load limit ....................................................................................................18
Sharp edges and edge protection .............................................................................19
Operating instructions for synthetic slings ................................................................19
Inspection and condition monitoring of lifting belts and round slings ....................... 19
Maintenance and repair ...........................................................................................20
LIFTING CLAMPS .....................................................................................................21
When using clamps ...................................................................................................21
Special operating instructions for screw clamps ........................................................22
LIFTING TONGS ......................................................................................................22
Inspection .................................................................................................................22
LIFTING MAGNETS ...................................................................................................23
VACUUM LIFTERS .....................................................................................................24
LIFTING FORKS ........................................................................................................25
LIFTING BEAMS ........................................................................................................ 25
Introduction
Lifting and transfer operations typically entail
some risk factors that cannot be totally eliminated. The danger area generally cannot be
isolated entirely to prevent the transferred load
from causing danger to those participating in
the lifting operation or to others nearby. The
lifting appliance operator and load handler each
play a crucial role in ensuring a safe lifting operation. However, as the lifting appliances used
in industry become more and more radio-controlled, the operator increasingly also performs
the role of load handler.
Compared to many other types of work
equipment, lifting appliances have a central role
in terms of safety, as failure of practically any
one of their parts can result in a hazard situation.
The idiom that a chain is only ever as strong
as its weakest link also applies well to the lifting operation. The lifting accessory and its
operation must be monitored and controlled
throughout its lifespan. Failure of even a single
link will result in danger.
Customers are interested in not only the
product itself, but also the operational quality of
the company that produces or supplies it. High
quality is demanded of production and of the
production environment, and a low incidence
of damage or accidents is considered by the
customer to be a key measure of quality. Provision of clear operating instructions indicates to
the customer that quality-conscious and safe
operations are being observed.
The transfer and transportation of materials
and personnel is the main accident black spot
for many fields of industry. According to some
estimates, nearly half of all industrial accidents
are related to lifting or transfer operations.
The size and weight of lifted loads has increased, and accidents that occur are often
serious in terms of occupational safety as well
as financially. Accidents are almost equally
influenced by technical factors as human factors. A significant proportion of accidents are
considered to be caused by substandard or
Safety factor
Lifting accessories each are assigned a specific
safety factor. The safety factor consists of a safe
working load limit set below a given safety
margin. The limit ensures that no immediate
danger will occur if the maximum safety load
is exceeded. The safety factor does not give
the operator licence to exceed the working
load limit, rather it provides a safety margin to
compensate for the weakening of the lifting
The inspections are recorded in a suitable manner with respect to the needs of the
workplace. An inspection record, card index
or inspection register can be made, containing essential information on inspection dates,
perceived faults and defects and repairs carried
out. An inspection marking must be made on
each accessory in order to eliminate use of noninspected equipment and to facilitate the carrying out of inspection obligations.
An effective means of preventing accidental re-use of lifting accessories that have failed
inspection and are beyond repair is to disable
them completely.
Before bringing a new lifting accessory into
use, the device must be checked to verify that
it complies in all respects with its operating
requirements and is suitable for the purpose
of use. Furthermore, the user must check on
a daily basis all lifting accessories that are in
continuous use. The condition of less frequently
used equipment must always be checked each
time the equipment is taken into use. The check
should consist of a visual inspection to ascertain
that the lifting accessory is in due order and
all of its parts are fixed together firmly. After
overloading or damage, a thorough inspection
of the lifting accessory must always be made
before it can be used again.
The requirements for the site inspection of
lifting accessories used in construction work
are laid down in the Government Decision on
the Safety of Construction Work (629/1994,
amendment 427/1999). Chapter 4 of the decision states that the structure and condition of
lifting accessories shall be checked at the construction site to find out whether they are appropriate for the purpose of their use and compliant with the requirements. In addition, lifting
accessories shall be inspected at the workplace
before they are taken into use and at regular
intervals during operation and, if possible, at
least once per week.
The government decision concerning stevedoring work (915/1985, as amended 449/1995)
provides special regulations for the use and
inspection of lifting accessories used in the loading and unloading of vessels.
Procurement
Procured equipment must be suitable for its
purpose of use. Operating and maintenance instructions in Finnish and, if necessary, in Swedish must always be obtained from the lifting
accessory supplier.
Operational safety can be increased by
procuring lifting accessories that cannot be
accidentally or unknowingly used incorrectly.
Lift planning
The planning of lifting operations should be
integrated as part of productions material handling planning, the objective of which is the
economical, flexible and safe handling of products. All future lifting requirements should be
considered at the products planning stage.
Good lift operation planning and the correct
choice of lifting accessory can effectively eliminate the worst operating errors and hazards in
advance. The designer of the lifted item must
determine how and with which lifting accessories the lift is to be performed, determine the
points of lift and, as necessary, add lifting eyes,
lifting lugs or threaded holes for fastening lifting
eye bolts. At the planning stage, lifting instructions must be prepared for the product. The
lifting operations and transfers needed during
the different production stages of the products
subcomponents must also be taken into consideration in the lift plan.
A set of permanent instructions should be
drawn up for the load handling and lifting of
frequently recurring similar items.
Special lifting operations such as heavy lifts,
lifting of large items and joint lifting operations
always require a separate written plan.
To ensure a balanced lift, the weight, shape,
lifting position and centre of gravity of the
load must be determined. Mark the weight
and centre of gravity of the lifted item in the
drawings.
Table 1 Finnish standard SFS 5152 compliant load table for chain slings
Chain
diameter
mm
Single-leg sling
Straight
lift
Choked
lift
Double-leg sling
Straight
lift
Choked
lift
Multi-leg sling
Straight
lift
10
Choked
lift
Straight
lift
Straight
lift
Lifting slings, especially round slings and lifting belts, are susceptible to damage from
sharp load edges. Sharp edges can significantly weaken the strength of the lifting accessory and present a sudden hazard. The
best form of protection against sharp edges
is the use of edge padding designed for
this purpose. Any sharp edges on the load
should, as far as possible, be removed at the
production stage.
A preliminary lift should always be carried
out: once the load is raised free of its base,
stop the lift and check the load balance and
fastenings.
Avoid jolting during loading (e.g. due to
sudden starts and stops), and never swing
laterally, lift laterally or drag the load along
the ground.
Never attempt to manually stop a heavy load
from swinging.
Never lift using the bindings used for bundling the load if they are intended only for
load binding.
Never pull a sling from beneath the load if
the load is resting on the sling.
Store slings in their designated storage
places.
Chain slings
Structure
Chain slings are lifting accessories comprised of a chain and connected lifting gear. They can be single or multi-legged.
Each sling must be fitted with a marking plate displaying the working load limits for different
loading situations.
A visual inspection must be carried out before using the sling to verify that the sling and sling
fittings are in due order.
Chain slings can typically be used at maximum load in a temperature range of -40C to +200C.
The manufacturers instructions must be observed for operation in temperatures outside this range.
Chain slings should have a designated storage place (e.g. rack) where they are not susceptible
to damage and can be easily obtained. Load tables and lifting instructions should also be located at
the storage place.
Figure 2
Chain slings
Chain
The chain consists of steel links. Lifting slings must be made of short link chain only.
Figure 3
Chain
The required properties of the chain are stipulated in the relevant standards for sling chains.
Documents specifying the technical properties of the chain must be readily available during chain
sling assembly.
Any fittings attached to the sling must be at least as strong as the chain itself.
12
Equipment
Master link
One or more sling legs are connected to the master link via a suitable connection method.
Figure 4
Master links
For each lifting operation, check that the master link is compatible with the lifting appliances hook
(i.e. big enough).
Hook
Sling hooks must consist of self-locking hooks or sling hooks equipped with a sufficiently strong
safety latch.
Figure 5
Different hook models
Open hooks may be used only in special cases where it is ensured that no hazard to personnel,
nearby objects or materials will be created during the lifting operation.
The load must always be set squarely within the hook bowl.
The hooks safety latch must be of sufficient strength and laterally supported to be able to fully
withstand the loading and operating stresses.
Other equipment
Mechanical connector
Connectors are used in chain sling assemblies to connect its various components.
The hitch configuration system ensures that components of the wrong size cannot be connected
to each other.
Sling importers each supply connectors that are compatible with their own chains.
Figure 6
Examples of mechanical connectors
Marking plate
Each chain sling must be fitted with a marking plate showing its designated working load limit. The
marking plates of standard SFS-EN 818-4 compliant slings contain the information shown in Figure 7.
Figure 7
Chain sling marking plate
1.
2.
3.
4.
5.
Shorteners
In order to balance the load, length adjustment of the chain sling legs is needed.
Shorteners consist of shortening clutches, shortening hooks or quick-acting chain length regulators
which lock the chain in place with spring-loaded pegs.
Figure 8
Slings equipped with
different types of chain shorteners
The impact of shortening hooks on the chains strength must be verified and users informed of any
restrictions.
Before beginning the lifting operation, check that the chain is securely locked in the shortener
and unable to come loose at any stage during the lift.
14
The slings master link, hooks or other components contain bends, fractures, warping,
other deformation or the hook mouth has
opened more than 10%.
Any chain link has worn more than 10%. The
chain links are measured in two planes. Their
average dimensions must be at least 90%
of their original dimensions. In this way, the
level of wear until the next inspection can be
predicted.
Slashing, notching, pitting or corrosion
caused by external factors is more than 10%
of the material thickness, or the degree of
deformation is visually perceptible.
Colour change caused by heat damage is
perceived.
Figure 9
Typical wire rope slings
Always carry out a visual check before using the sling to ensure that it contains no faults that may
jeopardise safety. The interval between periodic inspections depends on the degree of strain of use.
Deformation
The sling must be rejected if it contains deformation caused by kinks, bird caging, crushing,
core failure or knots.
Heat damage
Broken wires
Wire breaks are usually caused by mechanical
damage or corrosion. They reduce the strength
of the rope and can cause hand injury to the
user.
The sling must be rejected and replaced if
any strands are totally broken, wire breaks occur
very close to each other or the number of wire
breaks exceeds 5% of the total number of wires
along a length equal to six times the diameter
of the rope.
The sling must be rejected if the nominal diameter of the rope has worn by more than 10%
at any point.
16
Figure 10
Lifting belts
Figure 11
Round sling
Material
Lifting belts and round slings are made from synthetic fibre yarns made of either polyester, polyamide or polypropylene. The most common yarn material used in Finland is polyester. The sling material must also be UV radiation protected.
The material properties of synthetic fibre round slings and belts are rarely considered at the procurement stage. The user must, nevertheless, at least understand the effect of the lifting site conditions on the lifting accessory. Is the site exposed to high temperatures? How might any chemicals
used affect the sling/belt?
Is there UV exposure? Do the lifted loads have sharp edges?
The sling/belt material is indicated by the sling label colour-coding:
Polyester
Polyamide
=
=
Polypropylene =
blue label
green label
brown label
More detailed information on the chemical tolerances of belts and slings is provided by the
manufacturer.
Markings
Round slings and lifting belts must have the following markings:
manufacturers/sellers details
nominal strength = WLL (working load limit:
nominal loads under 1,000 kg are expressed
in kilograms and nominal loads above 1,000
kg in tonnes).
safe working load (working load limit) at different sling angles
sling/belt material indicated by coloured
label.
CE marking
length
traceability code must be available. A double
marking label can also be used, i.e. a backup
label is fixed beneath the stitched marking
label.
Straight lift
WLL
Choked lift
Basket lift
Basket lift
0,8 WLL
2 WLL
1,4 WLL
1 WLL
0,7 WLL
0,5 WLL
18
Choked lift
0,8 WLL
Basket lift
2 WLL
Basket lift
1,4 WLL
1 WLL
Avoid sharp stops/starts by slowly accelerating and decelerating during the lift.
Avoid any kind of jolting during the lifting
operation.
Lower the load onto its landing platform so
that the sling can be removed without damaging it. Do not forcefully remove the sling.
If multiple slings must be used simultaneously due to the length of the load, prevent
sliding of the lifting accessory in the lifting
hook and on the load.
The sling cover has extensive abrasion damage or is generally worn and dirty.
More than 10% of the warp yarns (loadbearing yarns) are severed or yarns are damaged on the belt edge.
20
Lifting clamps
Clamps are used for lifting plates and sheets, profiled products and pipes. The holding force is typically based on the grip between the clamps toothed eccentric cam and the surface of the lifted
item.
Figure 12
Lifting clamps
1.
2.
3.
4.
5.
6.
7.
8.
Body
Lifting eye
Cam segment
Safety latch
Spring
Cam segment shaft
Lifting eye shaft
Pivot
Lifting tongs
Lifting tongs are used for lifting round parts or
bundles. Their holding force is based on the
curved shape of their arms and the leverage
effect. The broader the tongs, the better their
holding capacity.
Their holding capacity can be improved by
coating the gripping arms to increase friction.
The specified working load limit for the tongs
must not be exceeded. The load diameter must
also conform to the specified maximum/minimum limits.
The same documentation must be observed
upon delivery of the tongs as with clamps.
Inspection
Observe the instructions provided by the manufacturer, paying special attention to deformation, warp and cracking. Check the operation
of the tongs and their locking function (should
lock when in the open position), the tightness
of the screws, shaft wear and the tong markings.
22
Lifting magnets
There are two basic types of lifting magnet on
the market: permanent magnets and electromagnets. In addition, electrically connected
permanent magnets offer a third, intermediate
alternative.
Figure 14
Lifting magnets
1. Magnet
2. Instruction plate
+ type plate
3. Lifting eye
4. Release arm
5. Release button
6. Pole shoes
surface. In this case the lifting capacity is always lower than when lifting flat items.
The overall dimensions of the lifted item.
Long items tend to bend, creating air gaps at
the edges of the magnet.
Position of the magnet. Standard magnets
can be lifted only in the horizontal position.
Variable magnetism of lifted items. Some materials do not magnetize at all. The optimum
holding capacity is attained with unalloyed
low-carbon steel.
The weight of the lifted load must be proportioned according to the magnet manufacturers instructions.
Magnets must not be used in high temperatures. The manufacturers instructions must
be observed in this respect.
The holding capacity of the magnets must
be checked at regular intervals by test lifting
using the same loads typically lifted by the
lifting magnets.
Vacuum lifters
The vacuum lifter is a lifting accessory equipped
with one or more suction cups. The adhesive
force between the load and the suction cup is
created by means of a vacuum.
Vacuum lifters usually operate by means of
vacuum pumps, blowers or ejectors but they
can also be mechanically operated without a
pump.
The shape of the suction cup is selected according to the shape and quality of the load,
e.g. round, angular or oval. The suction cups
can be flat, for lifting flat items such as plates,
sheets, panels and glass panes.
The contact surface of the suction cups can
also be specially moulded for the lifting of
pipes or other non-flat items.
24
piston
cylinder
sealing ring
vacuum chamber
valve
f)
g)
h)
i)
reverser
torque rod
chain
rubber diaphragm
j)
k)
l)
m)
pressure chamber
alarm whistle
dust cover
bleed valve
Lifting forks
The same rules apply to lifting forks as to other
lifting accessories. Most hazardous situations
that arise when operating lifting forks involve
falling loads. Attention must therefore be paid
in the design and user instructions of the lifting
fork to ensure sufficient fastness and stability of
the load during the lifting operation.
User instructions and a Declaration of Conformity must be included in the lifting fork
delivery.
During periodic inspection of the lifting fork,
visually check for any permanent deformation
of the structures and wear of the wearing parts.
Check the joints of the structure, especially
welded joints, to ensure there are no visually
apparent cracks. If the lifting fork operation
involves any mechanical functions that stabilise
the lifting fork or load during the lifting operation, the functions and the wear of the components involved must also be inspected.
Lifting beams
A wide range of different loading capacities,
shapes and lengths of lifting beam are available. Lifting beam components and other equipment should also be optimally designed to suit
the beams specific function.
Lifting beams or spreader beams can effectively reduce the load stresses on the sling or
on the load itself.
Lifting beams are the ideal lifting accessories
for workspaces with limited headroom where
the use of lengthy top rigging is not possible.
The lifting beam designer and manufacturer
must have the necessary expertise in lifting
beam design and production, including suffi-
cient knowledge of material strengths and structural requirements. Lifting beams must have the
following markings:
working load limits for different loading situations
dead weight of the beam, to enable determination of the lifting appliances payload
capacity
production/serial number, name of manufacturer
and CE marking
The following must be observed upon delivery
of the lifting beam:
operating instructions,
including possible restrictions on use
maintenance and inspection instructions
and assembly drawing
Declaration of Conformity
Figure 19
Lifting eye bolt
26
Inspection
Visually check that the thread of the eye bolt
and fastening hole are intact and that the eye
bolt is free of deformation.
Shackles
Shackles used for lifting must be designed for
the lifting task in question.
Shackles are loose lifting gear.
As such, they must either be marked with
their working load limit or their rated capacity and possible restrictions on use must be
specified in the operating instructions provided
upon delivery.
Always fully tighten the shackle pin before
lifting. Fixed joints and attachments that can-
Inspection
Visually check that the pin thread is intact and
that the shackle is free of fracture or deformation.
Figure 21 Shackles
28
Appendix
LIFTING ACCESSORY INSPECTION REPORT
No.
CE MARKING Y
PARTS LIST
kg
60
PHOTOGRAPH
kg
DRAWING
SERIAL NUMBER
TECHNICAL DESCRIPTION
INSPECTION INTERVAL
INSPECTED BY
DATE
FAULT(S) OBSERVED
COMMISSIONING
ANNUAL INSPECTION
ANNUAL INSPECTION
ANNUAL INSPECTION
ANNUAL INSPECTION
ANNUAL INSPECTION
ANNUAL INSPECTION
Appendix
Hand signals
General hand signals
START
Attention
Start of signal
STOP
Halt/Pause
End of movement
END
of action
Vertical movements
LIFT
LOWER
VERTICAL
DISTANCE
30
Horizontal movements
MOVE FORWARD
MOVE
BACKWARDS
TO THE RIGHT
of the signaller
TO THE LEFT
of the signaller
HORIZONTAL
DISTANCE
Danger
DANGER
Emergency stop
QUICKLY
SLOWLY