Lifting Equipments

and Procedure

Compiled by
Safety Trainees
PECL

15 January 2011.
2. Factories Act-Section 28
(1):Hoists and Lifts
(a) In a factory hoists and lifts
should be of :

(i)-good mechanical construction

- sound material
- adequate strength

© SWL to be distinguishly marked and no load

greater than this be lifted or carried.
2
Sec 29. LIFTING MACHINES, CHAINS,
ROPES AND LIFTING TACKLES

3
 The Factories Act, 1948
Sec:2(ca): Competent Person
Means:
A person or an institution recognised as such by
CIF for carrying out tests, examination and
inspections required to be done in a factory under
provisions of this Act regarding:
(v)qualifications and experience of person and
facilities available at his disposal;
(ii) qualifications and experience of persons
employed in such institution and facilities a/v
therein, with regard to conduct of such tests,
examinations and inspections, and more than
one person or institution can be recognised
as a competent person in relation to a factory.

4
 The Factories Act,
1948
Sec:2(j): Machinery
Includes prime movers,
transmission machinery and
other appliances whereby power
is generated, transformed,
transmitted or applied.

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Lifting Equipments:
 Hydra’s
 CRANES: limit switches
 Fork lifts
 Magnetic lift crane
 Mobile cranes: wheel ,crawler
 EOT
 Gantry
 Chain pully:spur gear,worm wheel
 Winch machine 6
Lifting tackle:
 Slings
 Ropes
 Shackles
 Swivel
 Rings
 Couplers
 Sockets, Eyebolts.
 Frames & spreaders
 Plate lifting clamps
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 Overview
 Terms & definitions
 Planning the lift
 The lift
 Landing the load
 Do’s & Don’ts
 Case study
 Slinging methods
 Safe slinging practice
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Terms & Definitions
 Competent person:
 A person who has acquired, through a
combination of qualifications, training or
experience, the knowledge and skill to
perform the task required.
 Grommet:
 Endless wire rope sling.
 MBL:
 Minimum breaking load of the lifting tackle.
 SWL:
 Safe working load.
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Definitions
 Tag line:
 A rope of suitable strength, construction
and length attached with an appropriate
recognised bend or hitch to the load,
used to control the load during lifting or
positioning.
 Test certificate:
 A certificate issued by an authorized
person

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SIMPLE CHAIN PULLEY
BLOCK

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Planning the lift

e s se ntia l
p e r a t i o n is
e l i f tin go rr ie d out
a n ni ng th e l if t is ca
P l th a t th
e n s ur e f f ic ie n t ly
to l y a n de
sa fe

12
Planning the lift

Absence of planning leads to

Short cuts, using unsafe procedure, equipment
&
It may cause
An ACCIDENT OR DELAY

13
Planning the lift
 The following points must be
considered during planning:
 Where the load is to be picked up from
 Where the load is to be placed
 What areas to be passed over
 Any obstructions in the way
 How the load is to be slung
 How the slings are to be removed and
access to them
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Planning the lift
 For complex lifts, following points may have
to be considered:
 Special lifting accessories such as spreader
beams to ensure that the load is safely lifted and
without damage to the product (large
machineries, generators, etc.)
 Special connectors to connect special built in
connecting points. The operations may involve:
 Turning loads over or standing them upright
 Using more than one crane to lift a load.

15
The lift
After slinging but before lifting, the following
must be considered

 Are the slings undamaged and properly attached

to the load?
 Is the crane hoist rope vertical?
 Is the load free i.e not attached to any thing
else?
 Are the legs of multi legged sling equally loaded?
 Are all spare all spare legs of the sling are
hooked up to the master link on the lifting hook?

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The lift
After slinging but before lifting, the following
must be considered
 Are all personnel clear of the load?
 Is the landing site prepared to take the
load?
 If required, is hand/tag lines attached to
the load?

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Check Before Lifting
 Now lift the load a short distance above the
ground and check that:
 The load is balanced and stable.
 The legs of the slings are at correct angles.
 Any packing pieces used, are in place and
sound.
 The load itself is not stressed, especially when
lifting packing cases, timber etc, which can fail
under the loads applied due to lifting.

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Landing the load
 Before landing the load check that:
 The landing area will take the weight of the load.
 There is sufficient space for the load.
 There are strips of timber or similar on which to
land the load such that the slings can be easily
removed by hand.
 The load should be landed gently to
ensure that it is not damaged and
that the crane does not receive any
shock loading.
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 Do’s & Don’ts
Always
 Ensure that only
authorized
slingers/signalers attach
or detach loads, or signal
the crane operator.
 Discuss operations with
the crane operator
(special operations).
 Ensure that the capacity
of the crane is sufficient.
 Seek expert advice when
using eye bolts, plate
clamp etc.
 Use tag line always
Never
 Wrap tag line around
hand or body.
 Leave a suspended load
unattended.
 Pass loads over people.
 Ride or climb on
suspended loads.
 Stand or walk beneath
the loads.
 Use pipes to support
for landing the load
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 SWL OF SLINGS
SAFE INCLUDED SAFE
WORKING ANGLE θ WORKING
LOAD OF LOAD
SLING WITH ANGLEθ
G = 10 TON at 90 10 TON
90
160 3.45 TON
140 6.80 TON

120 7.07 TON

60 12.25 TON
0 14.14 TON
P = G / Cos 45
SWL at angle
=P X Cosθ /2 21
SLING ANGLES AND SAFE WORKING
LOADS

90˚ angle at hook

corresponds
to 45˚ sling angle

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SLING ANGLES AND SAFE WORKING LOADS
.

When L = S
Sling angle is 60˚

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SLING ANGLES AND SAFE WORKING LOADS

Calculating SWL
H is the vertical
distance from the
saddle
of the hook to the top of
the load.
L is the distance
measured along the
sling from the saddle of
the hook to the
top of the load.
The ratio H/L will be
same as the ratio h/l

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SLING ANGLES AND SAFE WORKING LOADS

Determining
capacity of 2-Leg
Bridle
Hitch

SWL
= SWL (of single
vertical hitch) X H/L
X2

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SLING ANGLES AND SAFE WORKING LOADS

When sling legs

are not of equal
length
use smallest H/L
ratio.

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SLING ANGLES AND SAFE WORKING LOADS

Determining
capacity of 3-Leg
Bridle
Hitch
SWL
= SWL (of single
vertical hitch) X H/L
X3
When sling legs are
not of equal length
use smallest H/L
ratio.
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SLING ANGLES AND SAFE WORKING LOADS

Determining capacity
of 4-Leg Bridle
Hitch
Load may be carried by
only 3 legs while
the fourth merely
balances it. Therefore
the recommended SWL
is:
SWL
= SWL (of single
vertical hitch) X H/L X 3
When sling legs are not
of equal length
use smallest H/L ratio.
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SLING ANGLES AND SAFE WORKING LOADS

Determining capacity
of Single Basket
Hitch
For Vertical legs (fig A):
SWL = SWL (of single
vertical hitch) X 2

For inclined legs (fig B):

SWL
= SWL (of single
vertical hitch) X H/L X 2

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SLING ANGLES AND SAFE WORKING LOADS

Determining capacity
of Double Basket
Hitch with inclined
angles

SWL
= SWL (of single
vertical hitch) X H/L X 4

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SLING ANGLES AND SAFE WORKING LOADS

Determining
capacity of Double
Wrap
Basket Hitch
Depending on the
configuration, SWLs
are the same for the
Single Basket Hitch
or the Double Basket
Hitch.

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SLING ANGLES AND SAFE WORKING LOADS

Sling angles less than

45˚ (formed by the
choker) are not
recommended. If
they
must be used the
formula is:

SWL
= SWL (of single
vertical hitch) X H/L
X
A/B X 2
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SLING ANGLES AND SAFE WORKING LOADS

Determining
capacity of Double
Wrap
Choker Hitch

Depending on the
configuration, SWLs
are the same for the
Single Choker Hitch
or the Double Choker
Hitch.

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Endless Sling choker Hitch Endless or Grommet Sling in
Configuration Vertical Hitch

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SLING ANGLES AND SAFE WORKING LOADS

Endless Sling in
Double Basket
Hitch
Configuration

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Endless or Grommet Slings Standard Eye-to Eye slings

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SLING ANGLES AND SAFE WORKING LOADS

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Effect of sling angle on
Webbing

38
Twisted Eye Slings

39
What can happen, if, adequate
safety is not observed?

40
A case study 1
 The incident:
 In June 2003, a tragic incident
occurred at one of the oil and gas
development site in Algeria, resulting
in one fatality and two injuries.
 The incident occurred during the assembly
of an onshore drilling rig. A large section
of the rig was being lifted when a lifting
chain failed.

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A case study 1

Actual measurement to
hook position was 9.43 m.

7.5 m to centre of crane

slew ring correct jib
Probably out of head/hook position
alignment in this
direction (this would
transfer entire load to
one sling)
Chain being pulled into
angle would increase
tendency to jam and
prevent chain slipping
Sketch of out-of-alignment load path round to equalize
during lift, resulting in lifting chain loading
failure 42
A case study 1
 The causes, as established by an investing
team:
 Use of an underrated chain sling.
 Incorrect slinging and lifting techniques.
 The crane hook was positioned off-centre,
resulting in the load path being out of alignment.
 Combined with a hinged load, this prevented the
sling from equalizing on all chain legs when
raised.
 Consequently, the entire load of 23.1 tonnes
was placed on one chain leg that had a breaking
load of 18.9 tonnes resulting in failure of chain

43
Case Study 2
 Job : erection of gantry crane beams
 Description of Accident:
 Two beams of 11.5m X 1.5m X 0.75m
weighing about 6 tones were lying on
concrete sleepers.
 Out of two beams one beam was lying on
sleeper in horizontal position.
 The other beam was in vertical position and
was to be positioned to make alignment with
the first beam.
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45
Case Study 2
 Job : erection of gantry crane beams
 Description of Accident:
 Slings were placed around the vertical beam.
 Mr. XYZ went up the beam to adjust the sling.
 He adjusted the sling and stood in between the
two beams.
 In the meantime someone gave signal to lift the
beam.
 Crane operator lifted the beam by about 4 mm
up its position.

46
Case Study 2
 Job : erection of gantry crane beams
 Description of Accident:
 During that operation beam swayed
towards the first beam and Mr. XYZ was
caught between the two beams.
 On hearing the scream, crane driver
placed the beam back on its original
position.

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Case Study 2
 Job : erection of gantry crane beams
 Description of Accident:
 Mr. XYZ got up and tried to get out of
two beams but he stumbled and fell
down on sleepers, got injury near left
eyebrow.
 He was taken to hospital, but was
declared as dead.

48
Case Study 2

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Case Study 2 - Investigation

1. No hand rope (tag line) was used to avoid

swinging of the job.
2 Both the lifting rope used are having N no. of
kinks on it., naturally these kinks will have
tendency to swing the job.
 No lifting hole or lugs were made to the beam
to rotate it.
 Crane operator does not know who gave
him signal for lifting the job.

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Learning from the incidents
 Apart from lifting machine, it
is also necessary to take care
of lifting tackles and lifting
procedure

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Safe Slinging Practice

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Safe Slinging Practice

Crane hook must

be on the CG

C.G.

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Safe Slinging Practice

This load is not stable. The hook is over

the CG, but the CG is above the lifting
hook.
This load is top heavy, and could
overturn while being lifted

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Safe Slinging Practice

This load is stable

The hook is right over
the CG.

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 Safe Slinging Practice

Unstable
The load will shift until the
CG is under the hook.
The hook is not over
the centre of gravity This will make landing the load
very difficult, and could cause
major problems in crainage

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 Safe Slinging Practice

500 500
Kg Kg
1000 1000
Kg Kg

707 707
Kg Kg 1932 1932
Kg Kg

90 90
45 45 30 30 15 15

1000 1000 1000 1000

kg kg kg kg

57
How to identify the correct
angle?
At 45 degrees, H = L

As the angle becomes

less than 45 degrees, H
will be less than L

Therefore ensure that

H is always = or > L
H
L
45

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 Safe Slinging Practice
Balanced ¼” off 1/2” off 3/4” off Point
load centre centre centre loading

Can carry Can carry Can carry Can carry Can carry
100% of 88% of 80% of 70% of 40% of
rated load rated load rated load rated load rated load
Safety latches
omitted 59
Safe Slinging Practice
Softeners, padding or use of blocking..

60
 Safe Slinging Practice

Tag line should be attached to the load swinging and to help it

landing in the right place.

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 Unsafe Slinging

Lift and lower the load

smoothly, do not jerk

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Unsafe Slinging

63
Unsafe Slinging

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Unsafe Slinging

Is it right method
to extend a chain
sling?

65
Unsafe Slinging

66
Sling storage

67
Hand Signals
 When should the crane operator
follow hand signals?
 A crane operator should always move
loads according to the established code
of signals, and use a signaler.
 Hand signals are preferred and
commonly used.

68
Hand Signals
 Who can give the hand signals?
 a person qualified to give crane signals
to the operator,
 there should be only one designated
signaler at a time,
 a crane operator should move loads only
on signals from one signaler,

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Responsibility of the signaler
 The signaler must:
 be in clear view of the crane operator,
 have a clear view of the load and the
equipment,
 keep persons outside the crane's
operating area,
 never direct a load over a person.

70
Standard Hand Signals For
Controlling Overhead Cranes

With forearm
vertical, forefinger
pointing up, move
hand in small
horizontal circle

HOIST

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Standard Hand Signals For
Controlling Overhead Cranes

With arm extended

downward,
forefinger pointing
down, move hand in
small horizontal
circle.

LOWER

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Standard Hand Signals For
Controlling Overhead Cranes
Arm extended
forward, hand open
and slightly raised,
make pushing
motion in direction
of travel.

BRIDGE TRAVEL

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Standard Hand Signals For
Controlling Overhead Cranes

TROLLEY TRAVEL.
Palm up, fingers
closed, thumb
pointing in direction
of motion, jerk hand
horizontally.

TROLLEY TRAVEL

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Standard Hand Signals For
Controlling Overhead Cranes

Arm extended,
palm down, hold
position rigidly.

STOP

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Standard Hand Signals For
Controlling Overhead Cranes
Use one hand to give
any motion signal
and place other
hand motionless in
front of hand giving
the motion signal.
(Hoist Slowly shown
as an example.)

MOVE SLOWLY

76
Standard Hand Signals For
Controlling Overhead Cranes
Crane operator
spreads both
hands apart –
palms up.

MAGNET DISCONNECTED

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Finally, we must remember….

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 Objective Of Good Slinging
 The sling and its method of use should
be suitable for the load.
 The method of attachment of the sling
to the load and the sling to the lifting
appliance should be secure.
 No part of the sling should be
overloaded either by the weight of the
load or by the method of slinging.

79
 Objective Of Good Slinging
 The slinging method should ensure
that the load is secure and that the
load will not fall from the sling.
 The load should be balanced and stable
and should not violently change its
attitude when lifted.
 The load must not be damaged by, or
cause damage to, the sling.

80
If we remember & achieve
this Objective…..

The probability of
accident will be
minimum
Sling storage

82
83