Basic Rigging PDF

BASIC RIGGING
1
Contents
• Introduction
• Roles and responsibilities
• Wire ropes
• Slings, belt slings, round slings,
• Bow Shackles
• Rigging Hitches & Slinging Methods
• Basic Knots
• Chain blocks
• Pull lifts
• Tirfors, eye bolts, plate clamps, turnbuckles, hooks,
lifting beams
• Lifting Appliances
• Procedure for lifting operations
2
INTRODUCTION
A. Mission
This course on Lifting Equipment, Rigging, and

Slinging is designed to identify and detail the
mandatory requirements for the safe utilization
of all lifting equipment operating on the Project.
The course will also provide a clear
understanding of Lifting tackles, Rigging and
Slinging practice, Safe Working Loads, Different
types of Cranes and Crane Signals.
3
B. Problem Analysis
Everyday, Routine Crane Operations –

• cause most of our accident due to lack of
adequate planning.
4
C. Expectation
• To analyze all lifts
• Ground Preparations
• Using proper lifting tackles
• Interpretations of capacity charts
• Operators and signalmen must
maintain continuous and undivided
communication
5
D. Objectives
Upon completion of the lesson, participants will
be able to:
• List the four major causes of crane accidents.
• Describe the pre-planning that is required

before putting a crane in use.
• State the main precautions that apply to

working with cranes.
• Explain at least three ways to eliminate
hazards that may lead to injury when using
cranes or slings to handle materials.
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Roles and Responsibilities (Cont.)
Rigging Superintendent
– Ensuring that the lifting equipment and gear
selected to work, has been inspected,
certified and is maintained according to
procedure
– Ensuring that only
qualified and competent
riggers/slingers/banks-men
are assigned to any lifting
operations
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• Appointed Competent Person (Lifting
Equipment) – Third Party
• Appointed Competent Person (Lifting
Gear) – Third Party
– Responsible for ensuring that the testing,
examination and certification of lifting
Equipment / Gear is carried out in
accordance with the Requirement
8
Line Supervisors
– Ensuring the adequate supervision of personnel,

carrying out, or involved in, lifting operations
– Ensuring that work method statements, task risk
assessments, Lifting Plan /Rigging Study have been
carried out
– Ensuring that areas around the lifts are suitably
barricaded and warning signs posted
– Ensuring that the Load weight, shape and radius of lift
are suitable for selected lifting equipment and gear
9
Riggers and Slingers
– Identifying any defects in lifting gear

– Conforming the weight, center of gravity and
characteristics of a load prior to lifting
10
•Banks-men
– Preventing all unauthorized

personnel from entering the
restricted area around the lifting
operation
– Ensuring that taglines are attached
and used on all loads
11
Wire Ropes
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Single Layer Rope
• One layer of outer

strands (usually 6 or 8)
laid helically over a
centre core of fibre or
steel
• Illustration - rope with
independent wire rope
core (IWRC)
13
Wires in a Stranded Rope
Outer wire Centre wire
Inner wire Core wires
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Stranded Ropes
Single layer Two layers Three layers
Rotates Rotational Resistant Low Rotation
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Rotation-resistant rope
(Illustration is 35LS - Low rotation rope)
16
Rope Dimensions
Actual (measured) diameter Nominal diameter (d)

22.2 mm 22 mm
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Measurement of Rope Diameter
(New rope)
• 2 measurements at right angles at two
positions spaced approximately one metre
apart.
– (Measurements taken over strand crowns)
• Average of the four measurements is the
rope diameter.
18
Sheave Groove Profile
Wrong Wrong
19
WHIP LASH:
A damaged or overstrained rope may break and cause serious
injury to anyone in its path.
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Slings
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WIRE ROPE SLINGS
Inspection Soft Eye
• Safe working load stamping.
• Identification mark.
• Correct colour code (if applicable).
• Broken wires (Randomly distributed wire breaks are not to
exceed 5% in any length of 10 diameters. Localised breaks are
not to exceed 3 in a close group or in any one strand within a
length of 6 diameters).
• Ensure rope end of the looped parts does not terminate inside
ferrule.
• Excessive wear (max 10% loss of nominal diameter)
• Kinks.
• Exposure of core.
• Flattening of rope (especially in the eye).
• Stretch by reduction in diameter or circumference.
• Corrosion.
• Heat damage, look for evidence of discoloration, loss of
lubricant, pitting and the presence of weld blobs.
Soft Eye Endless
Action
If any of the above faults are present refer to a competent
person for through examination.
Maintenance
• Keep ropes clean and free from grit.
• Lubricate at regular intervals.
• Slings should be suspended from storage rack if not in use.
Grommet
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CARE AND USE OF WIRE ROPES.
Examine all wire ropes for damage before use.

Faults which may render a rope unserviceable
include;
Broken and fraying
Badly worn strands strands
•Corrosion
•Kinking.
•Broken and fraying strands.
Corrosion Kinking
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Wire Rope Capacities
24
The stresses in the legs of the sling increases as the
angle between them increases. Using the human
body and two buckets filled with water it will not be
difficult to demonstrate the effects of lifting a load at
narrow and wide angles. The arms represent the
sling and lift angle.
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SKETCH “A” SHOWS THE ARMS VERTICAL AND A
REASONABLY EASY LIFTING CONDITION.
SLING
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SKETCH “B” SHOWS THE ARMS STRETCHED BEYOND ITS LIMIT WITH THE LOAD.
THE BODY AND SLINGS ARE NOT DESIGNED TO TAKE UN-NECESSARY STRAINS.
SLING
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Caution — Slung Angles are Critical
Slings should always On two leg sling work always be

be used as near aware of the changing SWL factor
vertical as possible. with the changing angles of the
In general if L is slings.
greater than S then
the slinging is OK
29
Chain Slings
Only Grade 8 or better ALLOY Chain can be used for
overhead lifting purposes! All chain is not rated the same!
Chain must have a capacity tag attached to it.
Chains will withstand more rough handling and abuse, but a
chain with the same rated lifting capacity of wire rope will be
much larger in diameter and heavier in weight.
Chains must be inspected daily before use and as often as
necessary during use to assure safety.
It is the riggers responsibility to do the inspections!
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Chain Slings
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SPECIFIC REQUIREMENTS FOR THE
WEBBING SLING (FLAT & ROUND)
• All webbing sling shall;
• Be stored away from direct sunlight to minimize
the effect of UV deterioration.
• Be stored on a non-corrodible rack, away from
any source of heat.
• Not be used in knotted or twisted condition.
• Never be repaired. A damaged webbing sling or
sling with damaged cover shall be discarded
and taken out of service.
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BELT SLINGS
Identification
• Safe working load marking.
• Identification mark.
• Colour inspection code (if used).
• Condition of stitching.
• Tears or abrasions
• Burning of outer surface.
• Excessive wear. Belt Sling with Eyes
If any of the above faults are present refer to a
competent person for through examination.
Maintenance
• Keep surface clean and free from grit.
• Re-apply colour code if necessary.
• Sling should be suspended in storage when not in use.
Endless Belt Sling
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Flat Webbing and Round Synthetic
Slings
Types of synthetic slings and fittings
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Slings
• INSPECTION
• Synthetic slings must be inspected before each use.
• They must also be inspected by a competent person at least once

every 3 months. If a sling is subject to severe conditions the
inspections should be more frequent.
• Send slings for a proof load test at least every 12 months.
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Slings
• LOOK FOR:
• Any external wear such as abrasion or cuts and contusions.

• Internal wear which is often indicated by a thickening of the sling
or the presence of grit and dirt.
• Damage to the protective coating of the sling.
• Damage caused by high temperatures, sunlight or chemicals
(indicated by discolouration).
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Slings
• Damage to the label or stitching.
• Damage to the eyes or any terminal
attachments or end fittings.
• Where the sling is covered by a sleeve, the
sleeve must cover the sling for the full length
from eye to eye.
37
Slings
• DISCARD A SYNTHETIC SLING IF:
• It is considered that it has lost more than 10% of its original

breaking strength. (Send the sling to the manufacturer for
regular testing.)
• The label has been removed or destroyed.
• There is any damage to the sleeve or protective coating.
• A nylon sling comes into contact with acid.
• A polyester sling comes into contact with alkaline substances.
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Slings
• A polypropylene sling comes into contact with an organic solvent
such as, paint, coal tar or paint stripper
• There are any visible cuts on the sling.
NB: A nylon sling will lose more than 10% of its strength
when it is wet.
After 6 months exposure to sunlight send a sling in for

testing.
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Slings
(b) Some damage to load-bearing fibres (c) Badly damage sleeve
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Slings
(e) Cut load-bearing fibres

(d) Load-bearing fibres have been cut (f) Broken load-bearing yarn
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Slings
(g) The use of hooks that are too narrow (h) Burn damage to sleave and (i) Surface wear evident by furry surface
load-bearing yarn
has damaged the eye of the sling
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ROUNDSLINGS
Typical Round sling colour coding
Identification (Basic Configuration)
A further category of man-made fiber slings is the round sling. WLL Tonnes Colour
This is manufactured from an endless polyester yarn and 1.0 Violet
covered with a protective polyester sleeve stitched as illustrated. 2.0 Green
3.0 Yellow
4.0 Grey
Maintenance 5.0 Red
• Safe working load markings. 6.0 Brown
8.0 Blue
• Identity number. 10.0 Orange
• Colour inspection code.
• Broken load bearing internal yarn.
• Cuts and abrasions to external cover. Endless Round Sling
• Cuts in stitching.
• Discoloration (due to chemical attack).
• Burn marks on outer surface.
• Knots.
Action
If any of the above faults are present refer to a competent
person for thorough examination.
Maintenance
• Keep clean and free form grit.
• Re-apply colour code if necessary
• Sling should be suspended in storage when not in use.
Round Sling with eyes
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SLING INSPECTION
while inspecting the sling;
• Sling should be laid out in good light and

examined over its entire length for:
1. Damage caused by sharp edges (cuts)

2. Damage caused by abrasion (burning or scuffing)
3. Impact damage.
4. Contamination by chemicals.
5. ID tag with SWL marked ID number and length.
6. Certification.
44
COLOR CODING
• The project operates a system where by all
―Lifting Equipment‖ is color coded with a unique
color, at monthly intervals, after inspection where
applicable.
• Red color is reserved especially for items

scrapped or not to be used. We have to comply
with the project color coding system every 3
months or depending upon the project
requirement.
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Thumb Rules
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Bow Shackles
47
SHACKLES
Three types of shackles are commonly used for rigging
applications. They are the anchor (bow type), chain shackle (D-
shackle) and wide-body type shackle.
Many more different type shackles are available in the market-

place which should not be considered for rigging use.
Three suppliers of shackles are well known in the construction

industry with Crosby and Green Pin being the leaders and most
widely utilized. Le Beon shackles can occasionally be found as
well.
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Screw Pin Anchor Shackle Bolt Type Anchor Shackle
Screw Pin Chain Shackle Bolt Type Chain Shackle
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Wide Body Shackles
Greatly improve wear-ability of wire
rope slings and can be used to connect
high strength Synthetic Round Slings
or Wire Rope Slings by improving the
D/d ratio. The sling bearing area
increases by a minimum of 58 %
which increases sling strength by a
minimum of 15 %. Pins are smaller
than equally rated quenched and
tempered shackle pins and for
instance a 75 Tonne wide body
shackle can be utilized where a 55
Tonne normal quenched and
tempered shackle is intended to fit.
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Normal Shackle
Reduced Sling Bearing Area in Shackle Bow
Wide Body Shackle

Increased Sling Bearing Area up to 58 %.
Increases usable sling strength up to 15 %
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A simple Formula is used to calculate the
Factor of D/d
0 .5
Factor = 1 -
D/d
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This means if a 25 mm Diameter Sling is
used over a 30 mm Pin the Equation will
be:
0.5 0 .5
1- = 1- = 1 – 0.416 = 0,584
30 / 25 1 .2
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54
Rigging Hitches & Slinging Methods
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IDENTIFICATION OF RIGGING HITCHES
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PRECAUTION WHEN USING
LIFTING GEAR
CURVATURE:
Sharp bends in a wire rope

sling reduce its strength and
cause crushing.
Fit a wire rope sling so that
the minimum radius around
which it is bent is atleast 3
times the diameter of the rope.
Packing may be inserted to
increase the radius of the
bend.
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Slinging Hazards
58
Slinging Hazards
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60
SOFT EYE
Not to be hammered
down
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DOUBLE CHOKER
OR
A PAIR OF CHOKER HITCHES
Not to be hammered down.
62
DOUBLE BASKET
OR
PAIR BASKET HITCHES
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64
SAFE WORKING LOAD (SWL)
A calculated, design approved and
certified maximum load, normally
specified in Kilograms (kgs) or Tones,
up to which, an item of ―Lifting
Equipment‖ is safe to operate.
65
CENTER OF GRAVITY
The center of gravity of an object is that point at which the object will balance.
The entire weight may be considered as concentrated at this point.
Any suspended object (load) will center itself directly under the hook.
STABLE Hook is directly above

Center of Gravity
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UNSTABLE
Load is not above Load will shift until
Center of Gravity Center of Gravity is
below the Hook
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UNSTABLE
Load is not above Center of Gravity
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69
Rules to Follow When Slinging and
Handling a Load
Move
Raise
Lower
slowly
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Basic Knots
71
ROUND TURN AND
TWO HALF HITCHES
Used to secure a rope to a column or post. Easily tied and does not jam.
Will stand heavy strain without slipping.
BOWLINE
A favorite knot with riggers and one of the best
known and widely used of all knots.
It is easily constructed and used wherever a
hitch is required that will not slip, jam or fail.
REEF KNOT
Also known as the square knot. Used to join two rope or
lines of the same size. Holds firmly and is easily united.
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Chain Blocks,
Pull lifts,
Tirfors, eye bolts, plate clamps,
turnbuckles, hooks, lifting
beams
73
USING CHAIN BLOCKS
Head Lifting
Ensure that the SWL of the

chain block is adequate for
the load to be lifted.
Attach the head fitting to a
suitable anchorage
Pull the operating chain to
determine the hoisting and Load Chain
lowering sides of the chain.
Attach the load to the hook
Safety catch
using correct slings and / or
shackles. Hook
Pull down the relevant side of
the operating chain to hoist
or lower the load. Operating Chain
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USING PULL LIFTS Head fitting
Hand wheel
Pawl Lever
Attach the head fitting to a Operating Lever

suitable anchorage taking
into account the load to be Step Line
lifted, lowered or pulled.
Hook with Safety catch
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PULL LIFT OPERATION:
HOISTING OR PULLING:
1. Turn the lever to the neutral

position.
2. Turn the hand wheel to adjust the
chain to the required length.
3. Attach the load to the bottom hook,
using appropriate slings and / or
shackles.
4. Turn the lever to the up position.
5. Turn the hand wheel to take up the
slackness in the chain.
6. Operate the handle backwards and
forwards to lift or pull the load.
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LOWERING:
• To lower the load, turn the lever
to the down position.
• Operate the handle backwards
and forwards to lower the load.
• When the load is securely in
position, operate the handle to
slacken the chain.
• Turn the lever to the neutral
position and turn the hand
wheel to give sufficient length
of chain to be able to release
the slings and / ore shackles.
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Examine a
chain before
using it.
Look for
stretched links,
wear, distortion
and any other
sign of
weakness.
78
HAND OPERATED WINCH / TIRFOR
Identification
A hand operated, lever controlled friction drive mechanism for lifting,
lowering and pulling a load.
Identification
• Identity number.
• Check for free operation of operation, reversing and rope release lever.
• Check that correct shear pins are fitted, and pin condition is satisfactory.
• Inspect complete machine for cracks, indentations or distortion.
• Wear in operation jaws
• Corrosion.
• Inspect wire rope and hooks.
• Correct rope.
• Damage to casing.
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Identification
This is a multi purpose tool made to pull and
pay-off wire rope.
A special wire rope is fitted through the
machine and cannot be removed whilst
there is a load on the winch.
When the operating handles are actuated by
hand, the rope is either pulled or paid-out
through the machine.
These machines are available in a range of
Sizes to suit different working conditions.
Using the hand-operated winch 2. Push the release handle into the notched position to
1. Uncoil the special wire rope, used with the machine, in a straight open the jaws inside the machine.
line to prevent loops which might untwist the stands or form kinks 3. Insert the tapered end of the wire ripe into the
under tension. machine at the hole in position A
Notched Release
position handle
A
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4. Push the rope through the machine until it emerges at 5. Anchor the machine using the correct slings. Fit
exit B. them to the hook attached to the machine.
B
Hoisting or Pulling
Fit the operating handle on to the actuating lever and work the handle
to and fro. 6. Pull the wire rope through the machine until the
This action pulls the rope through the machine and automatically locks desired length is reached and the rope
it in position when the operating handle is released. becomes tight on the load.
7. Lift the release handle out of the notched
position and allow it to return to the operating
position under its spring pressure. The rope is
now firmly held in jaws fitted inside the
machine.
Actuating lever
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Lowering or slackening off
Fit the operating handle to the lowering Lowering lever
lever and work the handle to and fro.
this action pulls the rope back through the
machine and when the handle ceases to
move automatically locks the rope in
position.
Releasing the wire rope

from the machine
1. Fit the operating handle on to the lowering lever
and work the handle to and fro until all the
tension is taken off the rope.
2. Remove the anchoring slings.
Push the release handle to the notched position
to open the jaws inside the machine
3. Pull the rope back through the machine.
The jaws in the machine automatically lock the

rope in position. It is therefore impossible to
release the wire rope form the winch whilst there
is any strain (load) on it.
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COLLAR EYE BOLT
This bolt has a small eye;

a large collar with a
machined under face
which is relieved to allow
a radius between collar
and shank and to provide
a thread run out.
83
EYE BOLT WITH LINK
This bolt is used for

normal lifting
purposes and has a
link forged in the
eye.
84
DYNAMO EYE BOLT
This is designed for

vertical lifting only.
85
PLATE CLAMPS
Identification
There are various types of plate clamps in use, the following three being the most common:
Inspection
• Identity number.
• Plate thickness marking
• Free working of assembly.
• Condition of ―teeth‖
• Wear at all bearing points and on pins.
• Cracks, nicks and gouges.
• Inspect weld (if used).
• Security of all pins.
• Deformation. Universal Vertical Horizontal
• Corrosion.
• Condition of springs
Action
If any of the above faults are present refer to a competent person for thorough
examination.
Maintenance
• Keep clean and free from grit.
• Lubricate moving parts if necessary.
• Re-apply colour code if necessary.
86
PLATE CLAMPS
Plate clamps are available in two basis designs, i.e horizontal plate clamps (sued in pairs and usually suspended by a two leg sling from
a lifting beam) for handling plates in the horizontal position. (These clamps can also lift from horizontal to vertical and vice versa, but
should NOT be used to transport plates horizontally).
Selection Horizontal Clamps Universal (Vertical) Clamps

The first consideration when selecting the clamp is how the plate is to be transported and stacked, ie horizontal or vertically.
The second consideration is the weight of the plate to be handled which will determine the SWL of the clamps.
The third consideration is the plate thickness which will determine the correct model of clamp with the appropriate jaw opening.
Pre-use Examination
Before using any plate clamps, the following checks should be made:
•The SWL is adequate for the load.

•The colour coding (where applicable) is current and the clamp has a plant number / ID mark.
87
Lock the jaw in the closed position and ensure the jaws have a firm bite on the plate.
Always
i) Check that the plate is clean and free from mill scale, dirt, Oil and grease.
ii) Double check that the jaws are locked.
iii) Use an adequate number of clamps to balance the load.
iv) Lift slowly to allow the jaws to obtain a good grip.
Never
Attach clamps to the side of the plate
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Never
• Fast lower onto the floor as this could cause the clamp to open and release the
plate.
• Lift horizontally with a vertical clamp.
• Lift more than one plate at a time.
• Use large capacity clamps to lift light loads.
When using horizontal plate clamps, do not exceed the sling angles indicated
below and do not lift more than one plate at a time unless the clamps are suitable,
i.e. sheet bundle clamps
Never
• Use endless slings with clamp pairs as this practice
can drastically overload the clamps.
89
COMMON TURNBUCKLE
Turnbuckles (Rigging Screws) can be obtained with various types and combinations of end
fittings, the most popular being the ―Jaw and Eye‖ type.
Jaw & Eye combination
Jaw & Jaw combination
Hook Hook & Hook combination

Eye Jaw Stub
(Has Reduced
Selection capacity)
The first consideration when selecting turnbuckles
Hook & Eye combination
is the SWL which is determined by the thread diameter.
The second consideration is the adjustability (commonly known as ―Take-up‖) of
the turnbuckle. The take-up often varies with different patterns.
90
When using a turnbuckle in an application where vibration is present, (most areas in an engineering
environment), it is extremely important to lock the end fittings to the frame or body to prevent them from
unscrewing and possible releasing the load. The most popular and preferred method is to wire the eye or jaw
to the body (see fig. 1). As an alternative (for open body type only) a split pin through the end of the screwed
shank is acceptable (see fig – 2). The split pin has to be removed to facilitate adjustment. Should lock nuts be
used, care must be taken not to over tighten them as this can put undue stress on the threaded shank (see fig
– 3)
Lock wire will hold
Preferred Acceptable Caution Required

Fig - 1 Fig - 2 Fig- 3
WARNING
When turnbuckles are to be left under load for any length of time, eg temporary hangers for
pope work, etc they should be visually checked on a daily basis to ensure they are still secure.
91
PRE-USE EXAMINATION
Prior to using a turnbuckle in a lifting situation, visually examine it and ensure that:
i) The SWL is adequate for the load.
ii) The colour code is current and the turnbuckle has a plant number / I.D. mark.
iii) The threads are free from wear, stretch and impact damage.
iv) The eyes/hooks are not worn or stretched.
v) The clevis pin and pin holes are free from distortion/wear.
vi) The threads are suitable lubricated.
Check for cracks & bends

Safety
Turnbuckles must always have the threaded shank protruding into the body to ensure
Check
that the load is borne over the correct length of the threaded for thread damage & bent rods
shank.
Particular care must be taken when using ―Closed Body‖ type screws. It may be necessary
CORRECT
to dismantle to dismantle the turnbuckle, measure the length of the UNSAFE
threaded shanks,
reassemble and use measurement to ensure the above ―unsafe‖ case is avoided.
92
SWIVEL HOOKS WITH SAFETY
CATCHES
These allow the load to be
moved round without
twisting and possibly
endangering slings, wire
ropes and chains. The
safety catch ensures that
the rope or chain does not
slip off the hook.
93
CARE OF HOOKS:
Fit a shackle between the
lifting hook and the eye bolt to
prevent the point of the hook
being strained.
The shackle will swivel to
allow the sling and hook to
make a correct lift as
illustrated along side and
below.
Note: Collar eye bolts are

not designed to take hooks.
94
CARE OF EYE BOLTS:
Always tighten eye bolts to

the correct position, but do
not over strain them. Fit a
shackle so that the
minimum strain is imposed
when the lift is made
unless an eye bolt with link
is used.
Ensure the collar is hard

down on the material and
the eye in the right
direction for the lift.
95
WEIGHT OF SPREADER BEAM AND
LIFTING BEAMS
Weight of spreader beams can be calculated from weight tables of

the steel section, from which they are made, or obtained from the
manufacturer‘s specification.
96
LIFTING APPLIANCES
97
LIFTING APPLIANCES
• CRANES (Tower, Mobile, Crawler.)

• Identification
• Hand signals
• Safety Procedures
• Inspection
98
Rough Terrain
(RT) All Terrain (AT)
Crawler
Truck Crane (TC)
99
Crane Selection
Weights, Dimensions and Lift Radii expected
Type of Lifting to be done
The Crane Position, where the Load is

to be lifted from, Access, Erection and
Dismantling restraints
Site Conditions
100
Site Review and Crane Setup
Character of the Ground and Soil
Conditions.
Access and Stability
Working Area
Presence and Location of any

Underground Hazards
101
RESPONSIBILITIES
• Be familiar with the lifting capabilities of the crane.

• Check the lifting equipment being used is in good condition,
certified for use, correctly color coded, and is of sufficient
capacity to carry out the lift.
• Ensure taglines are attached to loads which are likely to swing.
• Be aware of any obstruction within the crane radius and working
area.
• Check that the area around the load to be lifted is clear and that
the load is attached to the floor, transportation cradle or adjacent
equipment.
• Ensure that the escape route is identified.
102
THE PROCEDURE FOR SETTING UP
AND WORKING WITH A CRANE
Set up the crane as close as possible to the load , set the outriggers
and block out securely ensuring that the crane is as level as
possible. You can use a level or the main block to level the crane.
Barricade the area making sure that no other personnel other than
the rigging crew are within the barricade.
Prepare the load for lifting making sure all equipment used is of
sufficient size and Safe Working Load including crane radius and
boom length
Rig the load once everything has been checked float the load
making sure it is balanced this assists the crane to check his
brakes and stability
When all the checks have been completed continue with the lift
following all safety procedures only one person giving the signals,
using tag lines to control the load if required.
Once the load has been placed into its final position remove all the
equipment and barricades.
103
WHEN WORKING WITH CRANES YOU MUST
BARRICADE THE WORKING AREA
BARRIER .
TAPE
Z
A
W
E
CONES
D
.
Z
A
.
W
E
D
. .
WARNING Z
A
W
SIGNS
E
D
104
Crane Mats
105
Isolate Working Area
106
CRANE HOOKS
Most cranes are fitted with ‗C‘ type hooks to prevent snagging on protrusions such
as handrails, etc., and in certain cases also have safety catch to prevent the eye of
the lifting sling being accidentally displaced in the figure. Large cranes however tend
to be fitted with ramshorn type hooks which could have an effect on the sling
design.
Soft
Eye Hard
Soft Eye
Eye
‗C‘ Hook Ramshorn Hooks
107
IDENTIFICATION OF TYPES OF CRANE & THEIR
PARTS
108
Poor Ground Conditions are a Factor in
Many Accidents
Never attempt to make a lift

from soft or unstable ground
109
Poor Ground Conditions are a Factor in
Many Accidents
Over 50% of all crane accidents are REMEMBER: Failure to follow

the result of mistakes made and just one safety precaution can
rushed sloppy work done when the cause that accident, to men or
crane was being put together, readied machine.
and placed to make its lifts.
110
Failure to Level the Crane is a
Common Accident Cause
What can happen
when you swing
over the side!
Just a little side tilt when

lifting a load over the rear
can become dangerous Load radius increases when
when swung over the side. swung over the side.
111
LEVELING THE CRANE
The line
Should lie dead in the centre of the boom in all
positions, end, side and corner.
WRONG RIGHT
Leveling With the Load Line 112

Check That Cranes are Level
113
Possible Capacity Loss Due to being out of Level
Boom Length and Radius Capacity Lost

When out of Level
1° 2° 3°
Short Boom, Minimum Radius 20 % 20 % 30 %
Short Boom, Maximum Radius 8% 15 % 20 %
Long Boom, Minimum Radius 30 % 41 % 50 %
Long Boom, Maximum radius 5% 10 % 15 %
Accurate Calculations are available from the specific, applicable Crane Manufacturers
114
Failure to Level the Crane is a
Common Accident Cause
Remember — capacity chart ratings are
The machine must be level based on ideal conditions:
• Standing on firm, level surface

• CALM wind
• No side loads or outswing of load
• Good visibility
• Machine in A-1 condition and equipped
as when leaving the factory.
When such conditions cannot be attained,

loads being handled must be reduced to
compensate.
DON‘T FORGET:
If a tipping condition is suddenly sensed —

start lowering the load and retract or
elevate the boom to bring the load in. Never
lower the boom and aggravate the
condition.
115
Many Crane Accidents are Caused by
Poor Blocking Under Floats
116
Many Crane Accidents are Caused by
Poor Blocking Under Floats
USE SOLID BLOCKING

UNDER ALL FLOATS
THE CRANE’S BEARING PRESSURE MUST BE DISTRIBUTED TO THE GROUND BY USING

LARGE TIMBER BLOCKING
WARNING:
Only cranes with approved free on wheels ratings can be used without outriggers set.
117
Set Outriggers Correctly
118
OUTRIGGERS:
Capacities are based on all outriggers fully extended. Working

with outriggers partially retracted will reduce capacities and
machine stability considerably and may cause an accident. If it is
absolutely necessary to operate a machine with outrigger beams
partially retracted, reduce capacities to those shown on the chart
for ―on rubber‖. Remember — the machine must be level.
DON‘T OPERATE WITH ONLY REAR OUTRIGGERS EXTENDED. If

you swing over the side, the machine may tip over, or the boom
may be damaged from side loadings because the machine is not
level.
119
When working a machine with mechanical (non-hydraulic)

outriggers, make sure the beams are pinned in place, otherwise
they can ―creep in‖ while operating, causing an unstable
condition and possibly tipping the machine over.
WARNING
Before travelling make sure mechanical outriggers are securely

pinned in position otherwise they can come out on the road and
cause serious damage.
120
HYDRAULIC OUTRIGGERS:
When setting hydraulic outriggers make sure that
the outriggers are set evenly otherwise severe
twisting of the crane‘s chassis frame will result.
121
Exceeding the Rated Capacity of any
Crane is Dangerous
Overloads can damage the machine and such damage causes
failure and accidents.
It looks like about

10 tonnes.
Whoops!
122
Spreads out the load so the supporting surface can support it
Transmits the load without bending or breaking

123
WRONG
124
Setting Up and Parking
Do not set up too close

to trenches etc., as the
machine vibration can
cause the walls to
collapse.
125
WRONG
126
WRONG
127
Know Conditions and Use
Precautions
128
Ensure Handbook
and Chart are with
Crane
129
130
Required Clearance for Operations near
High Voltage Power Lines
To 50 KV 10 ft. 3.05 M
over 50 to 200 KV 15 ft. 4.60 M
Over 200 to 350 KV 115 ft. 4.60 M
Over 350 to 500 KV 25 ft. 7.62 M
Over 500 to 700 KV 35 ft. 10.67 M
Over 700 to 1000 KV 45 ft. 13.72 M
All overhead Lines and other apparatus should be treated

as live unless officially declared “DEAD” and “SAFE”.
If in doubt, seek advise
131
During Thunderstorms and Lightening STOP
Work and retract/lower Boom
132
Mechanical
Advantage
Correct
Wrong
133
MECHANICAL ADVANTAGE
134
Wedge Socket
135
Two Block Cutout
136
Know The Radius Of The Load
Watch for boom drawdown as the
crane takes the load. This increases
the radius and can result in the load
drifting away from the crane.
THE RADIUS WILL INCREASE WHEN

A LOAD IS LIFTED.
MEASURE THE LOAD RADIUS BEFORE

MAKING CAPACITY LIFTS.
137
Always Ensure
that the Hook
has got a
Safety Catch
138
Never let the
Boom touch a
Structure
139
It
Might
Cause
the Boom
to
Collapse
Or Damage
140
Use Taglines
141
Always Stand Clear
of Suspended Loads
Never Let Anyone Ride on a

Suspended Load
142
IDENTIFICATION OF CRANE HAND SIGNAL
143
The Users Responsibilities
Crane
Operator
Rigger
144
Protecting Rigging From
Damage or Environment
Rigging components are expensive to buy and to replace!
Use them properly and store them properly!
Keep wire rope slings lubricated and all rigging stored out of
the weather.
Treat the rigging as though your life depended on it!
Because it does if it fails!
Don‘t use makeshift rigging or attempt to repair any rigging
components.
Knots tied in rigging reduces the strength by 50% or more!
145
Lifting Operations Procedure
(Cont.)
Lifting operation planning:
 Planning shall basically contain and consider the following
steps:
 Weight of the load
 Method of lifting
 Working radius
 Communication system
 Ground stability
 Existing services (AG / UG)
 Height restriction
 Competent resources
 Over head power line
 Selection of equipment
146
(Cont.)
• Ground stability
– When planning a lift, consideration must be
given to the ground conditions.
• Outriggers
– Sound timber packing or metal plates shall
be positioned under each outrigger pad /
Crawler to distribute the load.
These should be a
minimum of 3 times
the area dimension
of the outrigger pad.
147
(Cont.)
– Outriggers must be fully extended on both
sides when performing a lifting operation.
– Outrigger pads are not to be permanently
attached to outriggers
• A sign warning of the danger of
overhead power lines shall be mounted
in each crane.
148
(Cont.)
Lifting Equipment
– The lifting equipment operator shall not begin
the machine movement, until the banks-man is
within his range of vision, or in radio contact,
and the signal is given and understood.
– Where several individuals are involved, the
crane operator shall obey the signal of the
banks men ONLY.
The only exception shall
be in the case of an emergency,
when the crane operator can
receive the Emergency Stop
Signal from anyone
149
(Cont.)
Restrictions to crane operations
– The most common restriction to lifting
operations is bad weather, specifically high
wind.
– However, No lifts will be permitted at wind
speeds exceeding 30 Knots or 35 Miles per
hour.
– When working in close proximity to overhead
electric lines or cables, the crane shall not be
positioned closer to the plumb of the nearest
line or cable than a distance equal to the length
of the crane Jib fitted, plus 6 meters measured
along the ground.
150
(Cont.)
Communication
– An effective communication
system shall be in place for all
lifting operations.
– The type of system will depend
on the nature of the task i.e.,
radio communication may be
necessary when visibility
between the crane operator and
the Banks-man is restricted.
151
(Cont.)
Color Code System
– The Color Code System shall be developed and

implemented for all Lifting Gear used within the Project
such as for slings, shackles, rope wire, belts.
– The color shall indicate to the user and the inspector, that
an examination has been performed within the prescribed
period.
– A new color shall be introduced on regular basis as per the
Project Color Coding System and each color shall be
current for a specified period
– Information boards showing the current
color coding shall be posted at prominent
locations at each work site where it is
anticipated lifting operations will take
place.
152
(Cont.)
Lifting Operations Check List

– A Risk assessment shall be conducted prior to
any lift being performed.
– The lifting operations check list acts as a
reminder and guidelines to the personnel
concerned, and basically consists of the items
shown below and listed in the Lifting Operations
Procedure.
153
CRANE OPERATION ANALYSIS
"our plan for a safe job"
Crane: Date: Time:

Crane has been inspected/ safe condition:.YesNo
Job Location:
Job Description:
The weight of the load is:

The swing radius of the lift is:
Net crane capacity at this radius is:
Is operator qualified to operate this crane? Yes No
Is operator’s certification card current? Yes No
Critical lift permit required for this lift? Yes No
Crane level/outriggers fully extended? Yes No
Is the rigger qualified for this task? Yes No
Is sling/hardware in safe condition? Yes No
Sling sizing/hookup reviewed? Yes No
Do sharp edges have softeners? Yes No
Tag lines needed to help control load? Yes No
Center of gravity of load located? Yes No
EMERGENCY INFORMATION
What is the wind direction?
Reviewed emergency alarms/phone numbers Yes
Escape route(s):
Location of eyebath/shower station:
Our evacuation assembly point is:

Operator Signature:
Rigger Signature:
Signalman Signature:
Supervisor Signature:
154
RIGGING PLAN
155
RIGGING COMPONENTS
List each component
Slings
Type Hitch Cap. Sling Angle Actual Cap.
Sling 1
Sling 2
Sling 3
Sling 4
Shackles
Size Capacity
Shackle 1
Shackle 2
Shackle 3
Shackle 4
Other Devices:
Description Capacity
How has the lifting area been restricted?

_______________________________________________________________
_______________________________________________________________
_______________________________________________________________
156

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BASIC RIGGING

This course on Lifting Equipment, Rigging, and

Everyday, Routine Crane Operations –

• List the four major causes of crane accidents.

• Describe the pre-planning that is required

• State the main precautions that apply to

– Ensuring the adequate supervision of personnel,

– Identifying any defects in lifting gear

– Preventing all unauthorized

• One layer of outer

Outer wire Centre wire

Inner wire Core wires

Actual (measured) diameter Nominal diameter (d)

Examine all wire ropes for damage before use.

Slings should always On two leg sling work always be

Endless Belt Sling

• Synthetic slings must be inspected before each use.

• They must also be inspected by a competent person at least once

• Send slings for a proof load test at least every 12 months.

• Any external wear such as abrasion or cuts and contusions.

• It is considered that it has lost more than 10% of its original

After 6 months exposure to sunlight send a sling in for

(b) Some damage to load-bearing fibres (c) Badly damage sleeve

(e) Cut load-bearing fibres

• Sling should be laid out in good light and

1. Damage caused by sharp edges (cuts)

• Red color is reserved especially for items

Many more different type shackles are available in the market-

Three suppliers of shackles are well known in the construction

Screw Pin Chain Shackle Bolt Type Chain Shackle

Wide Body Shackle

Sharp bends in a wire rope

Not to be hammered down.

STABLE Hook is directly above

Ensure that the SWL of the

Attach the head fitting to a Operating Lever

Hook with Safety catch

1. Turn the lever to the neutral

Releasing the wire rope

The jaws in the machine automatically lock the

This bolt has a small eye;

This bolt is used for

This is designed for

should NOT be used to transport plates horizontally).

Selection Horizontal Clamps Universal (Vertical) Clamps

•The SWL is adequate for the load.

Jaw & Eye combination

Jaw & Jaw combination

Hook Hook & Hook combination

Lock wire will hold

Preferred Acceptable Caution Required

Check for cracks & bends

Note: Collar eye bolts are

Always tighten eye bolts to

Ensure the collar is hard

Weight of spreader beams can be calculated from weight tables of

• CRANES (Tower, Mobile, Crawler.)

Truck Crane (TC)

Type of Lifting to be done

The Crane Position, where the Load is

Access and Stability

Presence and Location of any

• Be familiar with the lifting capabilities of the crane.