UNIT NO. 2.

18

LIFTING BEAMS

Under the general heading of lifting beams we can include spreader beams and lifting
frames as well as simple lifting beams. These may be manufactured to lift specific items or
as general purpose beams for a specified range of lifts. We will limit our studies to beams
that are intended to hang from a crane hook as an attachment.

TYPES OF LIFTING BEAM ARRANGEMENTS

Figure 1 shows diagrammatically seven of the most common types of lifting beam.

Figure 1
Diagrammatic Representation of Common Lifting Beam Arrangements

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Simple Lifting Beams and Spreaders
At this stage we must consider the differences between spreaders and lifting beams as the
loads and stresses act differently in the structural members.

Lifting beams and spreaders are fabricated from a range of steel sections, the choice
usually being dependent on the requirements of the specific lift. Let us consider the
simplest form of lifting beam, a flat bar of steel drilled at each end, to take shackles from
which are suspended lifting slings, and at the centre is another shackle by which the beam
can be suspended from the lifting appliance. The load would be equally shared by the end
shackles, each taking half of the imposed load, and the full load, transmitted through the
beam, would be taken by the suspension shackle. The maximum tensile stress would occur
on the top of the bar at the centre. The same condition would occur in a beam of fabricated
section, eg back to back rolled steel channel, if the loading arrangement is the same.

In order to balance a load, where the centre of gravity is not central but to one side of the
load, it would be necessary for the suspension shackle to be positioned to one side of the
beam over the C of G of the load. In this case the top suspension shackle still carries the
full load, but the load is divided between the end suspension shackles in proportion to their
distance from the suspension point, the shackle nearest the suspension point taking the
greater portion.

Figure 2 shows examples of a simple beam, a) with the suspension point centrally and b)
with the suspension point offset to balance a load.

Figure 2
Simple Lifting Beams with Alternate Lifting Points

Now let us consider a simple spreader made from flat bar with a top two leg sling. If the
top sling is connected to the same holes as the bottom lifting slings, the bar will be in pure
compression due to the inward force created by the angle of the top sling legs. In this case
the load is transmitted through the sling legs and not through the bar. See Figure 3.

Figure 3
Simple Spreader

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In practice, in today's world, such a design is impracticable for normal production as the
connecting shackles would have to be specially produced. In order to achieve the same
effect we can introduce a transmission plate at each end of the arrangement onto which the
upper and lower slings are connected. Provided that the line of the two leg top sling is
extended through the plate so that it crosses the extended line of the bottom sling legs on
the horizontal centre line of the spreader, the beam will be in compression, see Figure 4.

Figure 4
Simple Spreader with Transmission Plates

When headroom is restricted, it is not always possible for the top suspension sling to
stretch the whole length of the beam. In these cases a combination of spreader and lifting
beam is necessary. Figure 5 shows such a beam. In this case there will be bending in the
overhanging ends (like a cantilever) and bending and compression in the part of the beam
between the connecting position of the top sling. The maximum tensile stress will occur on
the top of the beam between the top sling connection points.

Figure 5
Combination Beam

The current Harmonised Standard for lifting beams is EN 13155: 2003, Cranes – Safety –
Non-fixed load lifting attachments. Clause 5.2.6 gives the specific requirements that lifting
beams must meet.

SAFETY REQUIREMENTS OF EN 13155

Mechanical Strength
Lifting beams must be designed to withstand a static load of 2 times the WLL without any
deformation taking place and with a static load of 3 times the WLL without release of the
load even if permanent deformation takes occurs.

Slings intended for use with the lifting beam must comply with the relevant Harmonised
Standard, eg EN 818-4, grade 8 chain slings.

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Stability During Storage
When not required for use, it must be possible to stand the lifting beam down so that it is
stable during storage. This can be achieved by the design shape of the lifting beam or by
the use of a stand or similar.

Crane Attachment Fittings

If it is necessary to move or remove any component of the lifting beam in order to attach it
to the crane, the component must be such that it can be locked prior to lifting so as to
ensure that it will not become accidentally displaced, eg bolt and nut shackle pins.

Adjustable Lifting points

If the lifting beam is constructed with movable lifting points to allow for adjustment, the
lifting points must be captive on the beam to prevent them falling off and they must be
provided with a locking device to keep them in position during the lift.

Tilt
If a lifting beam is designed to tilt the maximum angle of tilt to the horizontal must be
clearly indicated.

If the beam is not intended to tilt it must be designed to tolerate a tilt of 6º to the
horizontal.

MARKING
EN 13155 requires lifting beams to be permanently and legibly marked with the following
minimum information:
a) Name and address of the manufacturer
b) Model identification
c) Serial number (identification mark)
d) Year of manufacture
e) WLL
f) The self weight of the beam if it exceeds 5% of the WLL or 50kg.

MANUFACTURER'S TESTS
Type Verification
EN 13155 requires the manufacturer of lifting beams to carry out various type tests to
prove the design on one or more samples. These include:
a) Verification of the mechanical strength. The manufacturer has a choice; 1) this
may be been by calculation alone or 2) it may be done by a static test as follows:
A static overload test at 3 times the WLL (±2%) which replicates the
conditions of use, held for a period of 1 minute. The load must be held even
if there is permanent deformation.
b) Verification of the locking and holding devices during tilting. Again the
manufacturer has a choice; 1) this may be done by calculation or 2) by a live load
or static test in a test rig as follows:
The moving part must be subject to a force equal to twice the force it will
sustain at the WLL for a period of 1 minute at an angle of 6º. There must
be no slippage, deformation or visible defects.

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Manufacturing Tests and Examination
On completion of manufacture each lifting beam must be verified as follows:
a) The manufacturer has a choice, he may either confirm the mechanical strength by
calculation or by a static load test equivalent to 2 times the WLL.
b) Thorough examination.

NOTE: Since the publication of guidance notes to the 1988 UK Docks Regulations it has
been the UK practice to adopt the ILO tables of proof loads given in that
guidance as the basis for the design and testing of new lifting beams. This allows
for a proof load test of 2 times the WLL up to 10t WLL and then WLL x 1.04 +
9.6t, which gives a sliding scale from twice the WLL down to WLL + 10% at
160 t WLL and above.

USE OF LIFTING BEAMS

Before we consider the matters to be taken into account during an examination we will
take a look at the use of lifting beams and the defects and damage that can occur due to
misuse. Full details of the safe use of lifting beams, spreaders and lifting frames is given in
Section 20 of the LEEA Code of Practice for the Safe Use of Lifting Equipment, which
you should also study.

Most lifting beams and spreaders are designed for a specific purpose and should not be
used for other lifts without reference to the manufacturer, or someone able to make the
necessary checks and calculations, as the beam may be overloaded or subject to adverse
stress. This can result in the beam becoming bent, twisted and distorted.

Care must be taken to ensure the beam suspension is compatible with the crane hook as it
can be damaged and distorted by placement on an incorrect hook.

Particular care is necessary in the case of beams with multiple or adjustable lifting/load
attachment points to ensure that each is correctly positioned and loaded so that they carry
the intended share of the load, otherwise they may be overloaded leading to distortion,
elongation of eyes and cracked welds. Similar care is needed when lowering loads to
ensure that load attachment points are not overloaded or subject to sideways stresses.

When placed in storage, care must be taken to avoid any mechanical damage occurring.

EXAMINATION
Lifting beams, spreaders and lifting frames fall under the heading of 'lifting accessories' in
modern legislation and therefore should be examined by a competent person at periods not
exceeding six months.

The requirements for load tests to be made as part of the examination will vary dependent
on the circumstances. If a structural repair has been made a load test may be deemed
necessary, but great care will be needed to ensure that any load is applied correctly so as
not to damage the beam. We should also bear in mind that in most circumstances a load
test will serve no purpose as the strength of the lifting beam is already known. Further,
repetitive overloading of lifting beams will shorten their working life. We will therefore
consider load testing lifting beams once we have considered the general requirements for
the examination.

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The general appearance of the beam, should be considered during the examination, in
particular paying attention to the following:
a) Bending and distortion, mechanical/physical damage and corrosion of the
structural members. In particular attention must be paid to hollow sections which
may have dents or localised buckling and to the flanges of structural rolled steel
sections. Hollow sections need great care when looking for signs of corrosion as
this may be internal.
b) Fixings and welds. Welds and adjacent areas should be examined for cracks, bolts
and rivets examined for wear, distortion, corrosion, damage and tightness.
c) Lifting eyes, load attachment points etc looking for wear, distortion, elongation of
eyes and other physical damage.
d) Other lifting accessories that form a part of the lifting beam, or which are used in
association with the beam, must be included as a part of the examination.

Load Testing Lifting Beams, Frames and Spreaders

The need to load test lifting beams should be carefully considered. As we have already
noted there is more than one way in which the design loading of the beam may have been
arrived at. Similarly the basis for the design will vary with the application. For instance,
the beam may have been designed on the basis of the load being flexible, alternatively it
may have been designed on the basis of the load being rigid. This will affect the manner in
which the load is applied. If the load is applied in an incorrect way the stresses set up can
exceed those for which the design allows. It is then possible that the beam will be bent
beyond further use even if the load was that for which the beam was designed.

Where load testing is deemed necessary, before any load is applied the designers
instructions for load testing, both the manner of application and the actual test load to be
applied, must be obtained and then strictly followed. Under no circumstances should the
tester and examiner apply a load without taking these steps. NB: This applies equally to
new beams and to repaired beams which have been in service.

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