Lifting, Rigging and

Crane operation

Course Contents
ƒ Definitions.
ƒ History.
ƒ Crane Types.
ƒ Mobile Crane accidents ( Causes and
results).
ƒ Slinging.
ƒ Rigging Hardware.
ƒ Crane Safety.
ƒ Signal man
ƒ Lifting Plan
ƒ Sling applications

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 Tickets Please

Introduction &
Definitions
Rigging is one of the most important safety
and risk exposure considerations on any
activity.
Lifting —The process of lifting, or
positioning equipment, components, or
materials with a Lifting Device.
Rigging —The process of safely attaching a
load to a lifting device.
Crane: A machine for lifting and lowering a
load and moving it horizontally, with the
hoisting mechanism an integral part of the
machine

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 Definition of Rigging
Rigging is part of the lifting operation which
forms the link between the crane and the
load.

The Users Responsibilities

Crane
Operator

Rigger

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Working Load limit (WLL) —is the maximum load that
an item of lifting equipment is designed to raise.
-choke hitch SWL=WLL x 0.8
-WLL of the hooks and shackles shall not be less than that
of the leg

Safe Working Load (SWL)— In most cases, the Safe

Working Load will be the same as the WLL. The exceptions
are as following:
-Slings which are found to be unfit for use should be
destroyed by cutting them up
- SWL (in tons)= D2 x 8
- Rope in poor condition, you should reduce the
SWL as much as 50 percent

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 Types of cranes

ƒ Mobile Cranes
ƒ Fixed Cranes

1. Mobile Cranes
‹ Truck-mounted crane

A crane mounted on a truck carrier provides the

mobility for this type of crane.

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‹ Generally, these cranes are able to travel on highways,
eliminating the need for special equipment to transport
the crane. When working on the jobsite, outriggers are
extended horizontally from the chassis then vertically to
level and stabilize the crane while stationary and
hoisting.

‹ Many truck cranes have slow-travelling capability (a

few miles per hour) while suspending a load. Great care
must be taken not to swing the load sideways from the
direction of travel, as most anti-tipping stability then lies
in the stiffness of the chassis suspension.

‹ Most cranes of this type also have moving

counterweights for stabilization beyond that provided
by the outriggers.

‹ Factory-calculated charts (or electronic safeguards)

are used by crane operators to determine the maximum
safe loads for stationary (outriggered) work as well as
(on-rubber) loads and travelling speeds.

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 Side lift crane

A sidelifter crane is a road-going truck or semi-trailer,

able to hoist and transport containers. Container lift is
done with parallel crane-like hoists, which can lift a
container from the ground or from a railway vehicle.

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 ‹ Rough terrain cranes

‹ A crane mounted on an undercarriage with four

rubber tires that is designed for pick-and-carry
operations and for off-road and "rough terrain"
applications. Outriggers are used to level and stabilize
the crane for hoisting. High maneuverability.

‹ These telescopic cranes are single-engine machines,

with the same engine powering the undercarriage and
the crane, similar to a crawler crane. In a rough
terrain crane.

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‹ All Terrain Crane

‹ A mobile crane with the necessary

equipment to travel at speed on public
roads, and on rough terrain at the job site
using all-wheel. AT‘s combine the road
ability of Truck-mounted Cranes and the
maneuverability of Rough Terrain Cranes.

‹ AT’s have 2-9 axles and are designed for

lifting loads up to 1,200 tones.

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 ‹ Crawler crane

ƒ A crawler is a crane mounted on an undercarriage with

a set of tracks (also called crawlers) that provide
stability and mobility.
ƒ Crawler cranes have both advantages and disadvantages
depending on their use.
- Their main advantage is that they can move around on
site and perform each lift with little set-up, since the
crane is stable on its tracks with no outriggers.
- In addition, a crawler crane is capable of traveling with
a load.
- The main disadvantage is that they are very heavy, and
cannot easily be moved from one job site to another
without significant expense. Typically a large crawler
must be disassembled and moved by trucks.

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‹ Floating crane

‹ Floating cranes are used mainly in bridge

building and port construction, but they
are also used for occasional loading and
unloading of especially heavy or critical
loads on and off ships.
‹ Some floating cranes are mounted on a
pontoon ‫ﻋﻮاﻣﻪ‬, others are specialized crane
barges and have been used to transport
entire bridge sections.
‹ Floating cranes have also been used to
salvage sunken ships ‫اﻧﻘﺎذ اﻟﺴﻔﻦ اﻟﻐﺎرﻗﻪ‬.

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‹ Aerial crane

Aerial crane or 'Sky cranes' usually are

helicopters designed to lift large loads.
Helicopters are able to travel to and lift in
areas that are difficult to reach by
conventional cranes. They can lift anything
within their lifting capacity, (cars, boats,
swimming pools, etc.).

They also perform disaster relief after natural

disasters for clean-up, and during wild-fires
they are able to carry huge buckets of water
to extinguish fires.

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 2. Fixed Cranes

‹ Exchanging mobility for the ability to carry

greater loads and reach greater heights
due to increased stability, these types of
cranes are characterized that they, or at
least their main structure does not move
during the period of use. However, many
can still be assembled and disassembled.

‹ Fixed cranes have the following types:

‹ Tower crane

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‹ Tower cranes are a modern form of balance crane that
consist of the same basic parts. Fixed to the ground on
a concrete slab (and sometimes attached to the sides of
structures as well), tower cranes often give the best
combination of height and lifting capacity and are used
in the construction of tall buildings. The base is then
attached to the mast which gives the crane its height.

‹ Further the mast is attached to the horrizontal unit

(gear and motor) that allows the crane to rotate. On top
of this unit there are three main parts which are:
the long horizontal jib (working arm),
shorter counter-jib,
and the operators cab.

‹ Self-erecting crane

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‹ Generally a type of tower crane, these
cranes, also called self-assembling or
"Kangaroo" cranes, lift themselves off the
ground using jacks, allowing the next
section of the tower to be inserted at
ground level or lifted into place by the
partially erected crane itself. They can
thus be assembled without outside help,
or can grow together with the building or
structure they are erecting.

Gantry crane

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‹ A gantry crane has a hoist in a fixed
machinery house or on a trolley that runs
horizontally along rails, usually fitted on a
single beam (mono-girder) or two beams
(twin-girder). The crane frame is supported
on a gantry system with equalized beams
and wheels that run on the gantry rail,
usually perpendicular to the trolley travel
direction. These cranes come in all sizes, and
some can move very heavy loads,
particularly the extremely large examples
used in shipyards or industrial installations.

‹ Overhead crane

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‹ Also known as a 'suspended crane', an
overhead crane works very similar to a
gantry crane but instead of the whole
crane moving, only the hoist / trolley
assembly moves in one direction along
one or two fixed beams, often mounted
along the side walls or on elevated
columns in the assembly area of factory.
Some of these cranes can lift very heavy
loads.

‹ Deck crane

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‹ Located on the ships and boats, these are
used for cargo operations or boat
unloading and retrieval where no shore
unloading facilities are available. Most are
diesel-hydraulic or electric-hydraulic.

‹ Bulk-handling crane

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‹ Bulk-handling cranes are designed from
the outset to carry a shell grab or bucket,
rather than using a hook and a sling. They
are used for bulk cargoes, such as coal,
minerals, scrap metal etc.

Stacker crane

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‹ A crane with a forklift type mechanism used
in automated (computer controlled)
warehouses (known as an automated
storage and retrieval system (AS/RS)).

‹ Stacker cranes are often used in the large

freezer warehouses of frozen food
manufacturers. This automation avoids
requiring forklift drivers to work in below
freezing temperatures every day.

FACTS
CRANE ACCIDENTS…
… are relatively more serious than other
equipment accidents.
… are the most costly in terms
of insurance claims.
… result in more fatalities
than any other single cause.

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 FATALITIES

One out of every five deaths is

crane related!

20%

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CAUSES OF MOBILE CRANE FATALITIES

Rigging
15%
Load Handling
14% Electrocution
44%
Operator Error 7%
Overload 7%
Dismantling Boom 5%
Wire Rope Failure 3%
Struck by Crane 3%
Miscellaneous 3%
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 MAIN CAUSES OF MOBILE CRANE
ACCIDENTS
High Wind
1.6%
Machinery & Support Failure
Structural Failure 31.5%
11.2%
Failure to Use Operator Error
Outriggers 33.1%
22.6%

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Rigging

SLINGS SAFETY

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 Types of
Slings

1. Chain Slings

2. Wire Rope Slings

3. Synthetic Web Slings

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VERTICAL CHOKER BASKET

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 Factor of Safety
‹ A factor of safety is applied to a rigging
system after all known loads and
strengths have been considered.

‹ It is intended to allow for unknown

variability of material, deterioration of
equipment over time, acceleration and
other unforeseeable loads, and the like.

‹ The usual factor of safety is 5 (1 : 5)

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SAFE WORKING LOAD

CATALOGUE BREAKING STRENGTH OF ROPE

MAX. S.W.L. =
FACTOR OF SAFETY

CATALOGUE BREAKING STRENGTH OF ROPE

=
5

EXAMPLE: If the wire rope catalogue gives the breaking strength of the rope
as 10 tons, the maximum safe working load is’……………..

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 SAFE WORKING LOAD
Rule of Thumb of Computing Rope S.W.L.

S.W.L. = Rope Diameter x Rope Diameter x 8

EXAMPLE:
(a) 1/2 inch diameter rope
SWL = 1/2 x 1/2 x 8 = 2 tons
(b) 5/8 inch diameter rope
SWL = 5/8 x 5/8 x 8 = 3.125 tons
(c) I inch diameter rope
SWL = 1 x 1 x 8 = 8 tons

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Wire Rope Slings

Wire
Core
Center

Strand

Wire rope

Strand : ‫ﺟﺪﻳﻠﺔ‬
Lay : ‫ﻟﻔﺔ‬
Core :‫ ﻋﺼﺐ اﻟﻮاﻳﺮ‬fiber core or steel core
Increase the strength 7% and weight by 10%
Wire rob : ‫ﺳﻠﻚ اﻟﺮﻓﻊ‬

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Elements of Wire Rope

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Measurement of Rope Diameter

Correct Way

Incorrect Way

EDRIG009.PPT

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One complete wrap of a strand around the core

Rope
RopeLay
Lay

HOW TO WIND WIRE ROPE

ON TO a DRUM

Left Lang Lay LLL Left Regular Lay LRL

Right Lang Lay RLL Right Regular Lay RRL

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 6 x 25 Wire Rope
Each strand
contains 25 6 Strands
wires

There are some another types like :

6 * 19
6 * 37

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Wire Rope Clips

When using U-bolt wire
rope clips to form eyes,
ensure the "U" section is
in contact with the dead
end of the rope

Dead
End

This is the correct

method

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57

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 Spacing dimensions for clips.

- ANSI (American National Standards Institute ) 17.1 safety code for elevators and
escalators, -
- ANSI / ASME (American Society of Mechanical Engineers) B30.5 Mobile and
Locomotive Cranes 59

Protecting Slings From

Damage

1. Do Not Knot or Twist a Sling.

2. Avoid Dragging a Sling on the Deck Across Any Abrasive
Surface.
3. Use Buffers to Protect the Sling From Sharp Edges on the Load.
4. Use Buffers to Protect Rope From Kinking.
5. Do Not Try to Pull a Sling Out From Under a Load When the Load
Is resting on It.
6. Do Not Lift a Load Heavier Than the Rated Capacity of the Sling.
7. Keep the Sling Angle As High As Possible. Avoid Sling Angles
Below 45 Degrees.
8. Hands and Fingers Shall Not Be Placed Between the Sling and
Its Load While the Sling Is Being Tightened Around the Load.
٦٠

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 Lubrication

Regularly lubricate ropes and chains

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Remove From Service When

‹ 6 broken wires in 1 lay
‹ 3 in one strand

‹ Outer wire diameter worn 1/3

original diameter
‹ Bird caged , crushed, kinked

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 Wire Rope Slings
Remove From Service
If these happen, remove the wire rope sling from service

Bird Caging Kinking

Crushing

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Remove From Service

Immediately remove damaged or

defective slings from service

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 Type of Wire Wire Rope Sling
Damage

Birdcage damage
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Damaged wire rope

Crushed Rope

Broken
Strands

Damaged wire rope must be taken out of service

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 L
H

LOAD

(Load ÷ Number of legs) X (L ÷ H) = Load each sling leg

Example
Load = 120,000 pounds
4 load legs ÷ 120,000
equals 30,000 pounds
each leg if vertical hitch
Sling legs are 20 feet
Height from top of load to
lifting device is 15 feet
120,000 lb.
20 ÷ 15 = 1.33
Load on each leg is 1.33 x
30,000 = 40,000 pounds

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 Alloy Steel
Chains

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Advantages :
9 Adapts to shape of the load
9 Best choice for hoisting very hot materials.
9 Must have an affixed tag stating size, grade,
rated capacity, and sling manufacturer

Disadvantages :
9 Can damage by sudden shocks
9 When one link in a chain fails, the load will
come down.

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Chain Slings

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 Identification Tag

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Markings
Alloy Steel Chain

It must be marked with grade or manufacturer's mark

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 Chains Inspection
Chains

Should be inspected upon purchase, before

each use, and annually or as dictated by use.

Should be inspected by competent person

Should be inspected on a regular basis with

frequency depend on severity of service
conditions

Inspections are not to be performed at

intervals greater than once every 12 months

INSPECTOR Wear
Bent

should look for

ƒ
ƒ
ƒ
Wear
Nicks ‫اﻟﺸﻘﻮق‬
Cracks ‫اﻟﺸﺮوخ‬ Pitch
{
ƒ Breaks ‫اﻟﻜﺴﻮر‬
ƒ Gouges ‫اﻟﺘﻘﻌﺮ‬
ƒ Stretch ‫اﻻﻣﺘﺪاد‬
ƒ Bents ‫اﻻﻧﺤﻨﺎءات‬

Latch
Hook

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 77

Synthetic Web Sling

Markings

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 Synthetic Web Sling
Markings

‹ Mark or code to
show:
• Name or trademark
of manufacturer
• Rated capacities for
the type of hitch
• Type of material

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Sling Identification

80

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 81

82 c

94 c
82

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 Synthetic Web Sling
Stitching

Stitching

‹ Stitching is the only method allowed to

attach end fittings to webbing, or to form eyes

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84

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 85

Sling Configurations

86

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87

88

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Sling Angles

89

90

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 500 LBS
500 LBS

1000 LBS 1000 LBS

90° 60° 45° 30°

1000 LBS 1000 LBS 1000 LBS 1000 LBS

Note: A good operating practice is to keep sling

angles from going below 60 degrees 91

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 CENTRE OF GRAVITY

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SLINGING APPLICATIONS

CENTER OF GRAVITY

• if there is no dedicated lifting point then you will have to consider

where the center of gravity of the load is before you positions the
slings.
• remember this may not be in the middle of the load.

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