Crane Rigger Level III PDF

M_004 Basic Rigging Safety Lecture Milton J. Shoup III Mechanical Safety Officer University of Rochester Laboratory for Laser Energetics Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 1 of 101  Summary Safety is every...

M_004 Basic Rigging Safety Lecture Milton J. Shoup III Mechanical Safety Officer University of Rochester Laboratory for Laser Energetics Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 1 of 101  Summary Safety is everyone’s business and compliance with safety procedures is MANDATORY If an activity or practice seems unsafe, “Stop Work” and take the time to address concerns Only designated or qualified personnel may attach loads to an overhead hoist No LLE personnel are qualified or permitted to repair rigging equipment Only approved/rated rigging gear shall be attached to a load hook Load ratings shall never be exceeded It is the riggers responsibility to ensure all components used in a rigging operation meet the required load ratings — If a rigger is unable to determine a proper rigging configuration contact ME or an Advanced Rigger for support Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 2 of 101  There are two specific roles in moving materials overhead, hoist operators and riggers The definitions for hoist operators and riggers are as follows; — hoist operator: an employee who generally uses an overhead hoist as a tool to assist in the performance of their regular job — rigger: At LLE a rigger is responsible for safely attaching payloads to the load hook of a hoist. Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 3 of 101  There are two specific roles in moving material overhead, hoist operators and riggers There are 2 classes of training for Hoist operators — Hoist operator – for overhead vertical lifting with unpowered horizontal motion — Overhead Crane operator – for overhead vertical lifting with powered horizontal motion There are 3 classes of training for riggers — No training is required for rigging payloads 500 lbs to any hoist or any load using multiple load hooks Overhead rigging of material or equipment is to be performed only by designated personnel Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 4 of 101  Basic rigging scope of qualification Basic rigging training qualifies the individuals to use the following equipment; — Slings: Synthetic web slings, round and flat — Hardware: Hoist rings, eye bolts, shackles, hooks Basic rigging training qualifies the individuals to perform the following activities for payloads up to 500 lbs; — Conduct rigging operations — Rig payloads for overhead lifts using the equipment listed above — Attach payloads to any load hook Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 5 of 101  OSHA Department of Labor (DOL) establishes the rules for overhead hoists The rules for rigging equipment are established in 29 CFR 1910.184 Slings and 29 CFR 1926.251 Rigging equipment for material handling The DOL incorporates additional rules by reference by citing additional standards within the regulations ASME B30 pertains to lifting and material-handling related equipment — There are 28 subparts to ASME B30 Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 6 of 101  Purpose of the ASME B30 standard The B30 Standard is intended to (a) prevent or minimize injury to workers, and otherwise provide for the protection of life, limb, and property by prescribing safety requirements (b) provide direction to manufacturers, owners, employers, users, and others concerned with, or responsible for, its application (c) guide governments and other regulatory bodies in the development, promulgation, and enforcement of appropriate safety directives Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 7 of 101  Numerous portions of the ASME B30 standard apply to rigging equipment Each of the B30 sections listed below contain requirements on the selection, use, maintenance, and inspection — B30.1 Jacks — B30.9 Slings — B30.10 Hooks — B30.20 Below-the-Hook Lifting Devices — B30.26 Rigging Hardware This lecture distills the ASME requirements into the policies and practices used at LLE Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 8 of 101  The basic steps for moving a payload 1) Prep work a. Understand the payload b. Select the rigging gear c. Inspect all rigging gear d. Assign responsibilities 2) Attach the rigging gear to the payload 3) Attach payload to a load hook 4) Move the payload 5) Secure the payload 6) Detach the payload from a hook 7) Remove the rigging gear Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 9 of 101  A vital part of your Prep Work is knowing the payload and path of travel Weight — Can often be found in “notes” section of a part drawing — Calculations (volume x density) — Talk to Mechanical Engineering Center of Gravity — Drawings will sometimes denote CG — Test lift to determine CG Path of travel — Know that destination is clear and ready to accept the payload — Insure the path is clear of any obstructions and personnel that will hinder movement Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 10 of 101  Select rated rigging equipment based upon the payload and how it is used Know the load capacity of the overhead hoists and support structures — This includes hoist(s), bridges, jibs, or gantries Know the load capacity of rigging hardware used in the rigging operation — This includes the shackles, hoist rings, straps, etc. Know how use of the equipment affects the load rating Use only load rated products NEVER exceed the rated load capacity of any piece of rigging equipment Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 11 of 101  Rigging equipment must be inspected prior to each use to ensure that it is safe Hardware — Visually inspect all hardware for damage including but not limited to screws, lifting shackles, hoist rings/lifting eyes, etc. — Look for thread damage, bent or fractured pieces, intentional or unintentional modifications Slings — Visually inspect for damage or fraying — Insure load rating tag is on the sling and legible — Inspect sewn threads Any rigging equipment that is found to be unsafe must removed from service immediately Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 12 of 101  During Prep activities, personnel assignments and responsibilities are reviewed Hard hat and safety glasses must be worn during all rigging operations Make sure all personnel involved understand the purpose and the nature of the operation Designate specific tasks to individuals as needed Use a ground spotter when lifting loads to upper level areas Post a sentry or barricade to prevent personnel from walking under the payload Insure communication between all parties involved is clear and concise — Example – Crane operator “Moving the load North” – Rigger “ Moving the load North aye” NEVER leave a suspended load unattended Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 13 of 101  Rated versus non-rated rigging hardware The terms “rated” and “non-rated” have specific meaning in the rigging field “Load Rated” products are engineered with special considerations important to lifting loads with cranes and hoists “Non-rated” products often look the same, but are not engineered to provide the same design factors and safety features as the load rated versions Never use non-rated products for rigging Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 14 of 101  Definitions angle of loading: the acute angle between horizontal and the leg of the rigging, often referred to as the horizontal angle. designated person: a person selected or assigned by the employer or the employer's representative as being competent to perform specific duties hoist operator: an employee who generally uses an overhead hoist as a tool to assist in the performance of their regular job line pull: the tension load in a rope entering a rigging block. The term “pull” is commonly used to describe line pull. qualified person: a person who, by possession of a recognized degree in an applicable field, or certificate of professional standing, or who, by extensive knowledge, training, and experience, has successfully demonstrated the ability to solve or resolve problems relating to the subject matter and work. Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 15 of 101  Definitions rated load: the maximum allowable working load established by the rigging hardware manufacturer. The terms "rated capacity" and "working load limit (WLL)" are commonly used to describe rated load. rigger: At LLE a rigger is responsible for safely attaching payloads to the load hook of a hoist. Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 16 of 101  Synthetic slings Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 17 of 101  Synthetic slings are used with three basic hitch styles Sling ratings are specified for each of three basic styles; vertical, choker, and basket For the basket style hitch, the load rating is specified for a 90° sling angle Load Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 18 of 101  Synthetic slings come in two basic Styles Endless Loop ( EN) Eye and Eye (EE) — Type 3 Flat eye is the most popular for all three hitch styles — Type 4 Twisted eye is more commonly used for choker hitch Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 19 of 101  Only synthetic slings are to be used at LLE Slings are made of either Polyester or Nylon Various widths are available – at LLE most are from 1” to 3” wide Information sewn into the sling label includes; — Manufacturers' name — Serial number — Load ratings (per hitch style) — Material — Length — Sling Type — Material Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 20 of 101  Synthetic web slings shall be immediately removed from service if any of the following conditions exist Burn Damage from either heat or chemical sources — Heat damage may not be obvious — Any synthetic sling exposed to temperatures above 150 °F must be removed from service Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 21 of 101  Synthetic web slings shall be immediately removed from service if any of the following conditions exist Snags, punctures, tears or cuts The red thread (tattletale) exposed in this example mean the sling must be removed from service. Simply remember “Red is dead” Broken or worn stitches Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 22 of 101  Synthetic web slings shall be immediately removed from service if any of the following conditions exist Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 23 of 101  In a bridle hitch, two, three, or four single hitches are used together to hoist objects that have lifting lugs or other attachments Bridle hitches can be assembled from individual components (slings, shackles, hooks, etc.) Bridle synthetic slings are permanently assembled units consisting of a number web slings grouped together on a master link Bridle slings typically have 1-4 legs Sling ends can be either eyes or various types of hooks Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 24 of 101  Sling rigging practices using a choker hitch Set the sling angle to >120° for a full load rating Improperly setting the choke can Sling reduce the load rating by as much Angle as 50% Angle of choke, deg Rated Capacity, % Over 120 100 90-120 87 60-89 74 30-59 62 0-29 49 Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 25 of 101  Sling rigging practices using a basket hitch Remember that basket hitch ratings are for slings at 90° The legs of a basket hitch are typically collected on a single hook A sling angle less than 90° increases the tension (load) in the sling 1000 lbs 1000 lbs 1000 lbs 1000 lbs 1000 lbs Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 26 of 101  Synthetic Sling Do’s and Don’ts Do’s Don’ts Visually inspect slings for any Do not use if any part of sling is damage and remove from service damaged if necessary Do not use if the safety Insure the safety tag is attached, information is missing or not legible, and has all pertinent legible information Do not tie slings together Verify load ratings per hitch style Do not use a sling that has been Use “softeners” on sharp corners shock loaded (remove it from as necessary service) Never exceed the load rating Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 27 of 101  Is this sling safe to use? No the red tattletale is showing Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 28 of 101  The three primary pieces of rigging hardware used at LLE Swivel Hoist rings Eyebolts Shackles Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 29 of 101  Hoist rings Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 30 of 101  Hoist rings have free movement about 2 axes or Degrees of Freedom (DOF) This motion allows the hoist ring to always be aligned with the sling Bail Swivel Never use a hoist ring if the swivel or bail bind, this is an indication of damage Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 31 of 101  Swivel hoist rings are able to accommodate various use angles Load ratings based on: — Size – Ring size and thread size — Material – Commonly alloy steel or stainless steel — Thread length – Longer length usually designed for soft metals (aluminum) – Shorter lengths can be used in ferrous metals (steel) Each hoist ring is load tested and comes with a factory certificate Many different types and sizes are available Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 32 of 101  The longer “Effective Thread Projection” that is approximately twice the thread diameter must be used for a hoist ring threaded into aluminum Dimensions Effective Working Torque Thread Frame HR-125 Load in Projection Weight Size Stock No. Limit Ft-Lbs Bolt Size Length Radius Diameter Each No. (lbs.) A B C D E F G H (lbs.) 2 1016909 2500 28 1/2 - 13 x 2.00 0.7 4.85 1.96 0.87 0.69 3.35 2.29 2.33 2 1016912 2500 28 1/2 - 13 x 2.50 1.2 4.85 1.96 0.87 0.69 3.35 2.29 2.36 2 1016920 4000 60 5/8 - 11 x 2.00 0.7 4.85 1.96 0.87 0.69 3.35 2.16 2.41 2 1016924 4000 60 5/8 - 11 x 2.75 1.45 4.85 1.96 0.87 0.69 3.35 2.16 2.47 2 1016931 5000 100 3/4 - 10 x 2.25 0.95 4.85 1.96 0.87 0.69 3.35 2.04 2.52 2 1016935 5000 100 3/4 - 10 x 2.75 1.45 4.85 1.96 0.87 0.69 3.35 2.04 2.59 3 1016942 7000 100 3/4 - 10 x 2.75 0.89 6.57 2.96 1.36 0.94 4.87 2.98 6.72 3 1016946 7000 100 3/4 - 10 x 3.50 1.64 6.57 2.96 1.36 0.94 4.87 2.98 6.81 Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 33 of 101  Hoist ring load ratings and installation torque values are stamped or etched on an installation placard located on top of the hoist ring Use an allen wrench for initial installation of the hoist ring A torque wrench must always be used for proper installation of the hoist ring Never exceed the load rating Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 34 of 101  Hoist ring Do’s Visually inspect hoist rings for any damage or corrosion on threads and body Insure the installation placard is attached, if not remove the hoist ring from service Use an allen wrench for initial installation and then a torque wrench for final tightening Make sure the thread engagement is appropriate for the base metal the bolt is being threaded into — Approximately 1 times the diameter when threading into steel — Approximately 2 times the diameter when threading into aluminum Verify swivel and bail functionality after installation Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 35 of 101  Hoist ring Don’ts Do not use if any part of hoist ring is damaged Do not use if placard information if missing or not legible Do not use a hoist ring if it is not tightened to the recommended torque Do not use if the hoist ring does not swivel Do not use washers in between the hoist ring and mounting surface Do not repair, replace, or modify any piece of a hoist ring Do not use if a gap exists between the part being lifted and the hoist ring Do not use a hook larger than the diameter of the hoist ring bail opening Never exceed the load rating of the hoist ring Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 36 of 101  What is the WLL of this hoist ring? Zero, the threaded rod, nut, and washers are clearly not an original bolt Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 37 of 101  Eye bolts Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 38 of 101  Machinery eye bolts are not as versatile as hoist rings Fixed position based upon thread engagement makes them alignment sensitive when pulling at an angle Can accommodate thru hole applications Load ratings are based upon a number of factors — Size – Ring size and thread size — Material – Commonly forged from carbon steel or stainless steel (carbon steel and stainless steel have different load ratings for the same size) — Use angle – Can only be used up to 45° Two different styles and numerous sizes available Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 39 of 101  There are two styles of eye bolts Plain pattern Shoulder pattern — straight vertical pulls only — angular pulls up to 45° from vertical Shoulder Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 40 of 101  Machinery eye bolts must be used with great care Working load limits for eye bolts Working Load Limit are based on a straight vertical pull Diameter and Straight Pull 45° Pull (Y) “in a gradually increasing manner” Thread (X) Shoulder Only 1/4"-20 500 125 Angular pulls will significantly lower working load limits (see 5/16"-18 900 225 Shoulder Pattern) and should be 3/8"-16 1400 350 avoided whenever possible 7/16"-14 2000 500 If an angular pull is required, a 1/2"-13 2600 650 properly seated Shoulder Pattern 9/16"-12 3200 750 eye bolt must be used 5/8"-11 4000 1000 Loads should always be applied to 3/4"-10 6000 1500 eye bolts in the plane of the eye, 7/8"-9 7000 1750 not at an angle to this plane 1"-8 9000 2250 Angular pulls must never be more 1-1/8"-7 12000 2500 than a 45° pull 1-1/4"-7 15000 3750 1-1/2"-6 21000 4900 Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 41 of 101  Loads must always be applied to eye bolts in the plane of the eye Side pull in the plane of the eye Side pull out of the plane of the Sling angle must not exceed 45 ° eye. This configuration must not be used Flat washers may be used under the shoulder to position the plane of the eye Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 42 of 101  Do not reeve slings between attachment points Reeving introduces side pull For 1 lbf at 60° there is also a 1 lbf Although the upper sling angle is lateral load. The resultant load on 60°, the resultant sling angle is the eye bolt is 1.73 lbf at 30°. 30° 1 lbf 1.73 lbf 1 lbf Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 43 of 101  Eye bolt identification markings Manufacturer and Size Eyebolts are not required to be marked with the WLL or required installation torque. The user must look up this information prior to use Do not use any eye bolt for rigging unless there are clearly legible identification marks Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 44 of 101  All machinery eye bolts are not created equal, they vary between manufacturers A comparison of the same size Working Load Limit shouldered eye bolts from two Diameter and Chicago Crosby manufacturers shows different Thread Straight Pull Straight Pull WLL 1/4"-20 500 650 Chicago rates the shouldered eye 5/16"-18 900 1200 bolt for a side pull up to 45° 3/8"-16 1400 1550 Although Crosby rates the 7/16"-14 2000 - shouldered eye bolt for a side pull 1/2"-13 2600 2600 up to 90° (25% of in-line WLL), a 9/16"-12 3200 - maximum of 45° is permitted at 5/8"-11 4000 5200 LLE 3/4"-10 6000 7200 The user must look up WLL 7/8"-9 7000 10600 information prior to use 1"-8 9000 13300 1-1/8"-7 12000 15000 1-1/4"-7 15000 21000 1-1/2"-6 21000 24000 Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 45 of 101  Shoulder Nut Eye Bolt – Installation for In-Line and Angular Loading A. The threaded shank must protrude In-line through the load sufficiently to allow full Pull angle engagement of the nut 45° B. If the eye bolt protrudes so far through the load that the nut cannot be tightened securely against the load, use properly sized washers to take up the excess space BETWEEN THE NUT AND THE LOAD 90° C. Place washers or spacers between nut and load so that when the nut is tightened securely, the shoulder is secured flush against the load surface D. Thickness of spacers must exceed this distance between the bottom of the load C,D and the last thread of the eye bolt B A Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 46 of 101  Regular Nut & Shoulder Nut Eye Bolt - Installation for In-line Loading with a tapped hole More than one eye bolt diameter One eye bolt diameter of threads of threads, only (1) nut is required or less, use two (2) nuts Tighten hex nut securely against Tighten hex nut securely against load load Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 47 of 101  Regular Nut & Shoulder Nut Eye Bolt - Installation for In-line Loading with a tapped hole Minimum engagement depth is 2 x One eye bolt diameter of threads Diameter or less is not allowed Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 48 of 101  Examples of non-load rated eyebolts that should never be used for rigging welded eye bolt open eye bolt bent eye bolt Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 49 of 101  Machinery eye bolt Do’s Visually inspect eyebolts for any damage or corrosion on threads and body Always be sure threads on the shank and receiving holes are clean Insure the eyebolt has proper identification markings Always countersink receiving hole or use washers to seat the shoulder properly Always screw the eye bolt down completely for proper seating Always tighten nuts securely against the load When using blind tapped holes, make sure thread engagement is more than 1.5 times the diameter of the thread in steel and 2.5 times in aluminum Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 50 of 101  Machinery eye bolt Don’ts Do not use the eyebolt if it is bent, damaged, or has been modified Do not use if the eyebolt if it does not have proper identification markings Do not use shouldered eyebolts at angles between 45 and 90 degrees to bolt axis Do not repair, replace, or modify an eyebolt Do not use if a gap exists between the part and eyebolt Do not use a hook larger than the diameter of the eyebolt opening Do not use a plain pattern eye bolt for angular pulls Shock loading must be avoided Never machine, grind, or cut an eye bolt Never use eye bolt that shows signs of wear or damage Never use eye bolt if eye or shank is bent or elongated Never exceed the load rating Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 51 of 101  Is this eyebolt safe to use? No, because the shoulder has been damaged Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 52 of 101  Shackles Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 53 of 101  Shackles are used for connecting various pieces of rigging equipment together Used as a connecting link between items — Strap to hoist ring or eyebolt — Strap to strap — Used as single attach point for multiple straps Load rating based on: — Size — Material Many different types and sizes Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 54 of 101  Examples of shackle usage Strap to diagnostic With multiple straps Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 55 of 101  Round pin shackle Round Pin Shackles can be used in tie down, towing, suspension or lifting applications where the load is strictly applied in-line Round pin shackles should never be used in rigging applications to gather multiple sling legs, or where side loading conditions may occur Round pin shackles are not approved for use at LLE Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 56 of 101  Screw pin shackle Screw Pin Shackles are used in Pick and Place applications. For permanent or long-term installations, Crosby recommends the use of bolt type shackles. Alternatively, the screw pin shall be secured from rotation or loosening. Screw pin shackles can be used for applications involving side-loading circumstances Reduced working load limits are required for side- loading applications While in service, do not allow the screw pin to be rotated by a live line, such as a choker application Screw pin shackles are preferred for use at LLE Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 57 of 101  Bolt-type shackle Bolt-Type Shackles can be used in any application where round pin or screw pin shackles are used In addition, they are recommended for permanent or long term installations and where the load may slide on the shackle pin causing the pin to rotate The bolt-type shackle’s secondary securement system, utilizing a nut and cotter, eliminates the requirement to tighten pin before each lift or movement of load Bolt-type shackles must have the cotter pin installed Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 58 of 101  Shackle identification markings Manufacturer 45° mark (Crosby) Size (3/4) Working Load Limit ( 4 ¾ T) Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 59 of 101  Side loading of screw pin and bolt type shackles results in a reduction of the working load limit In-line 45° Angle of Side Load from Vertical In-Line of shackle Adjusted WLL 0° In-Line 100% of Rated WLL 90° 45° from In-Line 70% of Rated WLL 90° from In-Line 50% of Rated WLL In-line load 90° from in-line At LLE shackles are only permitted to be loaded in-line Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 60 of 101  Shackle load ratings are based upon the use angle with multiple straps Shackles symmetrically loaded with two leg slings having a maximum included angle of 120° and can be utilized to full working load limit of the shackle Never exceed a 120° included angle and only use bolt-type or screw-pin shackles 120° Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 61 of 101  Shackle rigging practices for Crosby shackles Point loading of shackle bows is Point loading of shackle pins is acceptable acceptable when the load is reasonably centered on the pin Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 62 of 101  Shackle rigging practices with synthetic slings Folding, bunching, or pinching of synthetic slings can occur when used with shackles Folding, bunching, and pinching of synthetic slings reduces the sling load rating and must be avoided Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 63 of 101  Shackle rigging practices Screw pins shall be fully engaged If designed for a cotter pin, it shall be used and maintained Applied load should be centered in the bow to prevent side loading Multiple sling legs must not be applied to the pin If the shackle is side loaded, the rated load shall be reduced Never have the pin against the live line in a choker. The pin must go through the bow of the sling. Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 64 of 101  Shackle Do’s Visually inspect shackles for any damage or wear on ring and pin Insure shackles have proper identification markings Finger tighten the pin into ring of shackle Check for proper fit of the pin into ring Check the load ratings and use according to manufacturer recommendations Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 65 of 101  Shackle Don’ts Do not use a shackle if it is bent, damaged, or has been modified Do not use if the shackle does not have proper identification markings Do not use a tool to tighten a shackle pin Do not repair, replace, or modify a shackle Do not use a shackle if the pin has been replaced with a bolt Do not use a hook larger than the diameter of the shackle opening Never exceed the load rating Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 66 of 101  What is the WLL of this shackle? Zero, because the screw pin has been replaced with a bolt Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 67 of 101  What is the WLL of this shackle? Zero, welding changes the strength of the shackle material Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 68 of 101  Never use counterfeit or unknown hardware Rigging hardware must be identifiable with all information clearly legible Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 69 of 101  Hooks Shank hook Swivel hook Eye hook Grab hook Slip hook Sorting hook Sliding choker hook Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 70 of 101  Of the wide variety of hooks that are available, only a few types are used at LLE In general, the only hooks used at LLE are the load hooks attached to hoists — The overhead cranes use shank hooks with latches — The electric chain hoists use clevis hooks with latches Most rigging situations at LLE do not require any additional hooks. Contact ME for situations where additional hooks may be required Of all of the hooks shown, only the sorting hook may be point loaded. All other types of hooks must not be point loaded. Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 71 of 101  The load hook Always inspect the hook and latch before use Never use a latch that is distorted or bent Always make sure spring will force the latch against the tip of the hook Insure there is no excessive wear in the saddle of the hook Always make sure the hook supports the load. The latch must never support the load Latches are intended to retain loose sling or devices under slack conditions Latches are not intended to be an anti-fouling device Only load the hook in the “saddle” or “bowl” within ±45° of vertical Hooks are only to be loaded In-line Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 72 of 101  What is wrong with this picture? Hook too big for eye Point loaded hook Eye bolt not seated Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 73 of 101  Loading the load hook When placing two sling legs in a hook, make sure the angle between the legs is less than 90° and if the hook or load is tilted, nothing bears against the bottom of this latch For two legged slings with angles greater than 90°, use an intermediate link such as a master link or bolt type shackle to collect the legs of the slings. The intermediate link can be placed over the hook to provide an in-line load on the hook. This approach must also be used when using slings with three or more legs. Make sure all rigging materials are secured inside the latch area and the latch closes Never point load a hook Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 74 of 101  Hook latches must be closed Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 75 of 101  Are these hooks acceptable for use? No! No!! and No!!! Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 76 of 101  Rigging math Load SlingTension = # legs sin θ θ Load CollapseForce = # legs tan θ The sling angle θ is always Load measured from the horizontal Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 77 of 101  Sling tension in a vertical hitch 10,000 Lbs. What is the of tension on Sling sling tension? 10,000 Lbs. Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 78 of 101  Sling tension in a two leg vertical hitch (basket hitch) What is the sling tension on 5,000 Lbs. each leg? 5,000 Lbs. of tension on of tension on each Sling each Sling 10,000 Lbs. Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 79 of 101  Sling tension in a two leg bridle hitch θ Load Sling tension will increase as the sling angle θ gets smaller Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 80 of 101  Sling tension in a two leg bridle hitch at 60° 5,775 lbs. 5,775 lbs. 60o 60o 10,000 Lbs. Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 81 of 101  Sling tension in a two leg bridle hitch at 45° 7,070 lbs. 7,070 lbs. 45o 45o 10,000 Lbs. Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 82 of 101  Sling tension in a two leg bridle hitch at 30° 10,000 lbs. 10,000 lbs. 30o 30o 10,000 Lbs. Notice that at 30° the tension in the sling is equal to the Load Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 83 of 101  Sling tension in a two leg bridle hitch at 10° 28,800 lbs. 28,800 lbs. 10o 10o 10,000 Lbs. Notice that at below 30° the tension in the sling is greater than Load Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 84 of 101  Using a sling at any angle other than vertical applies a collapsing force on the load High collapsing forces can lead to — load buckling — exceeding the pad eye strength of where the hoist attaches to the load Collapsing Force Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 85 of 101  Rigging with a 3 or 4 sling bridle hitches With 3 and 4 leg sling bridle hitches, only 2 legs will likely carry the load while the other two steady (balance) the load Use only 2 legs when calculating the required load rating for rigging equipment Use the smallest sling angle when calculating load rating Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 86 of 101  Checking sling angles with simple geometry For 60° sling angle L L — All sides of the triangle are equal length 60° L For 45° sling angle H — The base of the triangle is 45° twice the height 2H For 30° sling angle 2H 30° H — The height is one-half of the sling length Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 87 of 101  For a two leg bridle hitch the basic rigger should size rigging hardware based on a two leg bridle hitch at 30° Recall – Shackles symmetrically loaded with two leg slings having a maximum included angle of 120° can be utilized to the full working load limit of the shackle 10,000 lbs. 10,000 lbs. 120o 30o 30o 10,000 Lbs. Select the sling load rating to be equal or greater than the payload and use a sling angle greater than 30° Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 88 of 101  Basic rigging practices When multiple slings are used on a common hook or bridle; — Always use sling angles greater than 30° — For sling load calculations use Sling Tension = Load All rigging hardware must satisfy the load rating requirements of the lift to be performed — It either meets the load requirements or not (there is no such thing as just over the load capacity) Use single slings between hooks and attachment points on the payload — do not reeve slings between attachment points All slings must be straight and free of knots Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 89 of 101  Basic rigging practices – continued When more than one wide sling (>1”) or two narrow slings (1”) are required, they shall be placed in a shackle or bridle which is then placed on the crane hook CORRECT WRONG Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 90 of 101  Hand signals Posters containing complete hand single information are posted near the overhead bridge cranes Complete knowledge of the hand signals is required for operation of the overhead cranes Complete knowledge of the hand signals is required for all riggers Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 91 of 101  Knowledge of hand signals is required Hand signals are not likely to be needed in most spaces because of close proximity and the use of radios However, all operators must know all of the listed/posted hand signals The hoist operator will only follow hand signals from a designated signalman (usually a rigger) Anyone may call for a stop or an emergency stop and it must be obeyed by the hoist operator Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 92 of 101  Knowledge of these eight hand signals is required Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 93 of 101  Qualified Advanced Riggers Advanced Riggers are available to support Basic Riggers to ensure safe lifting conditions — Dan Neyland, Omega XOPS — Jeff Rodas, EP XOPS — Mark Romanofsky, ME — Milt Shoup, ME Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 94 of 101  Summary Safety is everyone’s business and compliance with safety procedures is MANDATORY If an activity or practice seems unsafe, “Stop Work” and take the time to address concerns Only designated or qualified personnel may attach loads to an overhead hoist No LLE personnel are qualified or permitted to repair rigging equipment Only approved/rated rigging gear shall be attached to a load hook Load ratings shall never be exceeded It is the riggers responsibility to ensure all components used in a rigging operation meet the required load ratings — If a rigger is unable to determine a proper rigging configuration contact ME or an Advanced Rigger for support Rev 10/20/2015 Ba s ic Rigging S a fe ty Le cture -2015-10-20.pptm 95 of 101  Example test questions A payload is being lifted using a vertical hitch with the following components; Plain machinery eye bolt (WLL 2600 lb), synthetic sling (vertical WLL 10000 lb), Hoist (1T). What is the maximum payload? — 1300 lb — 2000 lb — 2600 lb — 10000 lb — Not enough information or not safe 2000 lb – limited by the hoist Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 96 of 101  Example test questions A payload is being lifted with a sling in basket hitch configuration with the following components; synthetic sling (basket WLL 10000 lb), and Hoist (4T). What is the maximum payload? — 4000 lb — 8000 lb — 10000 lb — Not enough information or not safe Not enough information – What is the sling angle? Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 97 of 101  Example test questions A payload is being lifted using a 2 leg bridle hitch assembled with the following individual components; Plain machinery eye bolts (WLL 2600 lb), synthetic slings (vertical WLL 1000 lb), Shackles (WLL 4T), and Hoist (5T). What is the maximum payload? — 1000 lb — 1300 lb — 2600 lb — 8000 lb — 10000 lb — Not enough information or not safe Not safe – Plain eye bolts can ONLY be used for vertical lifts, no sling angle provided Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 98 of 101  Example test questions A payload is being lifted using a 2 leg bridle hitch assembled with the following individual components; Plain machinery eye bolts (WLL 2600 lb), synthetic slings (vertical WLL 1000 lb), Shackles (WLL 4T), and Hoist (5T). The sling angle is 30°. What is the maximum payload? — 1000 lb — 1300 lb — 2600 lb — 8000 lb — 10000 lb — Not enough information or not safe Not safe – Plain eye bolts can ONLY be used for vertical lifts Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 99 of 101  Example test questions A payload is being lifted using a 2 leg bridle hitch assembled with the following individual components; hoist rings (WLL 5000 lb), synthetic slings (vertical WLL 10000 lb), Shackles (WLL 4T), and Hoist (5T). The sling angle is 30°. What is the maximum payload? — 2500 lb — 5000 lb — 7500 lb — 8000 lb — 10000 lb — Not enough information or not safe Remember that in a 2 leg configuration at 30° the tension in the sling tension is equal to the load Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 100 of 101  Example test questions A payload is being lifted using a 4 leg bridle hitch assembled with the following individual components; hoist rings (WLL 5000 lb), synthetic slings (vertical WLL 10000 lb), Shackles (WLL 4T), and Hoist (5T). The sling angle is 30°. What is the maximum payload? — 2500 lb — 5000 lb — 7500 lb — 8000 lb — 10000 lb — Not enough information or not safe Remember that with a 4 leg bridle hitch the load must be assumed to be only on 2 legs Rev 10/20/2015 Basic Rigging Safety Lecture-2015-10-20.pptm 101 of 101