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Bridge And Gantry Crane Drivers Guide 0001

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BRIDGE AND GANTRY CRANE DRIVERS A GUIDE FOR POWER CRANE DRIVERS GUIDE 1997 WorkCover. Watching out for you. New South Wales Government Disclaimer This publication may contain occupational health and safety and workers compensation information. It may include some of your obligations under the various legislations that WorkCover NSW administers. To ensure you comply with your legal obligations you must refer to the appropriate legislation. Information on the latest laws can be checked by visiting the NSW legislation website (www.legislation.nsw.gov.au) or by contacting the free hotline service on 02 9321 3333. This publication does not represent a comprehensive statement of the law as it applies to particular problems or to individuals or as a substitute for legal advice. You should seek independent legal advice if you need assistance on the application of the law to your situation. © WorkCover NSW CONTENTS PAGE 1. CERTIFICATE OF COMPETENCY FOR BRIDGE AND GANTRY CRANES 2 2. TYPES OF BRIDGE OR GANTRY CRANES 3 3. FEATURES OF BRIDGE OR GANTRY CRANES 5 4. CONTROLS 8 5. HOIST LIMIT SWITCHES 10 6. BRAKES 12 7. SAFE OPERATION 13 8. MAINTENANCE SAFETY PROCEDURE 17 9. SLINGING AND SAFE WORKING LOADS 18 10. WEIGHT OF THE LOAD 25 11. RULES TO FOLLOW WHEN SLINGING AND HANDLING A LOAD 26 12. STACKING 35 13. PERSONAL PROTECTIVE EQUIPMENT 37 14. COMMUNICATION 39 15. FLEXIBLE STEEL WIRE ROPE 41 16. SHEAVES AND DRUMS FOR FLEXIBLE STEEL WIRE ROPE 46 17. CHAIN 50 18. FLAT WEBBING AND ROUND SYNTHETIC SLINGS 53 19. FIBRE ROPE 55 20. ACCESSORIES 56 APPENDIX (i) – Areas and volumes 59 APPENDIX (ii) – Tables of masses 63 APPENDIX (iii) – First aid 65 APPENDIX (iv) – Terms used in this guide 66 APPENDIX (v) – Sample assessment questions 67 1 1. CERTIFICATE OF COMPETENCY FOR BRIDGE AND GANTRY CRANES To gain a certificate of competency for a cabin controlled bridge or gantry crane you must pass an assessment for a Bridge and gantry crane certificate conducted by an assessor registered by the Workcover Authority. Before taking the assessment you must obtain a log book and learn the competencies required to pass the assessment. Applicants must be at least 18 years old to gain a certificate. It is illegal to operate a cabin controlled bridge or gantry crane without a Bridge and gantry crane certificate or a log book (under the supervision of a certificated driver). A cabin controlled bridge or gantry crane driver must know: t IPXUPTBGFMZPQFSBUFBCSJEHFPSHBOUSZDSBOF t IPXUPEFUFDUBOZNFDIBOJDBMGBVMUT t BCPVUTMJOHJOHMPBET TIFBWFTBOEESVNT SPQFUFSNJOBUJPOT BODIPSTBOEBUUBDINFOUT It is the responsibility of the applicant to make sure that a bridge or gantry crane of the correct class is available for the assessment at their workplace or has permission to use a crane at another location. If you operate this type of crane and sling loads in connection with the operation of this type of crane you will require a Dogging certificate in addition to being competent in its operation. See A guide for dogging available from the WorkCover Authority. 2 2. TYPES OF BRIDGE AND GANTRY CRANES Bridge and gantry cranes can be: t QFOEBOUDPOUSPMMFE t DBCJODPOUSPMMFE t SFNPUFDPOUSPMMFE Most bridge and gantry cranes are controlled by a pendant push button control suspended from the crane structure. Cabin controls are used for a wide range of applications particularly where it is not possible to have a DMFBSXBMLXBZPSXIFSFUIFESJWFSNVTUCFQSPUFDUFE'PSFYBNQMF JOUIFTUFFMJOEVTUSZESJWFSTNVTUCF kept away from the intense heat of the molten steel transported by the cranes. Bridge cranes Bridge cranes are commonly used inside factories for a wide range of jobs. They run on overhead rails usually attached to opposing factory walls. 3 Gantry cranes Gantry cranes have two upright supports (portals) which move along two ground based rails. The height of the portals depends on the maximum hook height. Gantry cranes are used in factories and in outdoor storage yards such as railway and shipping storage areas. Semi-portal cranes Semi-portal cranes have a single portal running on a ground based rail while the other end is attached to an overhead rail. They are usually used where there is an outdoor storage yard running parallel to an enclosed factory. Container handling cranes Container handling cranes can be either a bridge or a gantry crane. They are used to handle containers at TIJQQJOHBOESBJMXBZUFSNJOBMT5IFZIBWFBTQFDJBMMJGUJOHGSBNFDBMMFEBTQSFBEFS XIJDIBUUBDIFTUPUIF container by ‘twist locks’. 4 3. FEATURES OF BRIDGE OR GANTRY CRANES The bridge Each crane has a ‘bridge’ which extends across the crane structure from rail to rail. It sits on an end carriage that has a set of track wheels which run on a rail on either side of the building. Working load limit The working load limit (WLL) can be found printed on the bridge. It is the responsibility of the driver to know the WLL of the crane. In many cranes this will be printed as the safe working load (SWL). Long travel ‘Long travel’ is the direction of travel of the bridge along the rails. Cross travel ‘Cross travel’ is the movement of the ‘crab’ (see below) from one side of the bridge to the other. The crab The ‘crab’ is the ‘cross travel unit’ from which the hook is lowered and raised. The ‘crab’ houses the hoist NPUPS UIFHFBSCPY UIFSPQFESVN UIFCSBLF UIFMJNJUTXJUDIFT UIFDSPTTUSBWFMHFBSCPYBOENPUPS*U sits on rails attached to the bridge. The power for the ‘crab’ comes from a bus bar or cable on the bridge structure. The hook block The ‘hook block’ is used for raising and lowering the hook. It can be single or multi-roped. 5 The sheaves 5IFSPQFGSPNUIFESVNSVOTUISPVHIUIFTIFBWFTPGUIFIPPLCMPDLBOEDSBC BOEPWFSBOFRVBMJTJOH sheave (where fitted). The rule of thumb is that the diameter of a sheave must be about 20 times the diameter of the rope. The depth of an open sheave must be 1.5 times the diameter of the rope. Where the rope is contained in the sheave the minimum depth of the sheave must equal the diameter of the rope. The driver must make sure that any sheave showing signs of wear could damage the rope which is replaced and squeaking sheaves are inspected and greased repaired. The control cabinet 5IFDPOUSPMDBCJOFU XIJDIJTNPVOUFEPOUIFDSBOF IBTBOBMMNPUJPOJTPMBUJPOTXJUDIBOEDPOUBJOT the contactors. The resistor banks The resistor banks are usually located on the crane bridge or in a well ventilated area. They dissipate heat from the unused electrical current. Live wires – collector gear – bus bars There are two types of power supply – AC and DC. Each is usually supplied by collector gear from live wires or insulated bus bars running alongside the crane and runway. The main isolating switch 5IFNBJOJTPMBUJOHTXJUDIJTVTVBMMZBMPDLBCMFTXJUDIVTJOHFJUIFSBLFZPSBQBEMPDL GPSJTPMBUJOHUIF crane from the power source. It is used for maintenance or in an emergency. It is usually located near the ladder to the service platform or the crane cabin. Look for a switch with a bright yellow background with black writing. Buffer stops Buffer stops are fitted to absorb the impact from a collision at either end of the long travel. Earth wire The ‘earth wire’ connection takes any electrical leak to earth. It must be visible and near to the permanent wiring connection to the bus bar. The cabin 5IFDBCJOJTBUUBDIFEUPUIFVOEFSTJEFPGUIFDSBOF CSJEHFPSDSBCBOEDPOUBJOTUIFDPOUSPMT 6 The pendant control The hand-held ‘pendant control’ is usually suspended from the bridge on a strainer wire which can be moved from one side of the crane to the other. The controls are normally push button. Pendant controls usually have: t OPSUIoTPVUI t FBTUoXFTU t VQoEPXO IPJTUNPWFNFOU t FNFSHFODZTUPQ They may also have a creep speed control. The directional compass Each crane must have a directional compass under the bridge of the crane. The compass helps pendant control drivers with the pendant directional controls. Note: The compass is aligned with the crane travel EJSFDUJPOT OPUNBHOFUJDPSHSJEOPSUI 7 4. CONTROLS Cabin controls .PTUNPEFSODSBOFTIBWFKPZTUJDLTUPDPOUSPMUIFNPWFNFOUPGUIFIPJTU UIFMPOHUSBWFMBOEUIFDSPTT travel movement and the raising and lowering of the hook. Pendant controls 8 Remote controls Remote controls are usually worn on a belt around the waist. When using a remote control it is important to be in a position to review the load and the travel path. Remote controls can be either infra red or radio controlled. Both infra red and radio controlled remote controls have a limited range. lnfra red controls must be pointed towards the crane during operation or the crane will stop. 9 5. HOIST LIMIT SWITCHES Limit switches prevent over-winding and over-lowering of the hook block. The upper limit prevents the hook block coming into contact with the rope drum and sheaves. The lower limit will keep two full turns of rope on the drum when the hook is in its lowest working QPTJUJPO BOENBZQSFWFOUUIFIPPLNBLJOHDPOUBDUXJUIUIFHSPVOE-JNJUTXJUDIFTNVTUCFUFTUFECZUIF driver before the beginning of each shift. 10 Upper limit switches Most cranes have two upper limit switches to prevent overwinding: t UIFTIVOUXPSLJOHMJNJUTXJUDI t UIFXIPMFDVSSFOUOPOTFMGSFTFUUJOHMJNJUTXJUDI Some older cranes are fitted only with a whole current self-resetting upper limit switch. 5IFTIVOUXPSLJOHVQQFSMJNJUTXJUDIJTUIFGJSTUUPDPNFJOUPPQFSBUJPOBOEXJMMTUPQUIFIPPLCMPDL before it reaches the whole current non-self-resetting limit switch. 5IFXIPMFDVSSFOUOPOTFMGSFTFUUJOHVQQFSMJNJUTXJUDIJTTFUBCPWFUIFTIVOUXPSLJOHMJNJUTXJUDIBOE POMZPQFSBUFTJGUIFTIVOUXPSLJOHMJNJUTXJUDIGBJMT*UXJMMTUPQBMMIPJTUJOHNPUJPOVOUJMUIFGBVMUJTGJYFE A qualified electrician must be called to reset a non-self-resetting upper limit. The whole current self-resetting upper limit switch is used where there is no other upper limit switch. It will self-reset once the lower control is activated. The lower limit switch .PTUDSBOFTIBWFBTIVOUXPSLJOHMJNJUBTBMPXFSMJNJU*GUIFDSBOFPQFSBUFTBCPWFBTJOHMFMFWFMGMPPS UIJTMJNJUQSFWFOUTUIFIPPLDPNJOHJOUPDPOUBDUXJUIUIFGMPPS DBVTJOHBTMBDLSPQF Riding the limits Crane drivers must be careful about using the limit switches as a method of stopping the load at the maximum height. The contacts can burn out if this is done to excess. 11 6. BRAKES All bridge and gantry crane brakes work using the same principle: t 1PXFSPGGo#SBLFTPO t 1PXFSPOo#SBLFTPGG When the power is turned on the solenoid pushes the brake off allowing the drum or shaft to turn. When the power is turned off two springs or a counterweight apply the brakes to the drum or shaft. 5IFCSBLFTDPOUSPMIPJTUBOEMPOHUSBWFMNPWFNFOU BOETPNFUJNFTDSPTTUSBWFM Cabin controlled cranes have a long travel footbrake for easing the load smoothly to a stop. Pendant control cranes have automatic brakes. 12 7. SAFE OPERATION 4BGFPQFSBUJPOJTTNPPUIPQFSBUJPO"WPJEKVNQZBOEKFSLZPQFSBUJPO GMZJOHTUBSUT RVJDLSFWFSTBMTBOE sudden stops. Do not move a load over a busy work area without giving warning. Watch out for any unexpected movement or obstructions while a load is moving. Do not carry passengers or allow anyone to interfere with a load. Raising and lowering The driver must use the same control setting to lower the load as needed to raise the load. If the load needed No 3 setting to be smoothly raised then lower the load with No 3 setting. Do not use a lower setting to lower a load than was needed to raise the load. Some cranes have a creep lower speed for accurate positioning while lowering loads. Some cranes have two hooks from the same crab. Do not change hooks while the first hook is still under load. Some operations use both hooks such as tipping hot metals ladels and skips. Starting and stopping 4UBSUBMMNPUJPOTTMPXMZBOEBDDFMFSBUFTMPXMZ TUFQCZTUFQ VOUJMUIFGBTUFTUTQFFEJTSFBDIFE4UPQUIF crane slowly by returning the control to the ‘OFF’ position step by step. Rapid acceleration can cause the contacts to arc and burn. Chasing the hook Crane drivers must learn to ‘chase the hook’ (take the swing out of the load as it is brought to a halt). To chase the hook: 1. Stop the movement of the crane before the final stopping place. The load will swing forward. 2. Move the crane quickly to be above the load at the furthest extent of the swing of the load and stop again. 13 Do not ‘plug’ Do NOT bring the load to a halt by ‘plugging’ the controls. Plugging is continuously pushing and releasing the control button. This will run the motor too slowly to activate the cooling fan and can burn out the motor and overheat the contacts. Electrical faults Electrical faults are the greatest hazards associated with bridge and gantry cranes. If there is an electrical fault call an electrician. %POPUUSZUPGJYBOFMFDUSJDBMGBVMU FWFOBCMPXOGVTF*UIBTCMPXOGPSBSFBTPOBOENVTUCFBTTFTTFECZ an electrician. If a worker receives an electric shock while holding the hook or load and is unable to let go: t 3BJTFUIFIPPLJNNFEJBUFMZ UIJTXJMMTUPQUIFDVSSFOUHPJOHUPFBSUIUISPVHIUIFXPSLFS  t #MPXUIFIPSO t 4UBZJOTJEFUIFDBCJOVOUJMTPNFPOFIBTUVSOFEPGGUIFNBJOTXJUDI 14 Pre-checks prior to turning on the main switch 1. Make sure there are no maintenance signs. 2. Make sure there is no obvious damage to the crane. 3. Check mains switch box for ‘danger tags’. 4. Check the main isolating switch for ‘danger tags’. 5. Check for any maintenance crew working on the crane. 6. Check that collector wires have not been blown or knocked off the insulators. They must not have ladders or any other gear resting on them. 7. Check spreaders (container loading gantry cranes) for:  t IZESBVMJDGMVJEMFWFM  t PJMMFBLT  t EBNBHFUPUXJTUMPDLT 8. Check wires and anchorages for defects. Pre-checks inside the cabin and with the pendant control 1. Check the WLL (or SWL) stamped on the bridge of the crane. 2. Unlock emergency switch and switch power on. 3. Check control panel lights. (Cabin only) 4. Check for fire extinguisher. (Cabin only) 5. Make sure that you can identify each of the buttons on the pendant and that they operate freely without sticking. 6. Check that the pendant strainer wire is properly attached and that the pendant moves freely across the crane without undue force. 7. Drive and then stop the crane a few times in each direction to check the brakes for adjustment and operation of the crane for the job. 8. Test the operation of the working limit switches. 9. Where possible have a full view of the load and the general work area. 15 10. Make sure that the runways and the general work area are clear of obstructions. 11. If the load hook is fitted with a safety catch make sure it is working properly. 12. Make sure that the hoist rope is free of kinks or obvious broken wires. 13. Make sure that the rope passes easily through all the running sheaves. 14. Check for any obvious mechanical problems. 15. Make sure that the runways and the general work area are clear. Cross travel motion 5IFDSBCNVTUBMXBZTCFCSPVHIUEJSFDUMZPWFSUIFMPBECFGPSFMJGUJOH*GUIJTJTOPUEPOF UIFMPBEXJMM begin to swing as soon as it is hoisted. Do not stand directly beneath the load or allow anyone else to do so. Long travel motion The bridge must always be brought directly over the load. It is not possible to position the hook block directly over the load unless this is done. The bridge will always drift after the power has been removed. Cabin controlled cranes have a foot pedal brake to stop the bridge. It is important to learn to anticipate the amount of ‘drift’ and use the brake as smoothly as possible. Hoist motion 8IFOUIFMPBEJTSFBEZUPIPJTU TUBSUIPJTUJOHVQXBSETVOUJMUIFTMBDLJTUBLFOPVUPGUIFTMJOHT Only continue to hoist if the load is in balance. The person who has slung the load must check the balance of the load for the operator of a cabin controlled crane. Hoist slowly until the load is clear of the floor and then increase speed smoothly until the load is at the required height. When lowering the load gradually reduce the speed as the load nears its target. Reduce to the lowest speed and then ‘inch’ the load down. Follow the dogger’s directions if you are driving a cabin controlled crane. 16 8. MAINTENANCE SAFETY PROCEDURE Maintenance procedures vary according to the type of crane. Follow the specific maintenance safety procedures as laid down for your workplace. Before carrying out maintenance the main switch must be opened and tagged by every worker who will be working on the crane. This process isolates the crane from the power source while maintenance workers are on the crane. When all the tags have been removed from the main switch visually inspect the crane and call out to make doubly sure that there is no worker still on the crane before reactivating the power. Where there is more than one crane operating and one crane must be isolated for maintenance: t 3FNPWFUIFQPXFSUPUIFDSBOFCZUVSOJOHPGGUIFBMMNPUJPO isolation switch. t *OTUBMMUFNQPSBSZFOETUPQTPOUIFNBJODSBOFSVOXBZ t *OTUBMMBGMBTIJOHMJHIUBUUIFFOETUPQPOUIFPUIFSTJEFPGUIF driver’s cabin. t )BOHEBOHFSGMBHTGSPNUIFUFNQPSBSZFOETUPQPOPOFSBJM across to the other rail. t 8IFSFBQQMJDBCMFBXPSLFSNVTUTJUJOUIFESJWFSTDBCJO to observe. t $PSEPOPGGUIFBSFBCFOFBUIUIFDSBOFBOEQMBDFA.FO8PSLJOH Above’ signs on each side. 17 9. SLINGING AND SAFE WORKING LOADS The working load limit (WLL) of a sling is the maximum load that can be lifted by that sling making a straight lift. The load factor for a straight lift = 1. The lifting capacity decreases as the angle between the legs of the sling attachment increases. Different methods of slinging will also alter the lifting capacity. For example: t "SFFWFETMJOHBSPVOEBTRVBSFMPBEXJMMIBMWFUIFMJGUJOHDBQBDJUZPGBTMJOH5IFMPBEGBDUPSJT t "CBTLFUIJUDIBSPVOEBSPVOEMPBEEPVCMFTUIFMJGUJOHDBQBDJUZ5IFMPBEGBDUPSJT Below are the various methods of slinging with their load factors. SWL tables are available for all types of slings and rope. Make sure that you consult the correct table before lifting. You must know the load factors for each method of slinging shown on page 21. A working load chart for 6 x 24-1570 Grade – Galvanised steel wire rope Rule of thumb methods for calculating the WLLs of flexible steel wire rope, chain and fibre rope. Please note that these methods only give approximate answers. 18 Flexible steel wire rope (FSWR) To calculate the WLL in kilograms of FSWR square the rope diameter (D) in millimetres (mm) and multiply by 8. 2 Formula: WLL (kgs) = D (mm) x 8 For example: Rope diameter (D) = 12mm 2 WLL (kgs) = D (mm) x 8 = D (mm) x D (mm) x 8 = 12 x 12 x 8 = 1152 kgs WLL (t) = 1.15 tonnes The above equation can be reversed to calculate the diameter (D) in millimetres of FSWR needed to lift a given load. To do this divide the load (L) in kilograms by 8 and find the square root of the result. Formula: D (mm) For example: Load = Load 8 = 1152 kg D (mm) = 1152 ÷ 8 = 144 = 12 Therefore an FSWR sling of at least 12mm is required to lift a 1152 kg load. Chain The WLL of chain is determined by the grade (G). Do not use a chain to lift if it does not have a manufacturer’s tag that gives details of the WLL. Return it to the manufacturer for WLL assessment and re-tagging. 5PDBMDVMBUFUIF8--PGMJGUJOHDIBJOJOLJMPHSBNTTRVBSFUIFEJBNFUFS % JONJMMJNFUSFT NN BOE NVMUJQMZCZUIFHSBEF ( CZ 2 Formula: WLL (kgs) = D (mm) x G x 0.3 For example: $IBJOEJBNFUFS NN$IBJOHSBEF 5  JFHSBEF WLL 2 = D (mm) x G x 0.3 = D (mm) x D (mm) x G x 0.3 = 10 x 10 x 80 x 0.3 = 2400 kgs WLL (t) = 2.4 tonnes. Fibre rope To calculate the WLL of fibre rope in kilograms square the rope diameter (D) in millimetres (mm). 2 Formula: WLL (kgs) = D (mm) For example: Diameter WLL (kgs) WLL (kgs) = 25mm 2 = D (mm) = D (mm) x D (mm) = 25 x 25 = 625 kgs WLL (t) = 0.625 tonnes. 19 Flat webbing and round synthetic slings Flat webbing and round synthetic slings are labelled with the WLL. Do not lift if the label is missing. Return to the manufacturer for testing and relabelling. Synthetic slings are colour coded (see table below). Label for a flat webbing synthetic sling Indicator stripes - each stripe represents 1 tonne WLL - safety factor 8: 1 20 Single sling Basket hitch Endless sling or grommet Comparing methods of slinging and load factors 21 Load factors and slinging In the examples below all the load and reeve factors are for FSWR. The arithmetic is set out so that calculations can be easily worked out on a calculator. 1. To calculate the maximum weight of load that can be lifted multiply the WLL of the sling(s) by the angle factor by the reeve factor. Formula: Max load = WLL (of sling) x angle factor x reeve factor 'PSFYBNQMF5IF8--PGFBDIMFHPGBNVMUJMFHHFETMJOHJTFJHIUUPOOFT UIFBOHMFCFUXFFOUIFUXPTMJOH legs is 60° and they are reeved around a square load. This means a load factor of 1.73 for the angle and another factor of 0.5 for the reeve. Sling WLL 8 tonne Angle factor 1.73 Reeve factor 0.5 Therefore: Max load = 8 x 1.73 x 0.5 = 6.92 tonnes 6.9 tonnes is the maximum weight that can be lifted. 2. To calculate the WLL of multi-legged slings needed to lift this load divide the weight of the load by the load factor. Formula for a calculator: WLL = weight ÷ load factor Formula can be written: WLL = weight load factor 22 For example: The weight of the load to be lifted is 20 tonnes and the angle between the two legs of a multi-legged sling is 60º. This means that the load factor is 1.73 for the angle. Weight 20 tonnes Load factor 1.73 Therefore: WLL = 20 ÷ 1.73 = 11.56 tonnes Therefore use a sling with a lifting capacity greater than 11.56 tonnes. 3. To calculate the WLL of a sling needed to lift this load divide the load by the angle factor and divide by the reeve factor. Formula for a calculator: WLL = weight ÷ angle factor ÷ reeve factor Formula can be written: WLL = weight angle factor x reeve factor For example: Two slings have a 60° angle between them and are both reeved around a 4 tonne square load. This means a load factor of 1.73 for the angle and 0.5 for the reeve. Weight 4 tonnes Angle factor 1.73 Reeve factor 0.5 Therefore: WLL = 4 ÷ 1.73 ÷ .5 = 4.62 tonnes Therefore use a sling with a lifting capacity greater than 4.62 tonnes. 23 4. To calculate the WLL of the sling needed to lift this load divide the load by the angle factor and divide by the reeve factor. Formula for a calculator: WLL = weight ÷ angle factor ÷ reeve factor Formula can be written: WLL = weight angle factor x reeve factor For example: Two slings have a 60° between them are reeved around a 20 tonne round load. This means a load factor of 1.73 for the angle and 0.75 for the reeve. Weight 20 tonnes Angle factor 1.73 Reeve factor 0.75 Therefore: WLL = 20 ÷ 1.73 ÷ 0.75 = 15.41 tonnes Therefore use a sling with a lifting capacity greater than 15.41 tonnes. 5. To calculate the diameter (D) in millimetres (mm) of FSWR needed to lift a load of 5 tonnes as a TUSBJHIUMJGU DPOWFSUUPOOFTJOUPLJMPHSBNT EJWJEFCZBOEUIFOGJOEUIFTRVBSFSPPUPGUIFBOTXFS Formula: D (mm) = Load ÷ 8 Formula can be written: D (mm) = Load 8 D (mm) = 5000 ÷ 8 = 625 = 25 Therefore a 25mm diameter FSWR is needed for the lift. 24 10. WEIGHT OF THE LOAD Do not lift if the weight of a load is not stamped on the load or the delivery docket and it is not possible to calculate the weight. It may be possible to calculate the weight of a load from the weighbridge certificate from the delivery vehicle. #FDBSFGVMPGUIFMPBEXFJHIUTUBNQFEPOUIFMPBEPSEFMJWFSZEPDLFU5JNCFSGPSFYBNQMF DBOCF heavier when wet. In foundries when large castings are raised from a mould there can be suction created by the sand adding substantially to the weight. Pipes are often weighed down by sludge. Fuel and water tanks may not always be empty. Check for this. When lifting a load for the first time watch the lifting equipment carefully for signs of strain in case the stated weight is incorrect. 25 11. RULES TO FOLLOW WHEN SLINGING AND HANDLING A LOAD A simple rule of thumb for a good safe working to angle Make sure that the horizontal distance between the points of attachment of the load does not exceed the length of the slings. This will ensure that the angle between the two legs of the sling does not exceed 60°. Multi-legged slings The recommended maximum angle between the two legs of a sling is 90°. The recommended maximum angle between the vertical and a leg of a sling is 45°. At the absolute maximum angle of 120° the WLL of the two slings must be halved. Common sling arrangements Single-part, single-leg slings Double-part, single-leg slings 2-Leg slings 26 3-Leg and 4-Leg slings When slinging a rigid object with a multiple legged sling it must be assumed that only two of the sling legs are taking the load. Additional legs do not increase the WLL. Where an object is flexible and the load is evenly distributed make sure that each leg takes an even share of the load. Be careful when lifting irregular shaped objects - it is possible that only one leg of the sling is taking the whole load. The larger the angle from the vertical made by slings on a hook the more likely the slings eyes are to slip to the bill of the hook. In this case put the eyes into a ‘bow’ shackle large enough so that they do not jam. Make sure that the shackle pin is resting on the hook. 27 Direct lifting It is the duty of a dogger to direct the crane operator to position the head of the jib or the bridge directly over the load. Then make sure that the load hook is positioned directly above a load before slinging and lifting. "MXBZTMJGUWFSUJDBMMZ*GUIFDSBCJTOPUEJSFDUMZPWFSUIFMPBE UIFMPBEXJMMCFHJOUPTXJOHEBOHFSPVTMZBT soon as it is raised. Dragging a load can put undue strain on the lifting gear and crane boom especially if the load is dragged from the side. General handling .BLFTVSFUIBUUIFSFJTTVJUBCMFQBDLJOHPSMBHHJOHBUBMMTIBSQFEHFTPGTUFFMCFBNT BOEPUIFS hard materials. Use packing to prevent the sling from coming into contact with sharp edges. This will lengthen the life of the sling and prevent breaks. Make sure that packing or lagging is secure so that it will not fall out when the slings go slack. Before lifting a load make sure that it is not caught or trapped in some way. Machinery and plant with lifting lugs should be marked with the mass. Caution: Some lifting lugs are used GPSUIFBTTFNCMZBOEEJTNBOUMJOH OPUGPSMJGUJOHUIFFOUJSFVOJU .BDIJOFSZ QMBOUBOENBUFSJBMCPYFTXJUIMJGUJOHMVHTNVTUIBWFUIF8--DMFBSMZNBSLFE "MMMPBETEFMJWFSFEUPBTJUFUIBUDPVMECFIB[BSEPVTTIPVMECFTUSBQQFEPSXSBQQFE'PSFYBNQMF MPBETPG QJQF NFUBMPSUJNCFSTIPVMECFTUSBQQFECFGPSFMJGUJOH 4QSFBEFSTBSFSFDPNNFOEFEGPSMJGUJOHMFOHUITPGUJNCFS QJQFPSTUFFM*GBTQSFBEFSJTOPUBWBJMBCMFo double wrap before lifting. 28 Do not bash the eye of a sling down at the nip point. This practice will decrease the WLL and damage the sling. Structural steel -PBETPGTUSVDUVSBMTUFFM VOJWFSTBMCFBNT 34+T POUSVDLTNVTUIBWFSFTUSBJOJOHTQJLFTGJUUFEJOUIFUSVDL to prevent them from falling out. Removing the chains or straps if there are no restraining spikes in place is very dangerous. Structural steel can be very dangerous. When a load arrives on site walk around the truck and check that the steel has not shifted into a dangerous position for lifting after the load binder chains were secured. Many serious accidents have occurred as load binding chains were removed from steel beams. Deep beams can inflict especially severe injuries. Always lift steel reinforcing level. Do not lift it vertically or at a slope. It is not possible to make the inside steel in a bundle tight enough to prevent them falling out if the bundle is at an angle. Steel reinforcing can kill if it falls. As the load is lifted keep hands well away. Steel beams tend to snap together or roll up as the sling bites into the nip. Loose items Loads of loose items such as scaffold clips must be raised in properly constructed boxes branded with the WLL or SWL. Do not lift loads of this kind in 200 litre drums because: t UIFTFESVNTIBWFOPSBUFEMJGUJOHDBQBDJUZ t JUJTOPUQPTTJCMFUPLOPXUIFDPOEJUJPOPGUIFCBTFPGUIFESVN 5IFZIBWFVTVBMMZCFFOEJTDBSEFE because they are unfit to hold liquid). t UIFIPMFTDVUJOUPUIFTJEFTGPSUIFTMJOHPSIPPLTPGUFOQVMMUISPVHIVOEFSUIFXFJHIU t UIFTIBSQFEHFTPGUIFIPMFTDBODVUUISPVHIBTMJOH 29 Rubbish bins Rubbish bins should have proper lifting lugs and be branded with the WLL or SWL. Rubbish bins that are overloaded must not be lifted. Where rubbish can be blown out or spill from a bin secure the load before MJGUJOH FTQFDJBMMZJOXJOEZDPOEJUJPOT 4MJOHSVCCJTICJOTXJUIBGPVSXBZTMJOH5PUJQUIFCJO SFMFBTFUIFUXPGSPOUTMJOHTBOESBJTFUIFCJOXJUI the two back slings. %POPUVTFUIFTQFDJBMMJGUJOHQPJOUT USVOJPOT EFTJHOFEUPBUUBDIUPUIFTVQQMJFSTUSVDLGPSMJGUJOH GPS slinging a bin. These are often unsuitable for use with general purpose slings. Do not stand behind a bin when tipping rubbish out. It will whip back suddenly as soon as it is clear of the ground. Handling steel plate Steel plate can be lifted with: t QMBUFDMBNQTUIBUBSFEFTJHOFEUPJODSFBTFUIFQVSDIBTFPOUIFQMBUFBTUIFQMBUFJTMJGUFE t IPPLTPSTIBDLMFTXIFSFUIFSFBSFMJGUJOHIPMFTJOUIFQMBUF Do not use home made type plate clamps or plate dogs. Remember that steel plate can injure or kill. The angle between the legs of a sling must not be more than 60° unless a spreader beam is used. Steel plate can be lifted vertically or horizontally. Lifting vertically: t 6TFBOBQQSPQSJBUFQMBUFDMBNQXIFSFBTMJOHDBOOPUCFBUUBDIFEBOEUIFSFJTOPMJGUJOHIPMF"O example is the dished and flanged end-plate for a pressure vessel. t 1MFBTFOPUF UIBUJUDBOCFEJGGJDVMUUPSFNPWFPSBUUBDIBTMJOHXIFSFQMBUFJTTUPSFEWFSUJDBMMZJOB rack or is to be fed into bending rolls. t "TBQMBUFUPVDIFTUIFHSPVOEBOEUIFUFOTJPOJTSFMFBTFEGSPNUIFTMJOHTBTJOHMFIPPLDBODPNFPVU of the hole causing the plate to fall. To prevent this lift with a hook put through a ring attached to a short length of chain that is shackled to an appropriate plate clamp. 30 t "MXBZTNBLFTVSFUIBUUIFUFOTJPOSFNBJOTJOUIFTMJOHTVOUJMUIFQMBUFJTJOQMBDF Lifting horizontally: t 6TFBQQSPWFEHSJQQJOHQMBUFDMBNQT6TFBTQSFBEFSCFBNGPSMPOHUIJOQMBUFTUPQSFWFOUEBOHFSPVT GMBQQJOH TBHHJOHBOEWJCSBUJPO Pallets A wide variety of loads are delivered to worksites on pallets. Before a palleted load is lifted from a truck check that: t UIFQBMMFUJTGSFFGSPNEFGFDUT t UIFMPBEJTTFDVSFETPUIBUOPUIJOHDBOGBMMPGG t UIFMPBEJTQSPQFSMZTMVOH The WLL of a standard hardwood pallet is 2000 kg. The WLL can be dramatically reduced if there are any missing boards or any other defects. Please note: Some pallets are designed for packaging not lifting. Do not lift a pallet that has defects. To lift a load on a damaged pallet raise the load just enough to slide an undamaged pallet underneath. Alternatively place an undamaged pallet beside the damaged one and then lift and move it onto the new pallet. Then lower the load and sling properly before lifting and moving the load to the desired place. If no spare undamaged pallets are available send the load back to the supplier to be re-palleted. Always raise palleted bricks inside a brick cage to prevent loose bricks falling. 31 Turning over loads When turning over a load such as a steel beam the sling must be attached to the hook on the side of the load that is to be lifted. This will ensure that it will be raised on a diagonal through the centre of gravity. It is then a simple matter to lower the crane or lifting media turning the beam over in a safe and controlled manner. It is important that the beam is slung so that when the beam is lowered the nip will pull against the eye. "TUFFMCFBN 34+ IBTBIJHIDFOUSFPGHSBWJUZBOEBOBSSPXCBTFXIFOJUJTTUBOEJOHPOJUTGMBOHF*GB EPHHFSOJQTUIFTMJOHJODPSSFDUMZUPUVSOUIFCFBNJUXJMMGMPQ UPQQMFPWFSBOEQPTTJCMZCSFBLUIFTMJOHT The same principles apply when turning over all loads. 32 Bends and hitches Doggers must know how to secure loads and tag lines with bends and hitches. Learn those described and illustrated below. Snubber turns for holding and lowering heavy loads. Two, three or more turns should be used. Rolling hitch – To secure stopper, or two ropes pulling in opposite directions. Very useful – preferable to clove hitch or blackwall hitch, providing rolling turns are put on in proper direction of pull. Safe. Timber and half hitch – useful for hoisting lengths of timber. Only safe when additional half hitch is put on end of hauling part. Clove hitch – used to commence rope lashing. Not safe for other purposes unless ends secured, with additional half-hitch. Bowline single – used for making temporary eye in end of rope. Buntline or becket hitch – to secure ends of tackles to beckets. Foolproof; cannot come undone like half hitches. Sheet bend – to join two dry ropes of different sizes. Safer when double sheet bend is used. The smaller rope must be bent around the larger rope. Bowline running – used for making a temporary eye to run along another part of rope. (i) Bowline on the bight. Double sheet bend. (ii) Bowline on the bight. Fisherman’s bend and half hitch – useful for bending rope onto rings, handles of buckets, etc – requires the extra half hitch. (iii) Bowline on the bight – the bowline on the bight is formed by making the first part of a bowline with the bight of the rope and passing the whole hitch through its bight. 33 Shortener for single-part rope or snotter – to join rope to hook of tackle, etc. and does not damage the rope. At least two full turns of the standing part are to nip the two bights before the bights are placed on the hook. Overhand knot – to make a stop on a rope, to prevent ends from fraying or to prevent it slipping through a block. Single snotter shortener partly made. Two bights ready to be placed on hook. Figure of eight knot – as for an overhand knot, but easier to untie. Single snotter shortener with both bights fitted on hook. Round turn and two half hitches – widely used for securing running ends of tackles. The more turns made before hitches are made the more control is possible. Double shortener – each of the two parts of the bale-sling or strop is turned back on itself, so that two bights are formed at a suitable length. The bights are then turned about each other as in a simple overhand knot and place on the hook. Direction of pull on spike Double shortener for sling on hook. Marlin spike hitch – should not be used for sending tools or materials aloft. A better method for tools is to open up the rope and push tool through. Double shortener for sling partly made. N.B. When shortening synthetic rope slings it is usually advisable to twist the bights twice about each other because of the slippery nature of many synthetic ropes. 34 12. STACKING Make sure that on completion of moving a load all materials are securely and safely stacked. Stacks of materials must be arranged: t TPUIBUUIFSFJTBEFRVBUFDMFBSBODFGSPNNBDIJOFSZUIBUDPVMEUPQQMFBTUBDL t TPUIBUUIFSFJTBDDFTTGPSQFPQMF GPSLMJGUT DSBOFT USBJOTBOETPPO t TPUIBUUIFTMJOHDBOCFSFNPWFEBTFBDIVOJUJTQMBDFEPOUIFTUBDL "MXBZTQVMMBTMJOHPVUCZIBOE to prevent the possibility of the crane toppling a stack). t TPUIBUUIFSFJTBDDFTTUPGJSFFYUJOHVJTIFST #FGPSFTUBDLJOHNBLFTVSFUIBUUIFHSPVOEJTTUBCMF MFWFMBOEOPUMJLFMZUPGMPPEJOUIFFWFOUPGSBJO*G there is heavy rain check the ground for signs of it giving way. If the ground is not level make sure that the stacks are chocked level and secure. When a stack is removed check the ground for signs of it giving way before placing another stack in the same position. Clearance There must be clearance of: t OPUMFTTUIBONFUSFTBMPOHTJEFSBJMXBZUSBDLT t OPUMFTTUIBONFUSFTGPSUSVDLBDDFTT t OPUMFTTUIBONFUSFGPSXBMLXBZT t OPUMFTTUIBONFUSFTGPSBDDFTTGPSBCSJEHFBOEHBOUSZDSBOFPQFSBUPS t OPUMFTTUIBONFUSFTGPSBDDFTTGPSBCSJEHFBOEHBOUSZDSBOFXIFSFUIFTQFFEPGUIFDSBOFJT greater than 0.8 metres per second Use your common sense. There must be access to carry out the work normally carried out on site and for stretcher access in the case of emergency. Stacking steel plate Make sure that the stack supports are spaced between 2 and 3 metres apart. 35 Where plate is stored horizontally with no packing and is wider than 0.75 metres stagger into groups of plates that make up a suitable lift. When steel plate is stacked upright in racks the plate can easily swing (and could crush someone) when the crane takes the weight of the plate. Use adequate packing and the proper plate clamps to avoid having to stand inside a rack. Do not lift a plate from a rack if someone is inside the rack under any circumstances. To avoid horizontal stacks becoming dangerously high tie stacks together with packing. Stacking rolled steel, coils and other round loads Round loads must be blocked or chocked at the bottom to prevent the whole stack rolling away. Every round load must be blocked. Each layer of the stack must be one unit less than the layer below. The stack will then resemble a pyramid. Stacking timber When stacking shorter lengths of timber place the alternate layers at right angles. This is called pigstying. Bundles of timber must be strapped and have dunnage under and between the bundles. When stacks are high they must be straight and set on level beds. Check for movement in the ground after rain. Ladders must be provided for access to the top of high stacks. 36 13. PERSONAL PROTECTIVE EQUIPMENT (PPE) $SBOFESJWFSTBOEEPHHFSTPGUFOIBWFUPXFBSIFMNFUT HMPWFT FZFQSPUFDUJPO GBDFNBTLTBOESFTQJSBUPST and steel capped boots to protect themselves from injury. It is the responsibility of your employer to provide the necessary protective equipment. It is the responsibility of doggers or crane drivers to wear and use the equipment properly where and when necessary. Safety helmets Safety helmets with chin straps must be worn wherever there is a risk of objects falling from above and on any work site where the hard hat sign is displayed. Helmets should comply with AS 1801 Industrial safety helmets. Gloves Wear close fitting pigskin gloves to protect hands from: t )FBUBOEBCSBTJPO t .PMUFONFUBM t 4IBSQFEHFT 4QFDJBMQVSQPTFHMPWFTNBZCFSFRVJSFEGPSQSPUFDUJPOBHBJOTUDIFNJDBMTJODMVEJOHBDJET BMLBMJT TPMWFOUT  fats and oils. Eye protection Wear eye protection that conforms to AS 1337 Eye protectors for industrial applications if you are likely to be exposed to: t 1IZTJDBMEBNBHFDBVTFECZoGMZJOHQBSUJDMFT EVTU NPMUFONFUBM t $IFNJDBMEBNBHFDBVTFECZoUPYJDMJRVJET HBTFTBOEWBQPVSTEVTUT t 3BEJBUJPOEBNBHFDBVTFECZoTVOMJHIU WJTJCMFMJHIU JOGSBSFE MBTFS Respiratory protection Wear a face mask that conforms to AS 1716 Respiratory protective devices if you are likely to be exposed to: t 5PYJDHBTFTBOEWBQPVST t *SSJUBUJOHEVTUT TVDIBTTJMJDB Inhalation of some chemical vapours and gases can cause death or a wide range of unpleasant symptoms including narcosis and headaches. Common dusts such as silica can cause lung disease later in life and is found wherever there is FYDBWBUJPO JFCVJMEJOHTJUFT SPBEXPSLT UVOOFMMJOHBOENJOJOH 37 Hearing protection Hearing damage is likely if you are exposed to long periods of industrial noise above 85 decibels. This is the noise level of a large truck or loader. A chainsaw for example has a noise level of about 92 decibels. If you think it is likely that you are being exposed to dangerous noise levels ask your employer to provide you with hearing protectors complying with AS 1270 Acoustics – Hearing protectors. Footwear $IPPTFCPPUTXIJDIBSFDPNGPSUBCMF HJWFNBYJNVNHSJQBOEHJWFQSPUFDUJPOGSPNQJODIJOH KBNNJOH and crushing. A range of lightweight flexible boots with steel or plastic caps is available that comply with AS-2210 Safety footwear. Sun protection 5PQSFWFOUQFSNBOFOUEBNBHFDBVTFECZVMUSBWJPMFUSBZTBMXBZTXFBSBIBU MPOHTMFFWFT MPOHUSPVTFST and use UV cream when working outside. Know the location of the first aid room and the nearest first aid kit. There should be a first aid kit on every floor of a multi-storey building site or within 100 metres of any part of the workplace. The standard first-aid symbol in Australia is a white cross on a green background. First-aid kits on construction sites should have a carrying handle. There should be a notice near to the first-aid room with the name(s) of those in the workplace who hold an approved occupational first-aid certificate. It is recommended that riggers take the time to do an approved first-aid certificate course. First aid Crane drivers work in a high risk industry. Not only are there many minor injuries but there are also TFSJPVTJOKVSJFTXIFSFUIFJOKVSFEQFSTPOXJMMOFFEGJSTUBJEUPSFTUPSFCSFBUIJOH IFBSUCFBUPSUPTUFN blood flow. 38 14. COMMUNICATION Two-way radios Crane drivers must communicate by two-way radio when they are out of earshot and line of sight from the dogger. It is important that the two-way system provides clear and immediate signals without interference. There are two types of two-way radio: conventional and trunked. Conventional radio Great care is taken when allocating frequencies to make sure that there are no other operators using the same frequency in the area. Always use a good quality system from a reputable company with a properly allocated frequency for the area. Interference on your frequency can be a safety hazard. If there is continual interference have the system checked or a new frequency allocated. Trunked radio Trunked radio is a computer controlled two-way system that locks other radio users out of your frequency. No other operator can cut in and overpower your signal. With trunked radio it is possible to have several separate groups on one building site communicating by radio without interfering with each other. Trunked radio is recommended for large worksites. Directions for crane drivers Doggers must give crane drivers clear verbal signals when directing crane movements. The noise of the crane motor and distortion over the radio can make it difficult for the crane driver to hear directions. The following are the standard directions for crane drivers from doggers: Hook movement “Hook up” & “Hook down” Stopping “Stop” 39 Speak clearly and say the name of the part of the crane to be moved first - then the direction of movement. Creep speed: Appropriate hand signal for motion with hand opening and close 40 15. FLEXIBLE STEEL WIRE ROPE FSWR is constructed of wires and strands laid around a central core. In the illustration below there are 19 wires to the strand and 6 strands around the core making up the rope. *UJTJNQPSUBOUOPUUPDPOGVTFXJSFTBOETUSBOETMGBTUSBOEJTCSPLFO UIFSPQFJTVOVTBCMF"TJOHMF broken wire is not as important. The core can be: Fibre Core (FC) or Independent Wire Rope Core (IWRC) The tensile strength of FSWR ranges from 1220 megapascals (MPa) to 2250 MPa. The most commonly used tensile strengths are 1770 MPa and 1570 MPa. " TJYTUSBOETPGXJSFTFBDI JTUIFNJOJNVN'483DPOTUSVDUJPOUIBUDBOCFVTFEGPSTMJOHT Size The size of a rope is determined by its diameter. The smallest diameter FSWR that can be used for lifting is 5 mm. 41 Lay Lay is the direction the wires are formed into strands and the strands are formed into the finished rope. The strands can be laid either left or right around the core. In left hand lay the strands are laid anticlockwise and in right hand lay they are laid clockwise. Ordinary Lay is where the wires are laid in the opposite direction to the strands. Lang’s Lay is where the wires are laid in the same direction as the strands. There is therefore: Right hand ordinary lay – RHOL Left hand ordinary lay – LHOL Right hand Lang’s lay – RHLL Left hand Lang’s lay – LHLL Lay does not affect the working load limit of the rope but it does determine characteristics such as the spin of the rope. Most rope available in Australia for lifting is right hand lay. Inspection and discard It is important to check all rope for wear and tear before use. Rope can deteriorate due to several factors. 5IFTFGBDUPSTJODMVEFBCSBTJPO GBUJHVF DPSSPTJPO TUSFUDIJOH GSPNPWFSMPBEJOHBOETIPDLMPBEJOH BOE mechanical damage. When inspecting: t %FUFSNJOFUIFDPOTUSVDUJPOBOEMBZPGUIFSPQF t $IFDLGPSTJHOTPGTUSFUDIJOH t $IFDLUIFXIPMFSPQFGPSCSPLFOXJSFT8IFSFCSPLFOXJSFTBSFQSFTFOUDPVOUUIFOVNCFSPGCSPLFO wires in a length of rope eight times the rope diameter. The total number of broken wires in a length PGYEJBNFUFS NVTUOPUFYDFFEPGUIFUPUBMXJSFT 42 For example: In a 6 x 24 rope (6 strands of 24 wires) the total number of wires is 144. The diameter of the rope is 12mm. Length of rope to inspect = 12 (mm) x 8 = 96mm Number of wires = 6 x 24 = 144 PG  XJSFT Therefore: 14 broken wires in a 96mm length would indicate that the rope is unfit for use. There are also many new types of rope construction for special purposes. Manufacturers will advise about the best type of rope for a particular application. Discard FSWR sling if there is: t "TJOHMFCSPLFOXJSFCFMPXBUFSNJOBMGJUUJOHPSBNBDIJOFTQMJDF t "CSBTJPOBOEDPSFDPMMBQTF t $PSSPTJPO3FEPYJEFQPXEFSBOEMPPTFBOETQSJOHZXJSFTDBOJOEJDBUFTFSJPVTDPSSPTJPO$IFDLUIF valleys between the wires for corrosion beneath the surface. t ,JOLTPSGSBDUVSFTGSPNCFOEJOHPSSFFWJOH t $SVTIFEPSKBNNFETUSBOET t #JSEDBHJOH5IJTJTXIFSFUIFTUSBOETMPPTFOGSPNUIFJSQSPQFSUJHIUMBZ*UDBOCFDBVTFECZSPUBUJPO of the end of a rope or a sudden release from high loading. It is often found in Lang’s Lay. t )JHITUSBOEJOH5IJTPDDVSTXIFSFUIFSFIBTCFFOGBVMUZXIJQQJOHPGUIFSPQFFOETBOEBTUSBOEIBT slipped around the lay and projects above the surface. t "MTPDIFDLTQMJDFTGPSEBNBHF UVDLT DPSSPTJPOBOEESBXJOHPVU/FWFSBMMPXBTQMJDFUPQBTT BSPVOEBTIBSQPCKFDU SFNBJOJOUIFAOJQPGBSFFWFETMJOHPSCFQVMMFESPVHIMZGSPNVOEFSPS through an object. 43 t $IFDLUIFUBMVSJUPSTXBHFETQMJDFTGPSGBUJHVF DPSSPTJPOBOECSPLFOTUSBOETXIFSFUIFSPQF enters a splice. Reject a rope where there is one broken wire immediately above or below a talurit or swaged splice. 44 1. Mechanical damage due to rope movement over sharp edge projection whilst under load. 6. Typical wire fractures as a result of bend fatigue. 2. Localised wear due to abrasion on supporting structure. Vibration of rope between drum and jib head sheave. 7. Wire fractures at the strand, or core interface, as distinct from ‘crown’ fractures, caused by failure of core support. 3. Narrow path of wear resulting in fatigue fractures, caused by working in a grossly oversize groove, or over small support rollers. 8. Typical example of localised wear and deformation created at a previously kinked portion of rope. 4. Severe wear in Lang’s Lay, caused by abrasion at cross-over points on multilayer coiling application. 9. Multi-strand rope ‘bird caged’ due to tortional unbalance. Typical of build-up seen at anchorage end of multi-fall crane application. 5. Severe corrosion caused by immersion of rope in chemically treated water. 10. Protrusion of IWRC resulting from shock loading. Maintenance The lubrication applied to the rope when it is manufactured does not last the working life of the rope. Without lubrication a rope will be subject to greater internal friction. The frequency of lubrication is determined by the operating conditions. High speed heavy duty operation and wet or corrosive conditions both call for more frequent lubrication. Scrub or scrape free rust and examine for lack of lubrication. (Do not use a wire brush). Discard the rope if there is evidence of more than superficial corrosion. *GBSPQFJTFODSVTUFEXJUIEJSUBOEHSFBTF TDSVCDMFBOBOEBQQMZPJM"NFEJVNWJTDPTJUZCMBDLPJM is suitable. A shock load can lessen the WLL without signs of wear being immediately evident. If you are in doubt have it tested by the manufacturer or a competent testing organisation. When using FSWR: t "WPJESFWFSTFCFOET t 6TFTVJUBCMFQBDLJOHUPQSPUFDUUIFSPQFGSPNTIBSQFEHFT t %POPUFYQPTFXJSFSPQFUPUFNQFSBUVSFTFYDFFEJOH×$ t %POPUMJGUXJUIXJSFSPQFMFTTUIBONNEJBNFUFS t %POPUVTFBSPQFUIBUTIPVMECFEJTDBSEFE t %POPUVTF-BOHT-BZVOMFTTUIFFOETBSFGJYFEUPQSFWFOUUIFSPQFVOMBZJOH t %POPUBMMPXLJOLTPSLOPUTUPEFWFMPQ Storage 4UPSFXJSFSPQFDMFBSPGUIFHSPVOEJOBDMFBO ESZQMBDF Make sure that wire rope is not in contact with corrosive substances when it is stored. Make sure that wire rope is properly lubricated before storage to minimise the risk of corrosion. 45 16. SHEAVES AND DRUMS FOR FLEXIBLE STEEL WIRE ROPE Sheaves Sheaves are used in pulley systems to gain a mechanical advantage. Flare angle and groove depth 5IFHSPPWFEFQUIPGBTIFBWFTIPVMEOPUCFMFTTSPQFUIBOUJNFTUIFSPQFEJBNFUFS)PXFWFS JGUIF rope is positively prevented from leaving the groove the minimum depth of the groove can be equal to the rope diameter. The sheave groove sides should have a flare angle of a minimum of 42° and a maximum of 52°. The round grooves should be slightly larger than the nominal diameter of the rope. Grooves which are too large will flatten the rope. Grooves too small will pinch the rope and the extra friction can cut it to pieces. Sheaves should have a smooth finish with flared edges which are rounded-off. Sheave diameters The table below gives sheave diameters and safety factors for types of work: 46 Caution:.PEFSODSBOFTBOEIPJTUTBSFDPNQMFYFOHJOFFSJOHFRVJQNFOU BOENBOZIBWFTQFDJBM construction luff and hoist wires. It is essential that the sheaves which were designed for a particular crane or hoist are used for that purpose. *UJTBMTPFTTFOUJBMUIBUXIFOBSPQFJTSFQMBDFE UIFSFQMBDFNFOUJTUIFTBNFEJBNFUFSBOEDPOTUSVDUJPO and that the sheave system is thoroughly checked to ensure that any damaged or worn grooves likely to ruin the new rope are repaired or replaced. Inspection Sheaves should be inspected regularly. Pay particular attention to the sheave groove and flange. Any cracks or chips on the flange can cut the wire as it lays into the groove. 5IFHSPPWFTIPVMECFDIFDLFEGPSXFBSXIJDIIBTSFEVDFEUIFHSPPWFEJBNFUFS HJWJOHBOVOFWFOCFBSJOH surface for the wire. All sheaves should be checked for lubrication. Badly lubricated sheaves cause extra friction in the system and wear on the sheave pin and bearing. The pin should be prevented from rotating with the sheave. Some sheave pins only have a small cotter pin which fits into a recess on the cheek plate. The cotter pin sometimes shears and allows the pin to turn with the sheave. Rotating pins are dangerous as they turn and can cut through the cheek plate. A ‘jockey sheave’ is sometimes used as the first diverting sheave to reduce the fleet angle. This sheave fits on an extended pin to allow it to slip from side to side reducing the fleet angle. The jockey sheave pin should be kept well greased and free from grit and dirt to allow the sheave to slide across the pin. Drums %SVNTBSFUIFQVMMJOHNFDIBOJTNXIJDISPUBUFT IBVMTJOBOETUPSFTTVSQMVTSPQF5IFCSBLJOH mechanism is connected to either the drum or the gearing which is joined to the drive mechanism. The rope should lay neatly on the drum and not be bunched up. There should be a minimum of two full turns on the drum at all times. The rope must be anchored to the drum with a fixed mechanical anchorage. 47 Be aware of the danger of not properly tightening an anchorage. Do not rely on the frictional grip from the two turns on the drum. The top layer on a multi-layered drum must not be closer than two rope diameters to the top of the flange when the drum is full. Drum capacity Fleet angles The maximum fleet angle is measured from the centre of the drum to the centre of the first diverting sheave then back to the inside flange at the middle of the drum. The fleet angle for a grooved drum is 5° and for an ungrooved drum is 3°. To achieve these angles the distance from the drum to the first diverting sheave must be a minimum of: t UJNFTIBMGUIFXJEUIPGUIFESVNGPSBOVOHSPPWFEESVN t UJNFTIBMGUIFXJEUIPGUIFESVNGPSBHSPPWFEESVN Example 1: Width of the grooved drum = 1 metre 12 x 1 x 0.5 = 6 Therefore the sheave must be 6 metres from the drum. Example 2: Width of the ungrooved drum = 1 metre 19 x 1 x 0.5 = 9.5 Therefore the sheave must be 9.5 metres from the drum. 48 If the fleet angle is too large or the distance between the drum and the first lead or diverting sheave JTUPPTIPSU UIFSPQFXJMMOPUMBZOFBUMZPOUIFESVNBOEXJMMDSFBUFTFWFSFXFBSPOUIFSPQFBOEUIF sheave flange. Effect of fleet angle on spooling. 49 17. CHAIN Although chain is from 5 to 6 times heavier than FSWR of the same lifting capacity it is more durable. It can withstand rough handling and can be stored without deterioration. Types of lifting chain t .JMETUFFMTUSFTTSFMJFWFEDIBJOTUBNQFE- t )JHIUFOTJMF RVFODIFEBOEUFNQFSFEDIBJOoTUBNQFE1 t )JHIFSUFOTJMF RVFODIFEBOEUFNQFSFEDIBJOCSBOEFE5   18# PS$.BOE HA800 alternately. t 7FSZIJHIUFOTJMF RVFODIFEBOEUFNQFSFEDIBJOCSBOEFE 7PS High Tensile and Very High Tensile (Grade T. 80 and 100) are used extensively for lifting. Very little low HSBEFDIBJOJTVTFEGPSMJGUJOH.PTU JGOPUBMM DIBJODPNQPOFOUTBSFBMTP)JHI5FOTJMFTUSFOHUI (SBEF5 or 800) and are branded to show grade and chain size. *GEPHHFSTEPOPUVOEFSTUBOEUIFHSBEFNBSLJOHPGBDIBJO UIFZTIPVMEDIFDLXJUIUIFNBOVGBDUVSFSPS the manufacturer’s supplier for clarification. Caution: Industrial lifting chain is not normally sold through general hardware outlets. Chain from general hardware outlets is usually unsuitable for industrial lifting. Look for the grade markings Safe working loads for slings of special alloy chain (Marked “C.M.”, “A”, “T” or 8). 50 Safe use and maintenance Do not use a chain that is 5.5mm diameter or less for lifting. A chain sling is only as strong as its weakest link 8IFONBLJOHVQBDIBJOTMJOH BMXBZTVTFDIBJO IPPLT MJOLT IBNNFSMPDLTBOEDPVQMFSTPGUIFTBNF grade and WLL and that are in a good state of repair. Do not lift a load heavier than the WLL of the chain. %POPUVTFBDIBJOJOXIJDIUIFMJOLTBSFTUSFUDIFE MPDLFEPSEPOPUNPWFGSFFMZ %POPUVTFDIBJOUIBUJTHPVHFEPSXPSONPSFUIBOPGUIFEJBNFUFS %POPUUXJTU LJOLPSLOPUDIBJO Do not drop a chain from a height. Do not roll loads over a chain. %POPUVTFBDIBJOXJUIBMJOLUIBUJTDSBDLFE PSUIBUIBTCFFOXFMEFEPUIFSUIBOCZUIFNBOVGBDUVSFS Use protective padding when using chain around sharp corners. Do not attempt to use chain when the temperature exceeds 260° unless heat reduction charts are used. Inspection and discard lnspect your chain slings regularly. If necessary clean the chain before inspection. MOTQFDUFBDIMJOLGPSTJHOTPGXFBS UXJTUJOH TUSFUDIJOH OJDLTPSHPVHJOH Links that are stuck together show that the chain has been stretched. Cracks can be found by dusting chain with fine powder. Dust any link that is suspect and then blow the loose particles away. Dust particles left will be lodged in any cracks making them more visible. Magnetic particles can also be used. Any worn links should be measured for degree of wear which must not exceed that allowed for by the manufacturer. Measure the links to check for wear 51 5IFNBYJNVNBMMPXBCMFDIBJOXFBSJT 5IFNBYJNVNBMMPXBCMFFMPOHBUJPOPGBDIBJOJT 5IFNBYJNVNJODSFBTFJOIPPLPQFOJOHJTPGUIFPSJHJOBMUISPBUPQFOJOH 5IFNBYJNVNBMMPXBCMFXFBSJOUIFCJUFPGBIPPLJT Inspect upper and lower terminal links and hooks for signs of wear at their load-bearing points and for any signs of distortion. lnspect links and couplings for signs of wear at their load bearing points and for excessive play in the load pin between the body halves. Withdraw any chain from service immediately if it has defects. Clearly mark the chain with a tag stating that it must not be used until it has been inspected by the manufacturer. Destroy any chain that cannot be repaired. If the chain is not tagged or properly stamped it must be removed from service. Enter all inspection details on an inspection record card. 52 18. FLAT WEBBING AND ROUND SYNTHETIC SLINGS Flat webbing and round synthetic slings are used for lifting where it is necessary to protect the load from EBNBHFBOEGPSQSPUFDUJPOGSPNFMFDUSJDBMIB[BSET5IFZBSFNBEFGSPNOZMPO QPMZFTUFS QPMZQSPQZMFOFPS aramid polyamide. Each sling must be labelled with the WLL. Round synthetic slings Types of synthetic slings and fittings Inspection Synthetic slings must be inspected before each use. They must also be inspected at least once every three months. If a sling is subject to severe conditions the inspections should be more frequent. Send each sling for a proof load test at least every 12 months. Look for: t "OZFYUFSOBMXFBSTVDIBTBCSBTJPOPSDVUTBOEDPOUVTJPOT t *OUFSOBMXFBSXIJDIJTPGUFOJOEJDBUFECZBUIJDLFOJOHPGUIFTMJOHPSUIFQSFTFODFPGHSJUBOEEJSU t %BNBHFUPBOZQSPUFDUJWFDPBUJOHPGUIFTMJOH t %BNBHFDBVTFECZIJHIUFNQFSBUVSFT TVOMJHIUPSDIFNJDBMT JOEJDBUFECZEJTDPMPVSBUJPO  t %BNBHFUPUIFMBCFMPSTUJUDIJOH t %BNBHFUPUIFFZFTPSBOZUFSNJOBMBUUBDINFOUTPSFOEGJUUJOHT t 8IFSFUIFTMJOHJTDPWFSFECZBTMFFWF UIFTMFFWFNVTUDPWFSUIFTMJOHGPSUIFGVMMMFOHUIGSPN eye to eye. Discard a synthetic sling if: t 5IFMBCFMIBTCFFOSFNPWFEPSEFTUSPZFE t 5IFSFJTBOZEBNBHFUPUIFTMFFWFPSQSPUFDUJWFDPBUJOH t "OZMPOTMJOHDPNFTJOUPDPOUBDUXJUIBDJE t "QPMZFTUFSTMJOHDPNFTJOUPDPOUBDUXJUIBMLBMJOFTVCTUBODFT t "QPMZQSPQZMFOFTMJOHDPNFTJOUPDPOUBDUXJUIBOPSHBOJDTPMWFOUTVDIBTQBJOU DPBMUBSPS paint stripper. t 5IFSFBSFBOZWJTJCMFDVUTPOUIFTMJOH 53 /#"OZMPOTMJOHXJMMMPTFNPSFUIBOPGJUTTUSFOHUIXIFOJUJTXFU After six months continuous exposure to sunlight send a sling in for testing. Synthetic slings must be stored: t *OBDMFBO ESZ XFMMWFOUJMBUFEQMBDF t "XBZGSPNUIFHSPVOEPSGMPPS t "XBZGSPNEJSFDUTVOMJHIU VMUSBWJPMFUMJHIUBOEGMVPSFTDFOUMJHIUT t "XBZGSPNFYUSFNFTPGIFBU t "XBZGSPNTPVSDFTPGJHOJUJPO t "XBZGSPNBUNPTQIFSJDPSMJRVJEDIFNJDBMT t "XBZGSPNUIFQPTTJCJMJUZPGNFDIBOJDBMEBNBHF The working life of synthetic slings will be shortened if exposed to any of the above. (a) Damaged sleeve (b) Some damage to load-bearlng fibres (c) Badly damaged sleeve (d) Load-bearlng fibres have been cut (e) Cut load-bearlng fibres (f) Broken load-bearing yarn (g) The use of hooks that are too narrow has damaged the eye of the sling (h) Burn damage to sleeve and loadbearlng yarn (i) Surface wear evident by furry surface Examples of extreme damage to flat synthetic-webbing slings. 54 19. FIBRE ROPE 'JCSFSPQFJTOPUXJEFMZVTFEGPSMJGUJOH*UEPFTOPUIBWFUIFTUSFOHUIPSWFSTBUJMJUZPG'483 DIBJOPS synthetic slings. Do not use a fibre rope that is less than 12mm for lifting. It is most commonly used as a tagline for guiding or steadying a load because it is flexible and nonconductive. Fibre rope taglines must be at least 16 mm in diameter. Maintenance Keep fibre rope neatly coiled when stored and protected from: t GBMMJOHPCKFDUT t GJSFBOEFYDFTTJWFIFBU t BDJETBOEPUIFSDIFNJDBMT t TQBSLTBOENPMUFONFUBM t XBUFSBOESVTU t TBOEBTIFTBOEEJSU t SBUT NJDF XIJUFBOUTBOEDPDLSPBDIFT Inspection When inspecting fibre rope look for: t 4JHOTPGCSJUUMFOFTT DIBSSJOHPSCSPXOEJTDPMPVSBUJPOEVFUPFYDFTTJWFIFBU t "EJSUZHSFZDPMPVS MPTTPGXFJHIUBOECSJUUMFOFTTEVFUPTVOSPU t 4JHOTPGNJMEFXCZPQFOJOHUIFTUSBOETBOEMPPLJOHBOETNFMMJOHGPSNPVME t %JTDPMPVSBUJPOBOEQPXEFSZGJCSFTEVFUPUIFFGGFDUTPGBDJEBOEPUIFSDPSSPTJWFBHFOUT t "EFDSFBTFJOEJBNFUFSBOEBOJODSFBTFJOUIFMFOHUIPGUIFMBZEVFUPPWFSMPBEJOH t 0OFTUSBOETUBOEJOHPVUIJHIFSUIBOUIFPUIFST$BMMFEIJHITUSBOEJOH JUDBOCFDBVTFECZGBVMUZ splicing or whipping. All of the above defects make the rope unfit for lifting purposes. 55 20. ACCESSORIES From the hook to the load the lifting gear can be made up of many parts. The WLL of lifting gear is only as great as the part of the sling with the lowest WLL. For example if the WLL of: the hook is 2 tonnes the shackle is 2 tonnes the ring is 1 tonne the rope is 2 tonnes then the WLL for the lift is 1 tonne. Always use accessories with at least the WLL of the sling to avoid errors. Hooks )PPLTNBZCFGJUUFEXJUIBTBGFUZDBUDI QBSUJDVMBSMZXIFSFUIFSFJTBDIBODFPGUIFTMJOHTCFJOHEJTQMBDFE A wide variety of hooks are available for use with chain slings. Hooks are mostly 80 grade alloy steel and are stamped with the WLL. Make sure when selecting a hook for a chain sling that the hook has at least the same WLL as the chain. .BLFTVSFUIBUUIFPQFOJOHJTXJEFFOPVHIUPBDDFQUUIFMBSHFTUSPQF SJOH MJOLPSTIBDLMFUIBUIBTUPCF placed over the hook. .BLFTVSFUIBUUIFJOTJEFPGUIFIPPL PSACJHIUJTSPVOEFETPUIBUJUEPFTOPUDVUJOUPPSEBNBHFTMJOHT and fittings. Crane hooks must freely rotate at all times. If the load exceeds two tonnes there must be a roller thrust bearing or ball between the trunnion and nut. *GBDIBJOIPPLPQFOJOHJTTUSFUDIFENPSFUIBOJUNVTUCFXJUIESBXOGSPNTFSWJDF%JTDBSECFOUPS distorted hooks. Do not attempt to weld or repair them. Hooks must not have any fittings welded to them. 56 Rings "SJOHNVTUIBWFBUMFBTUUIFTBNF8--BTUIFDIBJO IPPLBOEPUIFSQBSUTPGBTMJOH %JTDBSEBOZSJOHXIJDIIBTCFFOTUSFUDIFECZNPSFUIBO%POPUQMBDFBSJOH PSTIBDLMFPSFZFCPMU  over a crane hook unless it hangs freely. Shackles There are two main types of shackle – ‘Dee’ and ‘Bow’. All shackles used for lifting must be stamped with the WLL. Do not use a shackle that does not have the WLL marked. Make sure that the WLL of the TIBDLMFJTBUMFBTUBTHSFBUBTUIFDIBJO MJOLTBOESJOHTJOUIFTMJOHZPVBSFVTJOH Do not use a bolt and nut in place of the proper shackle pin. A bolt that does not fit tightly is likely to bend and break. %JTDBSEBOZTIBDLMFUIBUJTXPSOJOUIFDSPXOPSQJOCZNPSFUIBO%POPUVTFBTIBDLMFUIBUJT CFOU EFGPSNFEPSEBNBHFE%FGPSNFETIBDLMFTQSPCBCMZIBWFNJDSPTDPQJDDSBDLTXIJDIDBOMFBEUP complete failure during lifting. To prevent jamming tighten shackle pins finger tight and then release a quarter turn. Use washers or ferrules to centre thimbles and hooks on the shackle pin to prevent unnecessary strain. Where several sling eyes are to be connected to a lifting hook use a large bow shackle so that all the sling eyes can be safely accommodated. The pin must rest on the hook and the sling eyes in the bow section. Do not use a screw shackle where the pin can roll under the load and unscrew. Eyebolts There are collared and uncollared eyebolts. Do not use uncollared eyebolts for any lifts other than vertical lifts because they can break off. A typical use for an eyebolt is for lifting pre-cast concrete panels which have ferrules cast into them. Make sure that eyebolts are securely screwed into the ferrule or nut before use. Do not lift if the ferrule is loose. Do not hammer an eyebolt to tighten. Use a podger bar. Make sure that the eyebolt and ferrule has a ‘solid feeling’. Do not put a sling through two or more eyebolts. Use two slings attached to the eyebolts with shackles. Do not attach slings to eyebolts with hooks because the hook is usually too small. 57 Make sure the eyebolts are screwed down tightly so that the collar is in contact with the load. Here the strain on the eyebolt is doubled Use of collared eyebolts Swivels Swivels both prevent chain or rope from twisting and allow it to untwist. Swivels can have two eyes (eye and eye swivel) or have an eye attached to a shackle (clevis and eye swivel). Turnbuckles "UVSOCVDLMF PSSJHHJOHTDSFX JTVTFEGPSUFOTJPOJOH'4835IFDPOWFOUJPOBMUVSOCVDLMFIBTUXPUISFBET  POFMFGUIBOEBOEPOFSJHIUIBOE XIJDIXJMMJODSFBTFUIFUFOTJPOPGSPQFBTUIFZBSFTDSFXFEUPXBSET each other. They can have either eyes or clevises at each end. Only suspend loads with turnbuckles with eyes or clevises at each end not hooks. Turnbuckles must have the WLL marked. Do not lift if it is not marked. 8IFOJOTQFDUJOH DIFDLGPSXFBSBOETMBDLOFTTJOUIFTDSFXUISFBEBOENBLFTVSFUIBUUIFUISFBEJTGVMMZ engaged. Otherwise inspect in the same way as chain. 58 APPENDIX (i) – Areas and volumes Areas Area of a square = length x width For example: 2m x 2m = 4 square metres Area of a rectangle = length x width For example: 2m x 5m = 10 square metres 2 Area of a circle = diameter x .79 For example: 3m x 3m x .79 = 7.1 square metres 3 3 59 Area of a triangle = base x height ÷ 2 For example: 3m x 3m ÷ 2 = 4.5 square metres Volumes Volume of a cube = length x height x width For example: 3m x 3m x 3m = 27 cubic metres Volume of a rectangular solid = length x height x width For example: 2m x 4m x 6m = 48 cubic metres 60 Volume of a cone or pyramid = area of base x height ÷ 3 For example (pyramid): 2m x 2m x 1.5m ÷ 3 = 2 cubic metres For example (cone): 3m x 3m x .79 x 4m ÷ 3 = 9.5 cubic metres 3 Volume of a sphere = diameter x 0.53 For example: 3m x 3m x 3m x 0.53 = 14.3 61 Calculating the weight of a load 5PDBMDVMBUFUIFXFJHIUPGBMPBE JGJUJTVOLOPXO ZPVNVTUNVMUJQMZUIFWPMVNFPGUIFMPBECZUIFVOJU weight of the material. For example: A rectangular stack of hardwood 3 metres long – 1 metre high – 0.5 metre across. Volume of rectangular solid = length x width x height 3m x 1m x .5m = 1.5 cubic metres Unit weight of hardwood is 1120 kgs per cubic metre 1.5 x 1120 = 1680 Therefore the total weight of the load is 1680 kgs. 62 APPENDIX (ii) – Tables of masses Acid (crated maximum) 200 kg Grease (44 gal) 200 litre "MF CFFS MJUSF 250 kg (ZQTVN DVN 2.3 t 2.7 t (ZQTVN CBH 50 kg "MVNJOJVN DVN Aluminium ingot 5-15 kg "TCFTUPTDFNFOUTIFFU QMBJO NYN 18 kg 200 kg Hardwood (see Timber) )FSNBUJDPSF DVN 5.4 t "TIFT DPBM DVN 800 kg )FNQ CBMF 300 kg "TQIBMU MJUSF ESVN 200 kg *DF DVN 930 kg #BSCFEXJSF DPJM 50 kg #MVFNFUBM DVN 2.0 t *SPO DBTUN 7.25 t *SPO QJH LH *SPO PSF DVN Beer (see Ale) #JUVNFO MJUSF ESVN 200 kg #PMUT WBSJPVT CBH 50 kg #SBTT DVN 8.5 t #SJDLT DPNNPO   4t +VUF CBMF 150 kg Kerosene (44 gal) 200 litre 200 kg -FBE DVN 11.4 t -FBE NNUIJDL TRN 34 kg 36 kg #SPO[F DVN 8.5 t -FBE QJHPSJOHPU $BTUJSPO DVN 7.2 t -JNF TUPOF CBHT $BTUTUFFM DVN 7.9 t -JNF TUPOF DVN $MBZ DVN 1.9 t -JNF IZESBUFE CBH $FNFOU CBH 20 or 40 kg $PBM DVN 5.4t -JNF IZESBUFE CBHT 1t 2.6 t 22 kg 1t /BJMT DBTF 50 kg $PODSFUF DVN 2.4 t /FUUJOH XJSFNSPMM N 25 kg $PQQFS DVN 9.0 t 0JMT BMMUZQFT HBMESVN MJUSF $PQQFS NNUIJDL TRN %PPST  864 kg 27 kg 1BJOU MJUSF 200 kg 4 kg 1BMJOHT )8NTBXO  1t %PHTQJLFT  50 kg 1BMJOHT )8NTBXO  1t %SVNT FNQUZMJUSF 13 kg 1BSUJDMFCPBSENNUIJDL TRNFUSF &BSUI DVN 'BU UBMMPX FUD HBMCBSSFMT MJUSF 'FODJOHXJSF DPJM 'JCSPVTQMBTUFS TRN Fibre board. sq m 1t 1.9 t Petrol (44 gal) 200 litre 200 kg Pig iron 50 kg Pipes – 9 kg 0.6 kg Flat – NNUIJDL TRNFUSF  NNUIJDL TRNFUSF 7 kg 11 kg 200 kg 50 kg Stoneware – Fibro cement sheets –  12 kg  100 mm 55 m 1t 150 mm 32 m 1t 225 mm 20 m 1t 300 mm 15 m 1t $BTUJSPO NMPOH MJOFEo 80 mm nominal inside dia LHN  TUBOEBSE TRNFUSF 11 kg 100 mm pipe LHN  EFFQDPSSVHBUJPOT TRNFUSF 12 kg 150 mm pipe LHN 200 mm pipe LHN 26 kg 225 mm pipe LHN 1 kg 300 mm pipe LHN Corrugated – Compressed –  NNUIJDL TRNFUSF 'JTICPMUT NNEJB 'JTIQMBUFT IPMF 13 kg 'JTIQMBUFT IPMF 18 kg (MBTT 0NNUIJDL TRNFUSF (SBOJUF DVN 4UFFM HBMWBOJTFEo 8 N.B.0.D. 13.5 mm LHN 10 N.B.O.D. 17 mm LHN 7 kg 15 N.B.O.D. 21 mm LHN 27 kg 20 N.B.O.D. 27 mm LHN 2.6 t 25 N.B.O.D. 34 mm LHN Galvanised flat iron 0.5 mm sheet 1.8 m x 90 mm  63  32 N.B.O.D. 42 mm LHN 4DSFXT DBTF 50 kg 40 N.B.O.D. 48 mm LHN 4IBMF DVN 2.6 t 50 N.B.O.D. 60 mm LHN 4JTBM CBMF $PQQFS HJOUFSOBMEJBNFUFSoBQQSPY 12.7 mm O.D. 200 kg 4MFFQFST NNYNNYN LHN 80 kg 4MFFQFSQMBUFT  1t 16 mm O.D. LHN 5BMMPX  HBM MJUSF 200 kg 25 mm O.D. LHN 5BS  HBM MJUSF 200 kg 38 mm O.D. LHN 50 mm O.D. LHN 1JUDIBOEUBS  HBM MJUSF 200 kg 1MZXPPENN NYN 7 kg Plasterboard (Gyprock) 13mm thick – sq metre 27 kg 3BJMT TUFFM NBTTFTBSFCSBOEFEPOTJEF o 5FSSBDPUUB DVN 350 kg 5JMFT .BSTFJMMFT DPODSFUF  375 kg 5JO DVN 7.3 t 5JO JOHPU 32 kg 5JNCFS JSPOCBSL DVN 1.4 t 5JNCFSPUIFSIBSEXPPET DVN 1.1 t 5JNCFS TPGUXPPET DVN HEIGHT mm BASE width mm 157 229 LHN 102 165 LHN 157 146 LHN 8BUFS GSFTI MJUSF 173 140 LHN 8BUFS GSFTI DVN 137 127 LHN 8FBUIFSCPBSET SVTUJDBUFEo 94 94 LHN  65 60 LHN 8PPMQBDLT QBDLBWFSBHF 4BOE CFBDI ESZ DVN 1.8 t 5JMFT .BSTFJMMFT UFSSBDPUUB  640 kg Tubular scaffolding (1½ in bore) – 48 mm O.D. 4.8 mm thick LHN 1.0 kg 1.0 t )BSEXPPE NNYNNYN 1t 150-160 kg 2.0 t ;JOD DVN 7.0 t 4BOE CFBDI XFU DVN 2.3 t ;JOD JOHPU 26 kg 4BOE SJWFS XFU DVN 1.5 t 64 APPENDIX (iii) – First aid Crane operators and doggers work in a high risk industry. Not only are there many minor injuries but there BSFBMTPTFSJPVTJOKVSJFTXIFSFUIFJOKVSFEQFSTPOXJMMOFFEGJSTUBJEUPSFTUPSFCSFBUIJOH IFBSUCFBUPSUP stem blood flow. Know the location of the first aid room and the nearest first aid kit. There must be a first aid kit on every floor of a multi-storey building site or within 100 metres of any part of the workplace. The standard first aid symbol in Australia is a white cross on a green background. First aid kits on worksites should have a carrying handle. There must be a notice near to the first aid room with the name(s) of those in the workplace who hold an approved occupational first aid certificate. It is recommended that crane operators and doggers take the time to do an approved first aid certificate. 65 APPENDIX (iv) – Terms used in this guide DIAMETER: The length of a straight line drawn from one side to the other through the centre of a circle. DOGGER: A person qualified to sling and direct loads. DUNNAGE: Packing under loads. EYEBOLT: Lifting ring. GRADE: The tensile strength of chain. HAMMERLOCK & COUPLERS: Attachable chain links. LOAD FACTOR: The fraction of the safe working load created by a particular slinging method. REEVE: A method of slinging where the sling passes back through itself reducing the safe working load. RING: Chain link. SAFE WORKING LOAD: The maximum load that can be safely lifted by a particular sling or machine. SHACKLES: Attachment for joining a sling to a load or a hook. SHEAVE: A pulley through which steel wire rope moves. 4-*/(-JGUJOHHFBSNBEFGSPNTUFFMXJSFSPQF DIBJOPSTZOUIFUJDT SNIGGING: Dragging a sling or a load. SNOTTER: Fibre rope sling. SPREADER: A beam with a central lifting attachment that reduces the strain on the lifting gear. 48*7&-"SPUBUJOHTMJOHBUUBDINFOUUIBUBMMPXTUXJTUJOHXJUIPVUTQJOOJOHUIFXJSF IPPLPSMPBE TURNBUCKLE: Attachment to increase and hold tension in FSWR or for fine adjustment of load height. 66 APPENDIX (v) – Sample exam questions Below are some of the questions you could be asked in the examination for a Bridge and gantry crane certificate. You can find the answers to the questions in this guide. 1. How much weight can you raise and lower with your crane? 2. The crane hook is branded 20 tonne. The crane bridge is branded 5 tonne. What is the lifting capacity of the crane? 3. When can a crane be slightly overloaded? 4. Where is the main switch for your crane? 5. Can you remove a danger tag from the main switch and close the switch? 6. Before turning on the main switch what must be checked about the collector wires? 7. How often must you check the limit switches? 8. How does the hoist brake work? 9. Where is the cross travel unit or ‘crab’ and what is its function? 10 How many turns of wire must be left on the drum when the hook is at its lowest point? 11. The depth of an open sheave must be how many times the diameter of the wire? 12. What defects must be inspected for in a sheave? 13. Under what circumstances can a dogger ride on a load? 14. When can a load be moved ‘down shop’ over people’s heads? 15. What is the procedure if the crane chaser is receiving an electric shock from the sling or the load? 16. What must you do in the event of an electrical fault in your crane? 17. Why is it important not to snig or drag a load with a crane? 18. How many kilograms are there in one tonne? 19. Show by means of a sketch a circle of 12 mm in diameter. 20. What are the defects that condemn fibre rope? 21. What is the maximum heat that fibre rope can be subject to? 22. What is the formula for working out the WLL of steel wire rope (FSWR)?  6  TFUIFGPSNVMBUPXPSLPVUUIF8--PGB'483 NNEJBNFUFS 24. What are the defects that condemn FSWR? 25. What is the smallest diameter FSWR for supporting loads? 26. What is the maximum heat that FSWR can be subject to? 27. What is the formula for working out the WLL of chain? 28. Use the formula to work out the WLL of a grade 80 chain 20 mm in diameter. 67 29. What is the maximum allowable wear available in the link of a chain? 30. What is the maximum allowable stretch in the link of chain? 31. List the defects that condemn chain? 32. What is the maximum allowable heat that chain can be subject to? 33. What are the brand markings found on grade 80 chain? 34. How do you find out the capacity of synthetic webbing slings? 35. What are the main defects that affect the capacity of synthetic web slings? 36. What happens to the SWL when you reeve or nip a sling around a square load? 37. What happens to the SWL when you reeve or nip a sling around a round load? 38. What is the SWL of two one tonne slings with an angle between of: 60° 90° 120°? 39. What is the capacity of the slings needed to lift with two slings reeved around a 15 tonne round load where the angle between the slings is 60°? 40. What diameter FSWR sling is needed to lift a seven tonne load shackled into a lug? 41. What is the difference between the lifting capacity of a three legged and a four legged sling of the same size? 42. What type of shackle would you use for multiple slings? 43. Must the eyes of a sling rest on the pin or on the “D” of the shackle? 44. What type of eyebolts must be used for attaching multiple slings? 45. Where are uncollared eye bolts used?  8  IBUJTUIFXIJTUMFTJHOBMGPSIPJTUVQ IPJTUEPXO MPXFS TUPQ 47. What must you do if you are signalling to a driver by radio and someone keeps cutting across your channel? 68 Catalogue No. WC00001 WorkCover Publications Hotline 1300 799 003 WorkCover NSW 92-100 Donnison Street Gosford NSW 2250 Locked Bag 2906 Lisarow NSW 2252 WorkCover Assistance Service 13 10 50 Website www.workcover.nsw.gov.au ISBN 0 7310 5159 9 ©Copyright WorkCover NSW 0508