Rigging book

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HAND

RIGGING

BOOK

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FOREWORD

The handling, setting, and

erection of materials

and equipment is a

hazardous occupation. Each

operation presents its own peculiar problems and

no two jobs are

alike. With proper consideration

taken, each job can be performed free

of bodily

harm to the worker and without damage to the

equipment.

This manual has been designed as a reference to

assist in safely applying the basic rigging

equip-ment used in

ment used in

construction work.

The contents of this manual are minimum

requirements. Check with local and country

regulations for stricter

requirements.

The

Hand Rigging Book

contains recommenda-

contains

recommenda-tions for users to consider. The booklet is not

tions for users to consider. The booklet is not

legal advice and should not be relied upon

solely in any given situation. DuPont makes no

express or implied warranty or guarantee as to

the information content of the

Hand Rigging Book

or that

it contains all possible recommendations

concerning safety, health or the environmental

protection. DuPont assumes no liability or

responsibil

ity of

any kind whatsoever

resulting

from the use of

any information contained in this

booklet.

This handbook is issued and maintained

by Engineering’s Facilities Construction

& Support

organization.

All rights reservedreserved. The DuPont Oval Logo . The DuPont Oval Logo and The miraclesand The miracles of science

of science™™_{are registered trademarks or trademarks of}_{are registered trademarks or trademarks of} DuPont or its afﬁliates.

DuPont or its afﬁliates.

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KINK - The making of a loop in the rope so small that it will destroy the lay of the rope. This is one cause of bird-caging and also weakens the strands of the rope. KNOT - The intertwining of the end of a rope with a por-tion of the same rope or another rope of the same size. LAY OF ROPE - A term used to describe the forming (not twisting) of wires or bers into strands and strands into rope.

LIFE NET - A spring-type rope net used directly below an elevated work area to catch any worker who should lose his footing and fall.

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LIFT ANGLE - The angle between an imaginary line vertical to the load to be lifted and an imaginary line between the load and the hoist or tting device.

LINK - A piece of metal forged or formed to make an endless rod with half circle at each end and straight sides between.

LOAD (DEAD) - The total weight of all the suspended rigging.

LOAD (LIVE) - The weight of the object to be lifted. LOAD (TOTAL) - The sum of dead load plus live load. MANILA ROPE - A high-strength ber rope made from manila bers obtained from the abaca or wild banana plant grown in the Philippines.

MOUSED - Securing a wire, strap, rope or cord to close the throat opening of a hook to prevent the sling or

shackle from becoming detached.

OUTRIGGER - A part built or arranged to project

beyond the natural outline of a piece of equipment to provide additional support in preventing the equipment from overturning.

REEVING - The threading of the rope between the blocks in rope blocks and falls.

ROLLERS - Long pieces of hardwood about 7 or 8 inches in diameter (or long pieces of pipe) used to place under heavy pieces of equipment to facilitate rolling along at surfaces.

SHACKLE - A U-shaped or horseshoe-shaped piece of metal provided with a means for applying a bolt or pin through the ends and used to hold several lifting members together; sometimes called a clevis.

SKID - Normally a heavy timber used under heavy machinery or other equipment that is being moved on rollers.

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SLING - A length of wire rope, webbing, synthetic, or chain tted at each end with an eye splice or some other special rope or chain tting and used to tie on to the materials to be lifted.

SOFTENER - Wood or other soft materials placed over the sharp edges of objects to be lifted to keep them

from cutting or damaging the slings making the hitch. SPLICE - The method of permanently attaching two ends of rope together or joining one to the stranding portion of the rope to form an eye in the case of an eye splice.

STRAND - The result of twisting or forming several

bers or wires together. The strands then are formed in a twisted fashion to form a rope.

THIMBLE - A metal-formed piece inserted in the eye of an eye splice to prevent the wear on the rope in the eye splice area.

TURNBUCKLE - A tting used to tighten or loosen the stress on a rope by utilizing right- and left-hand threads at opposite ends and a common threaded centerpiece. WEDGE SOCKETS (beckett) - A socket attachment for the end of wire rope that employs the wedge principle to hold the rope in the socket.

WINCH - A power source for hoisting or moving. Usu-ally consisting of a cable drum with a gasoline-engine drive or with a gear-reduction unit for hand operation. WIRE ROPE CLIPS - A mechanical means of temporar-ily joining two wire ropes together.

WLL - Working Load Limit

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1. WIRE ROPE 1.1 WIRE ROPE INSPECTION

1.1.1 Inspection for handling damage should be made of the exposed turns of coils and reels when wire rope is received from the supplier.

1.1.2 Wire rope having been stored three

months or longer should be completely inspected for damage and corrosion just prior to installation. 1.1.3 Many wire ropes are permanently dam-aged by improper handling and use; kinks, twists, and untwisting are the results.

1.1.4 A permanent bend from pulling out a kink seriously damages the rope. These conditions are especially likely to occur when rope is rst unwound from the reel.

1.1.5 All wire rope should be inspected before each use and should be inspected periodically

according to specications; the periodic inspection may require written documentation.

1.2 IN-USE INSPECTION

1.2.1 Frequency - Wire rope should be

inspected at frequent intervals and frayed, kinked, worn, or corroded rope replaced. The frequency of inspection is determined by the amount of use of the rope.

1.2.2 Procedure - The weak points in the rope or the points where the greatest stress occurs should be inspected with great care. In general, examine the rope for worn spots and broken wires. Worn spots will show up as shiny attened spots on the wires. Measure some of these shiny spots. If it appears that the outer wires have been

reduced in diameter by one-fourth, the worn spot is unsafe.

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There may be several points in the rope where broken wires occur. Inspect each point to deter-mine whether it is a single broken wire or several. If several wires are broken next to each other,

unequal load distribution at this point will make the rope unsafe.

Consider the rope unsafe if three broken wires

are found in one strand of 6 x 7 rope or six broken wires are found in one strand of 6 x 19 rope.

1.2.3 Never allow wire rope to operate without lubrication.

1.3 HANDLING

1.3.1 Leather-palm gloves must be used at all times when handling wire rope.

1.3.2 Exposure of wire rope to dirt, grit, water, or corrosive material should be avoided.

1.3.3 Extreme precautions must be taken to avoid kinking wire rope. When a kink has

occurred, the wire rope or the damaged section of the wire rope must be removed from service.

1.3.4 When coiling or uncoiling wire rope, the reel should be reeled or unreeled slowly, in a

straight line, keeping the wire rope taut and free of kinks or large loops that could form kinks.

1.3.5 Wire rope should be stored on reels

whenever possible. When reels are not available it should be stored in coils and hung on a broad support to prevent concentration of the load of the coil on just a small area or a few wire strands.

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1.4 USE

1.4.1 Sudden stresses in wire rope should be avoided. Traveling over rough area with an automotive crane with load suspended or quick acceleration in lifting may cause stresses above the breaking strength of the wire rope.

1.4.2 After installing new wire rope on a crane or other hoisting equipment, the equipment should be operated for about an hour at no load to ensure that it will accommodate itself to the sheaves and drums before the heavy strain is applied.

1.4.3 Avoid crushing forces on wire rope at all times to avoid damage to cores and hidden wires. 1.4.4 Loose ends of wire rope must always be seized to prevent untwisting of wires and strands. 1.4.5 When applying a choker hitch on an object to be hoisted, care should be taken to avoid dam-age to the sling. Use softeners to safely handle objects with sharp corners or edges.

1.4.6 The listed safe load in Table 2 should never be exceeded unless the sling has a

manufacturer’s tag attached and that tag indicates a higher capacity rating.

1.4.7 When lifting at an angle such as with bridle slings, basket and choker hitches, the actual load on the sling parts increases as illustrated in Figure 1. To calculate the total stress implied to the sling by the angle and load, multiply the actual vertical load by the load angle factor listed in Table 1.

1.4.8 When using basket hitches, care should be taken that slings do not slip on the object being lifted.

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1.4.9 Effect of Sling Angle. It is best to use bridle slings with horizontal angles above 45 degrees

from the horizontal. However, at no time should the horizontal angle be less than 30 degrees. 1.4.10 Combined reductions must be considered when using a bridle sling conguration that

incorporates a choker hitch connected to the load being lifted. One reduction will be required for the horizontal sling angle and an additional for the choker hitch. Avoid using choked bridle slings at less than a 60-degree angle from the horizontal. Table 1 shows what happens to the vertical lifting capacity of a sling with a working load limit of 1000 pounds as the angle from the horizontal decreases from 90 degrees (a vertical lift) to 30 degrees (the minimum allowed horizontal sling). As the angle from the horizontal decreases, so does the capac-ity as compared to a vertical pull. Notice that the capacity decreases more rapidly as the horizontal sling angle decreases. For angles of less than 30 degrees from the horizontal, the horizontal forces are actually greater than the vertical lifting force. It is for this reason that the horizontal angle should never be less than 30 degrees.

FIGURE 1

Effect of Sling Angle Examples

Sling Load x Load Angle Factor = Implied Load 90 degree angle: 500 lbs x 1.0 = 500 lbs

60 degree angle: 500 lbs x 1.154 = 577 lbs 45 degree angle: 500 lbs x 1.414 = 707 lbs 30 degree angle: 500 lbs x 2.0 = 1000 lbs

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TABLE 1

Effect of Sling Angle

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It is important to remember as angles from the

horizontal decrease, the implied stresses to all involved equipment (i.e. slings, shackles, eyebolts, hoists, beam clamps) increase. Rigging equipment and hardware must be resized or increased, if necessary, to accommodate this extra loading. DO NOT assume the

equipment component safety factors will accommodate angle-induced overloads. N o r m a l O p e r a t i n g R a n g e C a u t i o n Sling Angle

from Working Load Capacity as a Load Angle Horizontal Limit (WLL) Capacity % of WLL Factor

90 1,000 lbs. 1,000 lbs 100.0% 1.000 85 1,000 lbs. 996 lbs 99.6% 1.003 80 1,000 lbs. 985 lbs 98.5% 1.015 75 1,000 lbs. 966 lbs 96.6% 1.035 70 1,000 lbs. 940 lbs 94.0% 1.064 65 1,000 lbs. 906 lbs 90.6% 1.103 60 1,000 lbs. 866 lbs 86.6% 1.154 55 1,000 lbs. 819 lbs 81.9% 1.220 50 1,000 lbs. 760 lbs 76.6% 1.305 45 1,000 lbs. 707 lbs 70.7% 1.414 40 1,000 lbs. 643 lbs 64.3% 1.555 35 1,000 lbs. 574 lbs 57.4% 1.743 30 1,000 lbs. 500 lbs 50.0% 2.000

Do not use slings at less than a 30-degree angle

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2. WIRE ROPE SLING CAPACITIES TABLE 2 Bridle Hitch Straight Pull Choke Hitch Basket Hitch 10

3. WIRE ROPE CLIP SPLICE

3.1 The number of clips and spacing required per diameter of rope used is given in Table 3. Make sure the saddle grooves on the clips match the lay of the rope.

3.2 Do not use clips made of malleable iron material. 3.3 “U”-bolt clips must be placed on the rope with the “U” bolts bearing upon the short or “dead” end of the rope (Table 3). Properly made, a “U”-bolt clip eye splice develops 80% of the strength of the rope.

3.4 Twin base clips have corrugated jaws on both parts and can be installed without regard as to which

2 leg basket or bridle hitch Wire Rope Sling Both Legs Vertical 60o Angle from Horizontal 45o Angle from Horizontal 30o Angle from Horizontal ¼ 0.56 0.42 1.1 0.97 0.79 0.56 5/16 0.87 0.65 1.7 1.5 1.2 0.87 3/8 1.2 0.93 2.5 2.1 1.8 1.2 7/16 1.7 1.3 3.4 2.9 2.4 1.7 ½ 2.2 1.6 4.4 3.8 3.1 2.2 9/16 2.7 2.1 5.5 4.8 3.9 2.7 5/8 3.4 2.5 6.8 5.9 4.8 3.4 ¾ 4.9 3.6 9.7 8.4 6.9 4.9 7/8 6.6 4.9 13.0 11.0 9.3 6.6 1 8.5 6.4 17.0 15.0 12.0 8.5 1 1/8 10.0 7.8 21.0 18.0 15.0 10.0 1 ¼ 12.0 9.2 24.0 21.0 17.0 12.0 IPS – Improved Plow Steel Grade Wire Rope

IWRC – Independent Wire Rope Core Diameter (inches) Straight Pull Choke Hitch

Working Load Limit in U.S. tons (2000 lbs) of 6x19 and 6x37 IPS IWRC

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installed, twin base clips will develop 90% of the

strength of the rope and cause very little deformation to the wire rope.

3.5 When forming an eye with a thimble, the clip farthest from the eye should be applied rst about four inches back from the end of the dead rope and

tightened evenly. Next, apply the clip close to the toe of the thimble and nger tighten. Space all intermediate clips evenly and nger tighten. Torque all clips evenly to the manufacturer’s recommended setting.

3.6 When making a lapped splice to a stay rope, apply a twin-base clip about four inches from each dead end and tighten evenly.

3.7 After assembly, the rope shall be loaded to the expected working load and the clips re-torqued to the manufacturer’s recommended setting. After approxi-mately one hour of service recheck torque settings on clips again. The wire rope clip torque value shall be checked on a regular basis.

3.8 After using clips on a wire rope, special inspection of the wire rope in the area where the clips are removed should be made. Look for any possible damage to the rope.

3.9 Always apply clips with the U-bolt on the dead end and the saddle of the clip on the live end of the wire

rope. “Never saddle a dead horse.”

3.10 Never use clips to form sling eyes used for overhead lifting.

4. USE OF CHAIN

4.1 For general construction rigging never use a chain when it is possible to use wire rope. The failure of a

single link of a chain can result in a serious accident. Wire rope on the other hand, is frequently composed of 114 wires, all of which must fail before the rope breaks. Wire rope gives you reserve strength and a chance to notice a hazard; chains do not.

4.2 There are certain jobs for which chain is better

suited than wire rope. Chains withstand rough handling, do not knit, are easily stored, have dead exibility, and

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W R O N G R I G H T 12

Figure 2

Joining Wire Ropes

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STEP 4

Apply tension and tighten all nuts to recommended torque.

Right and Wrong Ways of Using Cable Clips

Correct

U-Bolt of all clips on dead end of

rope.

Incorrect Do not stagger clips.

Incorrect U-Bolt of all clips

on live end of rope.

Double Saddle Clips (Flat Grip Clips)

STEP 1

APPLY FIRST CLIP - one base width from dead end of wire rope–U-Bolt over dead end–live end rests in clip saddle. Tighten nuts evenly to recommended torque. STEP 2

APPLY SECOND CLIP - nearest loop as possible–U-Bolt over dead end–turn on nuts ﬁrm but DO NOT TIGHTEN.

STEP 3

ALL OTHER CLIPS - Space equally between ﬁrst two.

STEP 5

Recheck nut torque after rope has been in operation.

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Proper Method of Installing Cable Clips

Figure 3 - Cable Clips

Apply tension Apply tension

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TABLE 3

CABLE CLIPS

N u m b e r o f C l i p s T u r n B a c k p a s t T h i m b l e A p p x . s p a c i n g b e t w e e n c l i p s ( i n c h e s ) R e q u i r e d T o r q u e ( f o o t p o u n d s ) W i r e R o p e D i a m e t e r ( i n c h e s ) T w i n - B a s e U - B o l t T w i n - B a s e U - B o l t M i n i m u m d i s t a n c e - d e a d e n d t o f i r s t c l i p ( i n c h e s ) T w i n - B a s e U - B o l t T w i n - B a s e U - B o l t 1 / 8 N / A 2 N / A 3 1 / 4 1 3 / 8 N / A 2 N / A 4 . 5 3 / 1 6 2 2 4 3 3 / 4 1 5 / 8 2 1 / 8 2 1 / 8 3 0 7 . 5 1 / 4 2 2 4 4 3 / 4 2 2 3 / 4 2 3 / 4 3 0 1 5 5 / 1 6 2 2 5 5 1 / 4 2 3 / 8 3 3 3 0 3 0 3 / 8 2 2 5 1 / 2 6 1 / 2 2 3 / 4 3 3 / 4 3 3 / 4 4 5 4 5 1 / 2 3 3 1 1 1 1 1 / 2 3 1 / 4 4 1 / 8 4 1 / 8 6 5 6 5 5 / 8 3 3 1 3 1 / 2 1 2 3 1 / 2 4 1 / 4 4 1 / 4 1 3 0 9 5 3 / 4 3 4 1 6 1 8 4 7 4 5 / 8 2 2 5 1 3 0 7 / 8 3 4 2 6 1 9 4 3 / 8 7 3 / 8 4 3 / 4 2 2 5 2 2 5 5 5 3 7 2 6 4 3 / 4 5 3 / 8 5 3 / 8 2 2 5 2 2 5 1

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when used as slings, grip the load well. They are much more resistant to abrasion and corrosion than wire rope and are particularly well suited as slings for lifting rough loads such as heavy castings which would quickly

weaken or destroy wire rope slings due to the sharp bends over the edges of the castings.

4.3 CARE AND USE

4.3.1 Use only alloy steel chain, Grade 8 or Grade 10, and never exceed its rated working load limits as specied by the manufacturer and indicated on the required attached information tag. 4.3.2 Chains must be inspected by the user

before each use and by a designated person, making a written record of the inspection, at intervals not to exceed 12 months.

4.3.3 Know the weight of all loads to avoid accidental overloads.

4.3.4 Avoid impact loading.

4.3.5 Store chains where they will not be dam-aged or corroded. A light coating of oil should be placed on chains before storage.

4.3.6 Never shorten a chain by twisting or knot-ting it or with nuts and bolts.

4.3.7 Never use a chain when the links are locked, stretched, or without free movement.

Stretching can be distinguished by small cracks in the links, elongation of the links, or a tendency for the links to bind on each other.

4.3.8 Never hammer a chain to straighten the links or to force the links into position.

4.3.9 Avoid crossing, twisting, kinking, or knot-ting a chain.

4.3.10 Never use the tip of chain hooks to carry a load.

4.3.11 Never re-weld alloy steel chain links. They must be replaced by the manufacturer.

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4.3.12 Inspect each link regularly for wear, nicks, gouges, stretch, localized bending, and shearing. 4.3.13 Make sure the chain is of the correct size and grade for the load.

4.3.14 Make sure all attachments and ttings are of a type, grade, and size suitable for service with the chain used.

4.3.15 Make sure that alloy steel chains are

never annealed or heat treated. Their capacity will be completely destroyed if they are.

5. SYNTHETIC WEB AND ROUND SLINGS 5.1.1 Synthetic slings offer numerous advantages:

conformity to regular shapes, not affected by moisture, won’t rust, non-sparking, minimized twisting during

lifting, lightweight, preclude hand cuts and bumps from swinging, resist crushing, and will not harm the surface being lifted.

5.1.2 Each synthetic sling shall be marked, coded or tagged to show the rated capacities for each type of hitch and type of synthetic material or it shall not be used. Do not use any synthetic sling that is not so identied.

5.1.3 Synthetic slings manufactured with nylon material shall not be used where fumes, sprays, mists, or liquids of acids are present.

5.1.4 Synthetic slings manufactured with polyester

material shall not be used where fumes, sprays, mists, or liquids of caustics are present.

5.1.5 The working temperature range for nylon and polyester synthetic slings is -20°F to +180°F

(-30°C – 82°C).

5.1.6 Avoid choking or hooking directly on the identi-cation tag, splices or stitching.

5.1.7 Wear pads and sling covers should be used to help protect the sling from sharp corners and abrasive surfaces.

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5.2.1 Synthetic ber web slings shall be immediately removed from service if any of the following conditions are present:

• Missing or illegible capacity tag • Chemical burns

• Holes, tears, cuts, snags or punctures • Excessive abrasive wear

• Melting or charring of any part of the sling • Knots

• Broken or worn stitching • Damaged end ttings

• Any condition which causes doubt as to the strength of the sling

(While many manufacturers incorporate the use of a red warning thread in the fabrication of web slings,

these threads are not to be used as the sole means for reason to remove a sling from service. In most situa-tions, visibility of the warning thread indicates the sling is severely past the removal from service point.)

5.3.1 Synthetic round slings shall be immediately

removed from service if any of the following conditions are present:

• Missing or illegible capacity tag • Visible inner cover or yarn

• Chemical burns

• Holes, tears, cuts, snags or punctures • Excessive abrasive wear

• Melting or charring of any part of the sling • Knots

• Broken or worn stitching • Damaged end ttings

• Diminished tattle tale visibility or broken ber optic (if so equipped)

• Any condition which causes doubt as to the strength of the sling

6. SYNTHETIC FIBER ROPE

Synthetic ber rope should only be used for rigging when other applications as hoists and slings are

impractical or undesirable for a particular job. Natural or

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plant ber (manila) rope should not be used for rigging or hoisting applications.

6.1 If using a synthetic ber rope for rigging, a minimum safety factor of 5 must be used to determine the work-ing load limit of the rope.

6.2 Synthetic ber rope suitable for rigging applications includes nylon, polyester and polypropylene.

6.3 Nylon rope is a strong, rough rope with excellent resistance to abrasion and will absorb greater shock loads than any other synthetic ber rope. However, nylon has a greater percentage of stretch than polyes-ter or polypropylene ropes. Do not use nylon rope in the presence of acids.

6.4 Polyester rope has good resistance to abrasion and has application where minimum stretch is desired. Do not use polyester rope in the presence of caustics.

6.5 Polypropylene rope is the lightest and lowest in cost of all synthetic ber ropes. It is exible, has minimum stretch and excellent shock resistance. While poly-propylene is generally not affected by moisture, acids, alkalis, oil, grease and other chemical, it does degrade in sunlight and its strength is less than polyester or

nylon of comparable size.

6.6 INSPECTION

6.6.1 Look and feel for broken bers or other signs of abuse of the rope. Broken bers are an indication of excessive abrasion or overloading. If approximately 5% of the bers are broken, the rope should be condemned.

6.6.2 The ber rope naturally will become dirty from use, however, inspect for excess dirt and grit penetrating between the bers making up the strands. If excessive to the point that it will cause internal wear in the strands, the rope should be condemned for hoisting.

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6.6.3 Inspect for excessive oil on the surface of the rope. This is an indication of excess loading and the rope should be condemned.

6.6.4 Check the rope for strands unlaying, high stranding, or the presence of a spiral appearance. This will cause uneven distribution of the load on the strands and early rope failure.

6.6.5 Inspect outside of rope for evidence of exposure to heat, acid, chemicals, or excessively moist atmosphere. Synthetic ber rope should be condemned if it is not resistant to the above exposures.

6.6.6 Open up the strands of the rope by twisting it in the opposite direction of the lay. Do not open to the extent of kinking the bers or damaging the rope lay. Inspect for the following:

- If excessive broken bers are found, the rope should be condemned. This is a denite indica-tion that rope has been overloaded.

- Interior of the rope should be as bright as the original new rope. If discolored or dirty, there are indications of chemical or dirt penetration and rope should be condemned.

- Inspect for the presence of a powder-like saw-dust. If present, there has been severe internal wear and rope should be condemned.

6.6.7 If possible to open up a strand, the follow-ing inspection inside the strands can be made:

- Pull on several bers near the center of the

strand. If they come out in short pieces, the rope has been overloaded and should be condemned. - Pull out some long bers from the center of the

strand and check for strength. If the strands

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break easily, the rope probably has been chemi-cally attacked and should be condemned.

- A condemned rope should be cut into short pieces and scrapped.

6.7 HANDLING, USE, AND STORAGE

6.7.1 In general, the uncoiling of rope should start with the loose end inside the coil. The coil

can be laid at and the rope uncoiled by pulling the loose end away from the coil to obtain the desired length.

6.7.2 As the rope comes out of the coil, it should unwind in a counterclockwise direction and may form loops. These loops should be removed care-fully to avoid damaging kinks in the rope.

6.7.3 Before cutting a ber rope, whipping should be applied on both sides of the intended cut to prevent unlay of the strands or upsetting of the bers in the strands.

6.7.4 Do not drag rope over dirty or gritty

surfaces. Abrasion to the outside of the rope will occur immediately and the picking up of gritty particles will cause later internal abrasion.

6.7.5 Avoid wrapping ber rope around sharp edges or corners. The use of padding or softeners is recommended.

6.7.6 Do not use ber rope in an atmosphere of acids, chemicals, or chemical fumes unless the specic rope has properties to resist that atmo-sphere.

6.7.7 Do not bend or ex frozen ber rope. Wet or frozen rope should not be placed against steam pipes for thawing or drying.

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6.7.8 Synthetic ber rope should be stored in a clean, well-ventilated area. Preferred storage is hanging loosely on large-diameter pegs, in

temperatures between 50°F- 70°F (10C – 22°C), between 40-60 percent humidity and out of direct sunlight.

6.7.9 If rope has become damp or wet in use, it should be dried before storing.

6.7.10 Do not expose synthetic ber rope to temperatures outside of –20°F to 180°F (-30°C – 82°C).

6.7.11 Never use rope that shows signs of cutting, unraveling, or breaking.

6.7.12 Keep rope ends seized.

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TABLE 4

SYNTHETIC FIBER

COMPARISON CHART

RESISTANCE TO* Abrasion

Wet Dry Acid Alka Water Heat Rot MATERIAL

Nylon E VG P E E G E Dacron® _VG _G _VG _F _E _VG _E

Polypropylene VG G E E E G E *Most chemical solutions and solvents affect rope to varying degrees; therefore, care should be taken to prevent contact with them.

KEY – E - Excellent VG - Very Good G - Good

F - Fair P - Poor

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22 T A B L E 5 P R O P E R T I E S O F F I B E R R O P E S i z e N y l o n P o l y e s t e r P o l y p r o p y l e n e M i n i m u m W o r k i n g L o a d M i n i m u m W o r k i n g L o a d M i n i m u m W o r k i n g L o a d B r e a k R a n g e ( l b s ) B r e a k R a n g e ( l b s ) B r e a k R a n g e ( l b s ) D i a m e t e r C i r c u m f e r e n c e S t r e n g t h W e i g h t D e s i g n F a c t o r S t r e n g t h W e i g h t D e s i g n F a c t o r S t r e n g t h W e i g h t D e s i g n F a c t o r ( i n c h e s ) ( i n c h e s ) ( l b s ) ( l b s / 1 0 0 f t ) 5 t o 1 2 ( l b s ) ( l l b s / 1 0 0 f t ) 5 t o 1 2 ( l b s ) ( l b s / 1 0 0 f t ) 5 t o 1 2 1 / 2 1 1 / 2 5 , 6 7 0 6 . 3 4 7 3 - 1 , 1 3 4 5 , 0 8 5 7 . 7 4 2 4 - 1 , 0 1 7 3 , 7 8 0 4 . 6 3 1 5 - 7 5 6 9 / 1 6 1 3 / 4 7 , 2 0 0 8 . 0 6 0 0 - 1 , 4 4 0 6 , 4 3 5 9 . 8 5 3 6 - 1 , 2 8 7 4 , 5 9 0 5 . 9 3 8 3 - 9 1 8 5 / 8 2 8 , 9 1 0 9 . 9 7 4 3 - 1 , 7 2 8 7 , 8 2 5 1 2 . 0 6 5 2 - 1 , 5 6 5 5 , 5 8 0 7 . 2 4 6 5 - 1 , 1 1 6 3 / 4 2 1 / 4 1 2 , 7 8 0 1 4 . 3 1 , 0 6 5 - 2 , 5 5 6 1 1 , 2 0 0 1 7 . 2 9 3 3 - 2 , 2 4 0 7 , 6 5 0 1 0 . 4 6 3 8 - 1 , 5 3 0 7 / 8 2 3 / 4 1 7 , 2 8 0 1 9 . 5 1 , 4 4 0 - 3 , 4 5 6 1 5 , 2 2 5 2 3 . 4 1 , 2 6 9 - 3 , 0 4 5 1 0 , 3 5 0 1 4 . 2 8 6 3 - 2 , 0 7 0 1 3 2 2 , 2 3 0 2 5 . 3 1 , 8 3 5 - 4 , 4 4 6 1 9 , 7 7 5 3 0 . 4 1 , 6 4 8 - 3 , 9 5 5 1 2 , 8 2 5 1 8 . 0 1 , 0 6 9 - 2 , 5 6 5 F i g u r e s a b o v e a r e s a f e t y f a c t o r s o f m i n i m u m 5 t o 1 .

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7. HOOKS, SHACKLES, BEAM CLAMPS, AND TROLLEYS

7.1 BASIC RULES

7.1.1 Only ONE eye in a hook. Use a shackle to hold two or more eyes.

7.1.2 Pin of shackle should be placed in hook with the eyes of chokers bearing on the shank. See Table 7.

7.1.3 All hooks should either bear a safety latch or be moused.

7.1.4 Never overload a hook beyond its rated capacity.

7.1.5 Hooks must be replaced when inspection shows spread, distortion, wear, or fracture.

7.1.6 Never place a load on the point of a hook - always in the center.

7.1.7 Get approval before applying a beam clamp to any structural member to assure that structural member will support the load being raised.

7.1.8 Use only approved type beam clamps for lifting any load. No welded rings or eld-fabricated lifting devices are to be used.

7.1.9 Check to make sure clamp ts beam and is adequate to support load to be handled. (Consider strength of ange of beam).

7.1.10 Beam clamps should be securely fastened to the beam.

7.1.11 The use of beam clamps is not recom-mended when angle lifts are to be made. The

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design calculations for beam clamp capacity are made for straight lifts. Lifting at an angle places the beam ange under multiple stresses and the beam clamp under point loading, making it pos-sible to exceed design capabilities.

7.1.12 Never use plate grips, tongs, girder hooks, pipe clamps, etc., as substitutes for beam clamps. 7.1.13 All hooks, where possible, shall be

equipped with a safety latch. For those hooks where safety latches are not possible, mousing must be applied to close the throat opening. Rigging using hooks with no safety latches that incorporate mousing should be avoided.

7.1.14 Beam clamps should be visually inspected before each use by checking hooks, locking pins, and lifting eyes for distortion or other defects;

inspecting welds for cracks; checking bolts or

locking devices for ease of operation; making sure that identication numbers, capacity, and beam size are clearly marked on the clamp.

7.1.15 Rebar shall not be used as a lifting device. 7.1.16 Installation of trolleys on monorails should be performed by trained personnel only.

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TABLE 6

STRENGTH OF STANDARD HOOKS

Carbon Steel – Forged, Quenched, Tempered

Design Factor = 5

EYE HOOK

SHANK HOOK

SWIVEL HOOK

Working

Load Throat Eye Shank Swivel Limit Opening A Size B Size C Thickness D

Tons Inches 3_/ 4 5 / 16 1 15 / 32 19 / 32 3 / 8 1 1 1_/₃₂ ₁ 3_/₄ 21_/₃₂ 1_/₂ 1 1_/₂ ₁ 1_/₁₆ ₂ 1_/₃₂ 23_/₃₂ 5_/₈ 2 1 7_/₃₂ ₂ 13_/₃₂ 7_/₈ 5_/₈ 3 1 1_/₂ ₂ 15_/₁₆ ₁ 5_/₃₂ 3_/₄ 5 1 7_/₈ ₃ 13_/₁₆ ₁ 13_/₃₂ ₁ 7 1_/₂ ₂ 1_/₄ ₄ 11_/₁₆ ₁ 11_/₃₂ ₁ 1_/₈ 10 2 1_/₂ ₅ 3_/₈ ₁ 27_/₃₂ ₁ 1_/₄ 15 3 3_/₈ ₆ 5_/₈ ₂ 1_/₄ ₁ 1_/₂ 20 4 7 2 3_/₄ ₁ 1_/₂ 24 4 3_/₄ ₉ 5_/₁₆ ₃ 1_/₂ _– 32 5 3_/₄ ₁₀ 3_/₄ ₄ 1_/₈ _–

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TABLE 7

STRENGTH OF SHACKLES

Screw Pin, Round Pin, Safety – Forged,

Quenches, and Tempered Alloy Steel Pins

Design Factor = 6

SCREW PIN

ROUND PIN

Working Load Size of Diam. of Inside Limit Shank A Pin B Width C

Tons Inches Inches Inches

1_/₂ 1_/₄ 5_/₁₆ 15_/₃₂ 3_/₄ 5_/₁₆ 3_/₈ 17_/₃₂ 1 3_/₈ 7_/₁₆ 21_/₃₂ 1 1_/₂ 7_/₁₆ 1_/₂ 23_/₃₂ 2 1_/₂ 5_/₈ 13_/₁₆ 3 1_/₄ 5_/₈ 3_/₄ ₁ 1_/₁₆ 4 3_/₄ 3_/₄ 7_/₈ ₁ 1_/₄ 6 1_/₂ 7_/₈ ₁ ₁ 7_/₁₆ 8 1_/₂ ₁ ₁ 1_/₈ ₁ 11_/₁₆ 9 1_/₂ ₁ 1_/₈ ₁ 1_/₄ ₁ 13_/₁₆ 12 1 1_/₄ ₁ 3_/₈ ₂ 1_/₃₂ 13 1_/₂ ₁ 3_/₈ ₁ 1_/₂ ₂ 1_/₄ 17 1 1_/₂ ₁ 5_/₈ ₂ 3_/₈ 25 1 3_/₄ ₂ ₂ 7_/₈ 35 2 2 1_/₄ ₃ 1_/₄ 50 2 1_/₂ ₂ 3_/₄ ₄ 1_/₈

Size of shackle identiﬁed by diameter of shank. All shackle pins must be straight.

If the width between eyes (C) exceeds +1/16”, the shackle has been overstrained and must not be used.

Working load limit must be permanently shown on each shackle.

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Pack the pin with washers to centralize the shackle.

Good Practice

TABLE 7 (Cont’d.)

Never allow shackle to be pulled at an angle – the legs will open up.

Poor Practice

Washers _Hook

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8. METHODS OF HANGING RIGGING

The method of hanging rigging depends largely upon the job to be done. It is important to check all phases of the job and all the potential possibilities of job

deviations that may affect the rigging components. Before hanging any rigging, it is imperative that the overhead structures be checked to make certain they will withstand the stresses of the load to be lifted. When starting the job, the affected area should be roped off and identied as an overhead work area.

8.1 Beam clamps are the preferred method for hang-ing rigghang-ing overhead. For beam clamps and their use in hanging rigging, see Section 7.

8.2 Slings are sometimes used to hang rigging and wire rope slings should be given preference for this application.

8.2.1 When slings are used they must be protected from sharp edges on the support member with the use of softeners.

8.2.2 If multiple points or eyes are used to support the rigging, they must rst be gathered in a shackle.

8.3 Lashing consists of a straight piece of wire rope wrapped around the overhead beam or strength

member from which the rigging can be fastened. The wire rope ends are secured by cable clamps. The cable clamps used should be selected and used in

accor-dance with Table 3.

8.3.1 The number of wraps around the beam is deter-mined by the load to be lifted and the diameter of the wire rope. However, a minimum number of three wraps are usually needed to prevent slipping.

8.3.2 To ensure maximum resistance to slippage when the load is lifted at an angle, a shackle should be placed through the middle wrap only; providing the single wrap is of sufcient strength to support the load.

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8.3.3 Rope wrapped around the beam or strength member must be protected from sharp corners by the use of softeners.

8.3.4 Severe angle lifts may require that additional wraps of lashing be used.

8.4 Use of Eveners: In cases where the overhead structure will not withstand point loading, or where two overhead strength members must be spanned to place the rigging directly over the object to be lifted, eveners should be used.

8.4.1 When an evener is used to distribute the load on the beam, it should be lashed to the strength member in two or more places.

8.4.2 When an evener is used to span two or more overhead strength members, the evener should be lashed to all strength members.

8.4.3 The rigging should be hung from the evener

only, in the same manner as it would be hung from the strength member.

9. CHAIN HOISTS

9.1 The spur gear chain hoist is the most efcient of all chain hoists. Chain hoists should be marked with capacity in tons. Use correct size hoists for the weight to be lifted.

9.1.1 Be certain that the attachment and the supporting structure will safely carry the load.

9.1.2 The term “heavy-duty” chain hoists refers to the job it is capable of performing and not the abuse it will stand.

9.2 Chain hoists must be equipped with an automatic load brake to prevent the load from dropping.

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9.3 Chain hoists must have an overload limiting device or be used under strict administrative controls.

9.4 A chain hoist should never be used beyond its rated capacity.

9.5 Do not leave a load hanging on a chain hoist unattended.

9.6 Do not stand below or have any parts of the body, i.e., hand or foot, below a load suspended on a chain hoist.

9.7 Do not wrap the load chain around the load to be lifted.

9.8 Do not load the point of the chain hoist lifting hook. Make sure the load is bottomed in the hook. Safety

latch or mouse all hooks.

9.9 If more than one lifting cable is to be handled by one chain hoist, use a shackle to join the lifting cables before placing them in the chain hoist lifting hook.

9.10 Chain hoists are designed so that one person can operate the hand chain to lift the full capacity load for the chain hoist. If not, use larger chain hoist.

9.11 Avoid making angle lifts with a chain hoist wherever possible. Never use a chain hoist for a

horizontal pull as design chain-sprocket engagement is not obtained. Lever hoists or come-alongs should be used for these conditions.

9.12 When drifting loads using two or more chain hoists, use extreme care in operation of the hand chain so that it is pulled in line with the sheave. The angle of lift should not exceed 30° with the vertical. This is one of the few permissible chain hoist angle lifts.

9.13 Inspection

9.13.1 All chain hoists should be inspected

visually before making any lift. Visual inspection

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should include (1) check hooks for any irregulari-ties,

(2) check chain for wear or damage, and (3) check housing and sheaves for any signs of damage

from abusive treatment.

9.13.2 Check top and bottom hooks. If the hook opening is greater than indicated in Table 6, it

should be replaced. Never try to straighten a bent hook.

9.13.3 Check load chain at inter-link points for signs of wear. Check pitch of chain against the original pitch as recorded in inches of length per twenty links of chain. If the pitch shows an increase of 3% elongation due to either stretch or wear or a combination of both, it must be replaced. 9.13.4 For hand chain hoists that have multiple parts of load chain reeved through a load block, always check to ensure that the block is not

capsized causing a dangerous “twist” in the load chain.

9.13.5 Lubricate the load chain as often as use warrants. Do not oil load brake surfaces.

10. LEVER-OPERATED HOISTS 10.1 Rig carefully, keep hoist chain straight. 10.2 Don’t use cheaters on hoist handle. 10.3 Don’t overload, stay within rated limit.

10.4 Load hook properly and inspect for open hooks. 10.5 Handle carefully, don’t throw or drop hoists.

10.6 Don’t use hoist chain as sling or choker.

10.7 Never let the hoist chain gouge the side of the frame, keep aligned with the work.

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10.8 Bending hoist chain under load could cause serious damage or breakage.

10.9 Set your footing before using a hoist to avoid slips, falls, and strains.

10.10 Inspect periodically for defects with a visual inspection prior to each use.

10.11 Link chain lever hoists may be used safely to lift or pull a load or to stretch cable or wire at any angle or in any position.

10.12 A lever-operated hoist under strain should not be left unattended for any lengthy period of time.

10.13 Always stand clear of load being lifted or away from the path of a load being pulled.

10.14 If more than one cable or chain is to be handled by one hook, use a shackle to join the cables or chains and place the shackle in the hook.

10.15 Lever-operated hoists must have an overload limiting device or overload warning device.

10.16 The use of roller chain hoists is not permitted. 10.17 The use of wire rope lever hoists incorporating a simple ratchet and pawl is not permitted for lifting.

11. USE OF JACKS

11.1 Jacking metal against metal is not permitted – use wood softeners. Never jack against rollers.

11.2 When jacking, always follow with chocks as a precaution against the jack kicking. Never leave a jack under a load without having the load blocked up.

11.3 Care must be exercised to ensure that jacks are properly positioned and the load raised uniformly to reduce tendency of the load to shift unexpectedly.

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11.4 When using jacks, always make sure that the base is placed rmly and evenly on a good solid foot-ing. Never place jack directly on the ground.

11.5 Jacks should be used in such a position that the direction of force is perpendicular to the base and the surface of the load to be moved.

11.6 Never exceed the capacity of the lift distance of the jack.

11.7 Do not use extensions to the handles furnished with the jacks.

11.8 If a load is to be raised in its entirety by several jacks, it should be braced laterally by struts to prevent

all the jacks from upsetting in unison.

11.9 When using jacks in a horizontal position to

move an object, the jacks should be lashed or blocked. 11.10 When using more than one ratchet-type jack for lifting, it is desirable to obtain matched jacks for uniform lifting.

12. USE OF ROLLERS

12.1 Rollers should not be used metal-to-metal – provide softeners.

12.2 Avoid pinch hazards – keep ngers and feet clear of rollers.

12.3 Loads must be properly chocked when they are to be left on rollers.

12.4 Use wood softeners under rollers when on smooth hard surfaces.

12.5 Material or load to be moved must be rmly bolted or lashed to the skid to prevent any shifting

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on the skid while it is being moved. On loads moving down a slope, restrainer lines should be used, securely fastened to both the load and the skid or dolly.

12.6 Force to move the load along the rollers or dol-lies should be applied to the skid and not the load itself. 12.7 Force to move the skid may be applied by a

winch, jack, come-along (tug-all), or manually with the use of lever bars.

12.8 When using dollies, they should be selected of sufcient capacity so that each dolly will take equal weight of the total load.

12.9 The load will be moved on rollers in a direction perpendicular to the center line of the rollers. To change the direction of movement, the rollers should be moved accordingly. Never drag a load over the rollers.

12.10 Force to move a skid on rollers should be

applied in the direction of movement as near as practi-cal.

12.11 To change direction of movement of the skid, the rollers may be moved by holding one end securely with a lever bar and moving the other end in the desired direction using jacks, lever bar, or a maul.

12.12 A minimum of three rollers must be under the skid at all times, and be spaced so that one roller is located forward of the load center of gravity and one roller located after the load center of gravity. Long skids will require additional rollers.

12.13 The forward end of the skid beams shall be

tapered on the bottom to more easily start on the roller. 12.14 The surface on which the load is to be moved should be smooth and level as far as practical. When moving skid on rollers over a dirt base, timber tracks should be provided with staggered joints.

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12.15 Before moving a load on skids, rollers, or dol-lies, the load should be thoroughly checked for stability with respect to the center of gravity of the load on its supports.

13. PLATE AND GENERAL PURPOSE GRIPS

When handling at stock such as plate, utilize only positive self-clamping and locking devices that must be intentionally unlocked. Consider hardness and

surface of material to be lifted to assure proper gripping and bite of gripper. Inspect before each use for wear and proper capacity. Use proper grip for use such as horizontal versus vertical lifts. Use tag line on load and never expose any part of body under the load.

14. EYEBOLTS

Misuse of eyebolts causes injuries and damage to equipment due to angular pulls on eyebolts. To avoid angular pulls use spreaders or devices which provide vertical or straight pulls. Before using eyebolts inspect for burrs, grooves, or defects on the eyebolt and mating part which could affect safety. Avoid painting or coating of eyebolts used for lifting because they hide defects or damage. Seat all eyebolts rmly and squarely against mating parts. All eyebolts must have 90 percent of

threads engaged and must t tightly into holes. Eyebolt shank length must not be altered without Engineering approval. Only swivel or shouldered eyebolts may be used for rigging purposes; do not use unshouldered eyebolts.

Note: Angular pulls on eyebolts should be avoided. Not all manufacturers allow angle loading of their equipment. If an angular pull is to be applied to an eyebolt, the user must verify with the manufacturer’s information that this type pull is allowed and abide by the manufacturer’s recommended safe working load for the angle at which the load is applied.

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36 S t r a i g h t P u l l s R e c o m m e n d e d S p r e a d e r B e a m R e c o m m e n d e d A n g u l a r P u l l s N o t R e c o m m e n d e d N u t m u s t b e t i g h t e n e d S h o u l d e r m u s t b e i n f u l l c o n t a c t w i t h s u r f a c e E n s u r e t h a t t a p p e d h o l e i s d e e p e n o u g h

F

I

G

U

R

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4 P

R

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P

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E

Y

E

B

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T

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P l a n e o f e y e b o l t P L A N E O F E Y E B O L T I L L U S T R A T E D P a c k w i t h w a s h e r s t o e n s u r e t h a t s h o u l d e r i s ﬁ r m l y i n c o n t a c t w i t h s u r f a c e