Beruflich Dokumente
Kultur Dokumente
Contents
Introduction Roles and responsibilities Wire ropes Slings, belt slings, round slings, Bow Shackles Rigging Hitches & Slinging Methods Basic Knots Chain blocks Pull lifts Tirfors, eye bolts, plate clamps, turnbuckles, hooks, lifting beams Lifting Appliances Procedure for lifting operations
INTRODUCTION
A. Mission This course on Lifting Equipment, Rigging, and Slinging is designed to identify and detail the mandatory requirements for the safe utilization of all lifting equipment operating on the Project. The course will also provide a clear understanding of Lifting tackles, Rigging and Slinging practice, Safe Working Loads, Different types of Cranes and Crane Signals.
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B. Problem Analysis
Everyday, Routine Crane Operations cause most of our accident due to lack of adequate planning.
C. Expectation To analyze all lifts Ground Preparations Using proper lifting tackles Interpretations of capacity charts Operators and signalmen must maintain continuous and undivided communication
D. Objectives
Upon completion of the lesson, participants will be able to: List the four major causes of crane accidents. Describe the pre-planning that is required before putting a crane in use.
State the main precautions that apply to working with cranes. Explain at least three ways to eliminate hazards that may lead to injury when using cranes or slings to handle materials.
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Wire Ropes
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Centre wire
Inner wire
Core wires
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Stranded Ropes
Single layer
Rotates
Two layers
Rotational Resistant
Three layers
Low Rotation
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Rotation-resistant rope
(Illustration is 35LS - Low rotation rope)
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Rope Dimensions
2 measurements at right angles at two positions spaced approximately one metre apart.
(Measurements taken over strand crowns)
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Wrong
Wrong
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WHIP LASH:
A damaged or overstrained rope may break and cause serious injury to anyone in its path.
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Slings
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Action
Soft Eye
Endless
Maintenance
Keep ropes clean and free from grit. Lubricate at regular intervals. Slings should be suspended from storage rack if not in use.
Grommet
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CARE AND USE OF WIRE ROPES. Examine all wire ropes for damage before use. Faults which may render a rope unserviceable include;
Corrosion
Kinking
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The stresses in the legs of the sling increases as the angle between them increases. Using the human body and two buckets filled with water it will not be difficult to demonstrate the effects of lifting a load at narrow and wide angles. The arms represent the sling and lift angle.
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SKETCH A SHOWS THE ARMS VERTICAL AND A REASONABLY EASY LIFTING CONDITION.
SLING
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SKETCH B SHOWS THE ARMS STRETCHED BEYOND ITS LIMIT WITH THE LOAD. THE BODY AND SLINGS ARE NOT DESIGNED TO TAKE UN-NECESSARY STRAINS.
SLING
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Chain Slings
Only Grade 8 or better ALLOY Chain can be used for overhead lifting purposes! All chain is not rated the same! Chain must have a capacity tag attached to it.
Chains will withstand more rough handling and abuse, but a chain with the same rated lifting capacity of wire rope will be much larger in diameter and heavier in weight.
Chains must be inspected daily before use and as often as necessary during use to assure safety. It is the riggers responsibility to do the inspections!
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Chain Slings
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BELT SLINGS
Identification
Safe working load marking. Identification mark. Colour inspection code (if used). Condition of stitching. Tears or abrasions Burning of outer surface. Excessive wear.
If any of the above faults are present refer to a competent person for through examination.
Maintenance
Keep surface clean and free from grit. Re-apply colour code if necessary. Sling should be suspended in storage when not in use.
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(g) The use of hooks that are too narrow (h) Burn damage to sleave and load-bearing yarn has damaged the eye of the sling
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ROUNDSLINGS
Identification
A further category of man-made fiber slings is the round sling. This is manufactured from an endless polyester yarn and covered with a protective polyester sleeve stitched as illustrated.
Typical Round sling colour coding (Basic Configuration)
WLL Tonnes Colour 1.0 2.0 3.0 4.0 5.0 6.0 8.0 10.0 Violet Green Yellow Grey Red Brown Blue Orange
Maintenance
Safe working load markings. Identity number. Colour inspection code. Broken load bearing internal yarn. Cuts and abrasions to external cover. Cuts in stitching. Discoloration (due to chemical attack). Burn marks on outer surface. Knots.
Action
If any of the above faults are present refer to a competent person for thorough examination.
Maintenance
Keep clean and free form grit. Re-apply colour code if necessary Sling should be suspended in storage when not in use.
Round Sling with eyes
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SLING INSPECTION
while inspecting the sling;
1. 2. 3. 4. 5. 6.
Sling should be laid out in good light and examined over its entire length for:
Damage caused by sharp edges (cuts) Damage caused by abrasion (burning or scuffing) Impact damage. Contamination by chemicals. ID tag with SWL marked ID number and length. Certification.
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COLOR CODING
The project operates a system where by all Lifting Equipment is color coded with a unique color, at monthly intervals, after inspection where applicable. Red color is reserved especially for items scrapped or not to be used. We have to comply with the project color coding system every 3 months or depending upon the project requirement.
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Thumb Rules
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Bow Shackles
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SHACKLES
Three types of shackles are commonly used for rigging applications. They are the anchor (bow type), chain shackle (Dshackle) and wide-body type shackle.
Many more different type shackles are available in the marketplace which should not be considered for rigging use.
Three suppliers of shackles are well known in the construction industry with Crosby and Green Pin being the leaders and most widely utilized. Le Beon shackles can occasionally be found as well.
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Normal Shackle
Reduced Sling Bearing Area in Shackle Bow
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Factor = 1 -
0 .5 D/d
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This means if a 25 mm Diameter Sling is used over a 30 mm Pin the Equation will be:
1-
0.5 0 .5 = 130 / 25 1 .2
= 1 0.416 = 0,584
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Slinging Hazards
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Slinging Hazards
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SAFE WORKING LOAD (SWL) A calculated, design approved and certified maximum load, normally specified in Kilograms (kgs) or Tones, up to which, an item of Lifting Equipment is safe to operate.
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CENTER OF GRAVITY
The center of gravity of an object is that point at which the object will balance. The entire weight may be considered as concentrated at this point.
Any suspended object (load) will center itself directly under the hook.
STABLE
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UNSTABLE
Load is not above Center of Gravity Load will shift until Center of Gravity is below the Hook
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UNSTABLE
Load is not above Center of Gravity
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Basic Knots
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BOWLINE
A favorite knot with riggers and one of the best known and widely used of all knots. It is easily constructed and used wherever a hitch is required that will not slip, jam or fail.
REEF KNOT
Also known as the square knot. Used to join two rope or lines of the same size. Holds firmly and is easily united.
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Chain Blocks, Pull lifts, Tirfors, eye bolts, plate clamps, turnbuckles, hooks, lifting beams
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Ensure that the SWL of the chain block is adequate for the load to be lifted. Attach the head fitting to a suitable anchorage Pull the operating chain to determine the hoisting and lowering sides of the chain. Attach the load to the hook using correct slings and / or shackles. Pull down the relevant side of the operating chain to hoist or lower the load.
Load Chain
Safety catch
Hook
Operating Chain
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Head fitting
Pawl Lever
Attach the head fitting to a suitable anchorage taking into account the load to be lifted, lowered or pulled.
Hook with Safety catch
Operating Lever
Step Line
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LOWERING:
To lower the load, turn the lever to the down position. Operate the handle backwards and forwards to lower the load. When the load is securely in position, operate the handle to slacken the chain. Turn the lever to the neutral position and turn the hand wheel to give sufficient length of chain to be able to release the slings and / ore shackles.
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Examine a chain before using it. Look for stretched links, wear, distortion and any other sign of weakness.
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Identification
Safe working load stamping. Identity number. Colour inspection code (if used). Check for free operation of operation, reversing and rope release lever. Check that correct shear pins are fitted, and pin condition is satisfactory. Inspect complete machine for cracks, indentations or distortion. Wear in operation jaws Corrosion. Inspect wire rope and hooks. Correct rope. Damage to casing.
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Identification
This is a multi purpose tool made to pull and pay-off wire rope. A special wire rope is fitted through the machine and cannot be removed whilst there is a load on the winch. When the operating handles are actuated by hand, the rope is either pulled or paid-out through the machine. These machines are available in a range of Sizes to suit different working conditions.
2. 3.
Push the release handle into the notched position to open the jaws inside the machine. Insert the tapered end of the wire ripe into the machine at the hole in position A
Notched position
Release handle
A
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4.
5.
Anchor the machine using the correct slings. Fit them to the hook attached to the machine.
B
Hoisting or Pulling
Fit the operating handle on to the actuating lever and work the handle to and fro. This action pulls the rope through the machine and automatically locks it in position when the operating handle is released. 6. Pull the wire rope through the machine until the desired length is reached and the rope becomes tight on the load. Lift the release handle out of the notched position and allow it to return to the operating position under its spring pressure. The rope is now firmly held in jaws fitted inside the machine.
7.
Actuating lever
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2.
3.
The jaws in the machine automatically lock the rope in position. It is therefore impossible to release the wire rope form the winch whilst there is any strain (load) on it.
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This bolt is used for normal lifting purposes and has a link forged in the eye.
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PLATE CLAMPS
Identification
There are various types of plate clamps in use, the following three being the most common:
Inspection
Safe working load stamping. Identity number. Plate thickness marking Colour inspection code (if used). Free working of assembly. Condition of teeth Wear at all bearing points and on pins. Cracks, nicks and gouges. Inspect weld (if used). Security of all pins. Deformation. Corrosion. Condition of springs
Universal
Vertical
Horizontal
Action
If any of the above faults are present refer to a competent person for thorough examination.
Maintenance
Keep clean and free from grit. Lubricate moving parts if necessary. Re-apply colour code if necessary.
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PLATE CLAMPS
Plate clamps are available in two basis designs, i.e horizontal plate clamps (sued in pairs and usually suspended by a two leg sling from a lifting beam) for handling plates in the horizontal position. (These clamps can also lift from horizontal to vertical and vice versa, but should
Selection
Horizontal Clamps
The first consideration when selecting the clamp is how the plate is to be transported and stacked, ie horizontal or vertically. The second consideration is the weight of the plate to be handled which will determine the SWL of the clamps. The third consideration is the plate thickness which will determine the correct model of clamp with the appropriate jaw opening.
Pre-use Examination
Before using any plate clamps, the following checks should be made:
The SWL is adequate for the load. The colour coding (where applicable) is current and the clamp has a plant number / ID mark.
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Lock the jaw in the closed position and ensure the jaws have a firm bite on the plate.
Always
i) ii) iii) iv) Check that the plate is clean and free from mill scale, dirt, Oil and grease. Double check that the jaws are locked. Use an adequate number of clamps to balance the load. Lift slowly to allow the jaws to obtain a good grip.
Never
Attach clamps to the side of the plate
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Never
Fast lower onto the floor as this could cause the clamp to open and release the plate. Lift horizontally with a vertical clamp. Lift more than one plate at a time. Use large capacity clamps to lift light loads.
When using horizontal plate clamps, do not exceed the sling angles indicated below and do not lift more than one plate at a time unless the clamps are suitable, i.e. sheet bundle clamps
Never
Use endless slings with clamp pairs as this practice can drastically overload the clamps.
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COMMON TURNBUCKLE
Turnbuckles (Rigging Screws) can be obtained with various types and combinations of end fittings, the most popular being the Jaw and Eye type.
Eye
Jaw
Stub
Hook
Selection
(Has Reduced capacity) The first consideration when selecting turnbuckles Hook & Eye combination is the SWL which is determined by the thread diameter. The second consideration is the adjustability (commonly known as Take-up) of the turnbuckle. The take-up often varies with different patterns.
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When using a turnbuckle in an application where vibration is present, (most areas in an engineering environment), it is extremely important to lock the end fittings to the frame or body to prevent them from unscrewing and possible releasing the load. The most popular and preferred method is to wire the eye or jaw to the body (see fig. 1). As an alternative (for open body type only) a split pin through the end of the screwed shank is acceptable (see fig 2). The split pin has to be removed to facilitate adjustment. Should lock nuts be used, care must be taken not to over tighten them as this can put undue stress on the threaded shank (see fig 3)
Preferred Fig - 1
When turnbuckles are to be left under load for any length of time, eg temporary hangers for pope work, etc they should be visually checked on a daily basis to ensure they are still secure.
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PRE-USE EXAMINATION
Prior to using a turnbuckle in a lifting situation, visually examine it and ensure that: i) The SWL is adequate for the load. ii) The colour code is current and the turnbuckle has a plant number / I.D. mark. iii) The threads are free from wear, stretch and impact damage. iv) The eyes/hooks are not worn or stretched. v) The clevis pin and pin holes are free from distortion/wear. vi) The threads are suitable lubricated.
Safety
Turnbuckles must always have the threaded shank protruding into the body to ensure Check for thread damage & bent rods that the load is borne over the correct length of the threaded shank.
Particular care must be taken when using Closed Body type screws. It may be necessary CORRECT to dismantle to dismantle the turnbuckle, measure the length of the UNSAFEshanks, threaded reassemble and use measurement to ensure the above unsafe case is avoided.
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CARE OF HOOKS:
Fit a shackle between the lifting hook and the eye bolt to prevent the point of the hook being strained. The shackle will swivel to allow the sling and hook to make a correct lift as illustrated along side and below. Note: Collar eye bolts are not designed to take hooks.
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LIFTING APPLIANCES
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LIFTING APPLIANCES
CRANES (Tower, Mobile, Crawler.) Identification Hand signals Safety Procedures Inspection
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Crawler
Truck Crane (TC)
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Crane Selection
Weights, Dimensions and Lift Radii expected
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RESPONSIBILITIES
Be familiar with the lifting capabilities of the crane. Check the lifting equipment being used is in good condition, certified for use, correctly color coded, and is of sufficient capacity to carry out the lift. Ensure taglines are attached to loads which are likely to swing. Be aware of any obstruction within the crane radius and working area. Check that the area around the load to be lifted is clear and that the load is attached to the floor, transportation cradle or adjacent equipment. Ensure that the escape route is identified.
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Set up the crane as close as possible to the load , set the outriggers and block out securely ensuring that the crane is as level as possible. You can use a level or the main block to level the crane. Barricade the area making sure that no other personnel other than the rigging crew are within the barricade. Prepare the load for lifting making sure all equipment used is of sufficient size and Safe Working Load including crane radius and boom length Rig the load once everything has been checked float the load making sure it is balanced this assists the crane to check his brakes and stability When all the checks have been completed continue with the lift following all safety procedures only one person giving the signals, using tag lines to control the load if required. Once the load has been placed into its final position remove all the equipment and barricades.
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WHEN WORKING WITH CRANES YOU MUST BARRICADE THE WORKING AREA
BARRIER TAPE
.
Z A W E D
.
Z A W E D
CONES
.
WARNING SIGNS
Z A W E D
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Crane Mats
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CRANE HOOKS
Most cranes are fitted with C type hooks to prevent snagging on protrusions such as handrails, etc., and in certain cases also have safety catch to prevent the eye of the lifting sling being accidentally displaced in the figure. Large cranes however tend to be fitted with ramshorn type hooks which could have an effect on the sling design.
Hard Eye
C Hook
Ramshorn Hooks
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Over 50% of all crane accidents are the result of mistakes made and rushed sloppy work done when the crane was being put together, readied and placed to make its lifts.
REMEMBER: Failure to follow just one safety precaution can cause that accident, to men or machine.
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Just a little side tilt when lifting a load over the rear can become dangerous when swung over the side.
RIGHT
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2
20 % 15 % 41 % 10 %
3
30 % 20 % 50 % 15 %
Accurate Calculations are available from the specific, applicable Crane Manufacturers
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When setting hydraulic outriggers make sure that the outriggers are set evenly otherwise severe twisting of the cranes chassis frame will result.
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Whoops!
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WRONG
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WRONG
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WRONG
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over 50 to 200 KV
Over 200 to 350 KV Over 350 to 500 KV Over 500 to 700 KV Over 700 to 1000 KV
15 ft.
115 ft. 25 ft. 35 ft. 45 ft.
4.60 M
4.60 M 7.62 M 10.67 M 13.72 M
All overhead Lines and other apparatus should be treated as live unless officially declared DEAD and SAFE. If in doubt, seek advise
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Mechanical Advantage
Wrong
Correct
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MECHANICAL ADVANTAGE
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Wedge Socket
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It
Might
Cause the Boom to Collapse Or Damage
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Use Taglines
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Treat the rigging as though your life depended on it! Because it does if it fails!
Dont use makeshift rigging or attempt to repair any rigging components. Knots tied in rigging reduces the strength by 50% or more!
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Ground stability
Outriggers
Sound timber packing or metal plates shall be positioned under each outrigger pad / Crawler to distribute the load. These should be a minimum of 3 times the area dimension of the outrigger pad.
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A sign warning of the danger of overhead power lines shall be mounted in each crane.
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Lifting Equipment
The lifting equipment operator shall not begin the machine movement, until the banks-man is within his range of vision, or in radio contact, and the signal is given and understood. Where several individuals are involved, the crane operator shall obey the signal of the banks men ONLY. The only exception shall be in the case of an emergency, when the crane operator can receive the Emergency Stop Signal from anyone
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The Color Code System shall be developed and implemented for all Lifting Gear used within the Project such as for slings, shackles, rope wire, belts. The color shall indicate to the user and the inspector, that an examination has been performed within the prescribed period. A new color shall be introduced on regular basis as per the Project Color Coding System and each color shall be current for a specified period Information boards showing the current color coding shall be posted at prominent locations at each work site where it is anticipated lifting operations will take place.
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Crane: Date: Time: Crane has been inspected/ safe condition:.YesNo Job Location: Job Description: The weight of the load is: The swing radius of the lift is: Net crane capacity at this radius is: Is operator qualified to operate this crane? Is operators certification card current? Critical lift permit required for this lift? Crane level/outriggers fully extended? Is the rigger qualified for this task? Is sling/hardware in safe condition? Sling sizing/hookup reviewed? Do sharp edges have softeners? Tag lines needed to help control load? Center of gravity of load located?
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
No No No No No No No No No No
EMERGENCY INFORMATION What is the wind direction? Reviewed emergency alarms/phone numbers Yes Escape route(s): Location of eyebath/shower station:
Our evacuation assembly point is: Operator Signature: Rigger Signature: Signalman Signature: Supervisor Signature:
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RIGGING PLAN
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RIGGING COMPONENTS
List each component
Slings Type Sling 1 Sling 2 Sling 3 Sling 4 Hitch Cap. Sling Angle Actual Cap.
Shackle 2
Shackle 3 Shackle 4
How has the lifting area been restricted? _______________________________________________________________ _______________________________________________________________ _______________________________________________________________
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