Lifting Guide

2010

Lifting Guide

2010

Lifting Guide 2010

How to use this guide
As far as were aware, this is the first Guide of its kind which is intended to provide the end-user with an overview of the Lifting Industry as a whole. The information is categorised so that readers can find their way through the various equipment and machinery with ease. Each item or product is accompanied by a short description and Susan Custers with Clarence (left) an illustration for easy and Cilla, not to be outdone reference. Having published the monthly magazine Bulk Handling Today for many years, we have a very good idea of whos who in the industry. As such, this Lifting Guide provides readers with a snapshot of the lifting fraternity but it would not have been possible without the assistance of LEEASA (Lifting Equipment Engineering Association of SA), and Ken Greenwood in particular. We thank them for their professional guidance and assistance in putting this publication together. As a first issue, Promech Publishing is very proud of this Guide and we intend to grow it in the years to come, so any suggestions for improvements from readers and end-users would be more than welcome. Keep this guide in your desk drawer its going to be of invaluable help as you grow your business. Or check out www.promech.co.za/ where youll find this guide, our monthly magazine Bulk Handling Today and our prestigious annual Buyers Guide in full on our website. Happy and fruitful reading! Warmest Regards,
Susan Custers, Publisher
Proprietor and Publisher: PROMECH PUBLISHING Tel: (011) 781-1401 Fax: (011) 781-1403 E-mail: editorial@promech.co.za bulkhandling@promech.co.za Website: www.promech.co.za Managing Editor: Susan Custers Advertising Sales: Surita Marx DTP: Zinobia Docrat / Sean Bacher Research: Sean Bacher Disclaimer Neither PROMECH Publishing nor its endorsing bodies will be held responsible for any errors or omissions in this publication and no responsibility will be borne by the publisher for the consequences of any actions based on information so published by Promech Publishing cc.
Printed by: Typo Colour Printing Tel: (011) 402-3468

Front Cover East Rand Cranes Jhb: (011) 817-3423/5 Fax: (011) 817-3019 Web: www.eastrandcranes.co.za

Index to Advertisers
Anglo Lifting Equipment 43 Bexl Control 4 Becker 35 CLT 10 Columbus McKinnon 53 Condra Cranes 38 Custom Crane 32 D&D Lifting 12 Delta Crane 52 Dymot Engineering 51 DSR Mining 40 East Rand Cranes Outside Front Cover, 3,17,37 Elephant Lifting Inside Front Cover Engineering Supplies 20 Fastlift Rigging 34 GM Technical Services 39 Gunnebo Industries 40 Linde 24 LMI Academy 31 Morris Material Handling 8 Phakamisa Safety 31 RGM Cranes 28,29 Raytoko Outside Back Cover Toyota Forklift 22 Tower Crane Services 41 fxdgdfgdfgdfgd

Also publishers of:

Lifting Guide

2010

Lifting Guide

2010

CONTENTS
3 6 9 How to use this Guide About LEEASA LEEASE Members

6 Carry deck cranes 7 Truck mounted side loading container carriers 7 Excavators & loaders used as mobile cranes

39 OVERHEAD & GANTRY CRANES

9 9 0 0

Overhead cranes Gantry crane Free standing and/or permanently attached jib crane Goliath cranes

11
1 1 1 1 1 1 1 16 16 16 17 17 17

Lifting Legally

40 TOWER CRANES 42 REACH STACKERS & STRADDLE CARRIERS

2 Reach stacker 2 Straddler carriers

13 LIFTING TACKLE

Flexible steel wire rope slings Chain slings Webbing slings Hooks Snatch blocks Coupling links Shackles Clamps Spreader beams Plate grabs Balanced fork attachment Coils grabs Bar tong

43 CONTAINER CRANE 44 SHIPS AND WHARFSIDE CRANES

 Ships cranes  Wharfside cranes

 Falling From Height

18 LIFTING RECEPTICAL 18 Lifting bins, buckets 18 Containers 18 Lifting tray 18 Lifting cages/cradles 19 UNDER THE HOOK MA CHINES 19 Magnetic hooks 19 Vacuum filters

47 AERIAL PLATFORMS

7 Boom type (cherry picker) 7 Specialy insulated aerial platforms 7 Scissor lifts (mobile or fixed)

48 SUSPENDED ACCESS PLATFORMS (SAE)

8 Temporary suspended platforms 8 Building maintenance unit (permanently suspended platform) 8 (MEWP) Mobile Elevated Work Platform

21 HAIN BLOCKS & LEVER C HOISTS

21 Chain blocks 21 Lever hoists 21 Cable pullers

49 HYDRAULIC INDUSTRIAL LIFTING DEVICES 50 VEHICLE HOISTS

0 0 0 1 1  posters 2 posters Scissor lift type (excluding dock levellers) Hydraulic type Tail lifters

23 FORKLIFTS
2 2 2 2 2 2

Counter balance Side loaders Rail or tyre stacker & reach lift trucks Pedestrain controlled lift trucks Order picking lift trucks including all models Pallet trucks

53 OTHER SPECIALISED CATEGORIES

 Side cranes  Secondhand/Hiring

2 The Importance of Regular Inspection 0 Training for Safe Operation

33 MOBILE CRANES
      6 6 6

Truck mounted cranes Fixed or truck mounted knuckle boom cranes Pick and carry cranes Mobile harbour cranes Crawler lattice boom cranes Lattice boom cranes on tyre wheeled carriers Rough terrain and/or centre mount cranes All terrain cranes Telehandlers

Copyright

All material published in this guide is copyrighted to Promech Publishing cc. No part of the material may be quoted, photocopied, reproduced or stored electronically without prior written permission. Lifting Guide 2010

About LEEASA
by Ken Greenwood National chairman of LEEASA

Lifting Equipment Engineering Association of SA (LEEASA) has come a long way since its inception in 2004. Year after year, LEEASA has made headway in its endeavor to assist in helping government and statutory bodies to implement and regulate our industry to make a difference, both in standards, and the safety of our people.

The change in government policy regarding education. The introduction of the QCTO system is in progress and LEEASA is actively participating in this process of change.

T
Ken Greenwood

The Association is concerned that their industry, which is inherently dangerous if not well run and regulated, could fall into disrepute and therefore the engineering team providing the service should be well trained to the correct standards and should at all times be ethical and responsible for their actions. The Association has joined the Chamber of Engineering Technology, who already have the necessary infrastructures to disseminate information and who already are recognised in representing engineering practitioners in the Engineering fraternities. Anyone interested in joining the association, should contact Ken Greenwood on (011) 475 5876

he period 2009 to 2010 was no exception and again we have seen changes for the better. The challenges that we faced at the beginning of this period were large, but we tackled each task with our usual enthusiasm and commitment.

These included, nominating someone to serve on the technical committee to re-write the Driven Machinery Regulations (TCDMR). This was done and the work is close to being finalised. LEEASA also has members on the committees on the National Code of Practice (NCOP) and the rewrite of the Construction Regulations (CR). The LEEASA members of these committees are in continual dialogue regarding these regulations. Formulating an auditing document to audit LME (Lifting Machinery Entity) members of LEEASA. A document has been developed and some pilot audits have been done. At the request of the Department of Labour, LEEASA has contributed to writing level 2, level 3 and level 4 qualifications for the vertical articulation career path to a LMI (Lifting Machinery Inspection). This will lead to vertical articulation to the existing registered level 5 qualification for LMIs. LEEASA continues to provide volunteers for the working committees at ECSA, SABS, SAQA and the DoL More issues that became challenges in the period 2009 to 2010. The extensions of scope of LMEs. To assist with this LEEASA has produced a survey to identify problems.

Mission & Vision of CET

The Chamber of Engineering Technology.

Mission / Policy

Established to enhance the standing and contribution of the South African Engineering Profession in the National Interest and to the benefit of Society.

Membership

Membership is open to Technicians, Technologists, Engineers and persons associated with engineering technology in a professional capacity. This includes Specialised Scope practioners, Students, Graduates and persons in Training.

Divisions

CET has an autonomous division in the form of the Lifting Equipment Enngineering Association of South Africa (LEEASA) under its wing.

Alternate Websites

For details of LEEASA please see www.leeasa. synthasite.com and www.leeasa.mirroz.com and www.engineeringchamber.mirrorz.com

Lifting Guide

2010

Make sure that the certificate you see looks like the one below to verify its authenticity

Lifting Guide

2010

Lifting Guide

2010

LEEASA Members
While every effort has been taken to check that this list is correct, LEEASA does not guarantee that errors do not exist. LEEASA does not accept any responsibility for any matters at all that may arise from the use of this list. The list is presented as is merely as a free service.

Accord Lifting cc Africa Rigging Services cc AJM Engineering Services (F/a D Rowe) Akhanani Electromechanical Engineering (Pty) Ltd Alfa Africa Testing cc Algar, MW Al-Kaassamany, R Allin One Crane Repairs cc Ally, FI Anchor Industries (Pty) Ltd Anglo Lifting Equipment (Pty) Ltd Arc Cranes cc Arlona Engineering (Pty) Ltd Barnes, GV Bartlett Construction Bexl Control Systems cc Blenner-Hassett, GW Brake Safe Mining Bri-Ton Lift Master cc Careys Tower Crane Services Check Lift cc CHL Services cc CLT Crane Load Technology Condra (Pty) Ltd Condux Natal (A div of Hudaco Trading (Pty) Ltd Cowley, R Crane Clinic cc Cranelec cc Culmen Wes-Kaap bk Custom Crane Safety (Pty) Ltd Daves Crane Services Delta Crane & Plant Hire (Pty) Ltd Demag Cranes& Components (Pty) Ltd DG Materials Handling cc Dockleveller Supplies cc DSR Mining & Industrial cc Dynamic Crane Systems (Pty) Ltd East Rand Cranes ECS Electric Crane Services (Pty) Ltd Elephant Lifting Equipment (Pty) Ltd Engineering Supplies Ltd Ergon Engineering cc Etis Mvelaphanda Engineering (Pty) Ltd F.B. Mining & Lifting Equipment cc

FastLift Rigging Products (Pty) Ltd FB Crane Builders & Repairs (Pty) Ltd FND Crane Services cc Fritz, PL G W Lifting & Engineering Supplies cc Gauteng Rigging Services (Pty) Ltd Giro Engineering cc Greenwood, K Haddath, RS Harman, V Hendry, MJ Hiab (Pty) Ltd Holland, JW Hydratech Ideal Lifting cc J. Express Crane Services J.V.Testing Projects cc Janse van Vuuren, G Karan, S Kelran cc Kori Engineering Kruger, JG Kruger, AGB L & R Electrical cc Lake, L LMI Academy cc Load Mass Crane Services cc Lott, RC Lowveld Cranes cc Machine Moving and Engineering Cape (Pty) Ltd Marine Equipment Supplies (Pty) Ltd Marlboro Crane Hire (Pty) Ltd Millwright Technical Services cc MME Manufacturing Pty Ltd Natal Crane & Hoist Services cc Nengwekhulu, SR Neuhoff, GE Newcastle Hoists & Eng Services (SA) (Pty) Ltd NewCorr Mining & Industrial cc North Coast Cranes & Lifting cc NVN Crane Repairs cc Palfinger Southern Africa Park Lifting & Mining (Pty) Ltd Premier Loadtesting and Services cc

Lifting Guide

2010

Quality Lifting & Engineering Supplies cc R G Maintenance Services cc Randall, B Raytoko Electrical & Mechanical Renniks Construction (Pty) Ltd Renvest cc T/a Cross Rigging Services Reynen, DL RFC Lifting Equipment cc Riggers Steeplejacks (Pty) Ltd Rigging Academy of SA (Pty) Ltd Rosieur, CR Sasol Infrachem Sauer, SL Scaw Metals Group Ltd (Chain Products) Schrader, S Searle Hoist & Tool (Pty) Ltd Servitrade Water Weights Lda Siteeco (Pty) Ltd Sommer, AH Special Industrial Supplies (Pty) Ltd Specialised Lubrication Services cc SSA Acoustic & Specialised Inspections (Pty) Ltd Steenkamp, AC Steyn, JJ STR Material Handling cc Submaro Offshore Support Services Tandem Crane (Pty) Ltd Tee, AE Teixeira, GJ The Crane Crew Timm, TN Toco Lifting (Pty) Ltd Toprope Tower Crane Services cc TransAfrica Equipment Company (Pty) Ltd Umbogintwini Riggers & LM Inspectors cc Umholi Steel Wire Rope & Accessories Uni- Cape Equipment (Pty) Ltd Universal Suppliers and Expiditors Ustica 1193 T/a Platinuim Services Van Biljon, JJ Van Hansen, LA Vermeulen, SD Vermeulen, CJ Vogt, RT Vryheid Cranes cc Water Weights (Natal) cc Water Weights (Tvl) cc Water Weights International S.A. (Pty) Ltd Weren Lifting Services Wimbush, DJ Yale Lifting Solutions (Pty) Ltd

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Lifting Legally
Because of the many potential hazards associated with lifting equipment such as cranes and hoists, the Department of Labour through the Lifting Machinery Entity (LME) enforces certain legislation.

Regarding test and inspection equipment, a complete set of minimum relevant equipment is required for a specific inspection. A list of the equipment used for said inspection must be kept, as must the Calibration Certificates for the equipment used. This system will contribute to the protection of the public with respect to the lifting equipment industry. With any company involved in the lifting machinery industry, management systems, including records of jobs and projects carried out, are required for audit purposes. Test records issued must be kept available for a minimum of ten years.

ll sole proprietors or companies engaged in load testing in the lifting equipment industry have to register with the Department of Labour (DoL).

The LME Registration requirements include: Competency and relevant experience of technical staff in specific disciplines. Having a copy of the Occupational Health and Safety (OHS) Act and its regulations available. Providing proof of training of technical staff on the Act and its regulations. That an updated copy of the Associates Codes and Standards be available. Providing proof of training of technical staff on the relevant Codes, Standards & Specifications.

New, young LMIs needed

A spokesman for LEEASA points out that LMIs are steadily becoming older. There is a dire lack of younger LMIs in the industry. He also points out that the trade of being an LMI is a reasonably well-paid occupation, and the prospects for career advancement are good. We urgently need to see more young LMIs being trained. If anyone is interested they can contact LEEASA for further details, See page 6 for details. A copy of a code of conduct for the technical staff must be displayed. Records of staff education and experience in the lifting industry working environment must be kept. For companies wanting to register with the DoL, its details are listed below. It is important to ask them for their latest forms. Keep copies of your submitted forms and use registered mail so you can prove your application and date of application.
Department of Labour Private Bag X117, Tshwane, 0001 Fax 012 309 4151 or Laboria House, 215 Schoeman Street, Pretoria , Email: mohlakola@labour.gov.za

Those who are exempted from these provisions are technical staff registered with the Engineering Council of South Africa (ECSA) as Lifting Machinery Inspectors (LMIs). Compliance includes having a considerable body of knowledge as well as familiarity with safety and ethical standards. A registered LMI conducts inspections of lifting machinery as defined in the Driven Machinery Regulations of the Occupational Health and Safety Act (Act no 85 of 1993). Lifting machinery is categorised to include tower cranes, mobile cranes, gantry cranes, harbour cranes, telescopic handlers, forklifts and work platforms etc. The LME is required to have at least one LMI on its staff. Registered LMIs will be allocated a registration number by ECSA. Any inspector from the Department of Labour paying a visit to a site can ask for the register to see whether the machines have been handed over and commissioned as well as the name and registration number of the LMI. Not only will this bring a companys processes into line with the legal requirements, but it will also ensure that best practice in terms of safety is implemented on site. Previously, under the Occupational Health and Safety Act, a person who undertook load testing of lifting equipment, was defined as a person with the knowledge and experience of the erection and maintenance of the particular type of equipment.

All entities performing load testing on all lifting machines should apply for registration with the Department of Labour

Did you know

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LIFTING TACKLE

Lifting Tackle
(Supported mainly by SANS manufacturing spec. documents)

This covers all loose tackle which does not form an integral part of the machine

Flexible Steel Wire Rope slings

The modern wire rope as we know it was originally invented by a German mining engineer named Wilhelm Albert in the years between 1831 and 1834. It was designed for use in the mining industry and was quickly adopted because of its superior quality over older ropes such as hemp or metal chains. The early ropes consisted of a bundle of wires being covered with hemp, however later advancements led to individual wires twisted into a strand and the six or so of these strands twisted around a steel core. There were however many variations of this steel core with it consisting of natural fibres such as sisal, manila, and jute. Today, steel wire ropes have a variety of applications including use in cranes, lifts, cable-cars, aerial lifts and suspension bridges.

Chain slings

Chain slings are used mainly for lifting operations and are often the preferred tool where the lifting job at hand requires ruggedness and at the same time, some flexibility. Chain slings do however have a drawback in that they are rather heavy and are only as strong as the weakest link. For this reason, the slings need to be inspected on a regular basis, should never be overloaded and should never be twisted. Chain sling are used in a variety of industries including aerospace, construction, crane and rigging, government and military, manufacturing, commercial fishing, mining, oil and gas, petrochemical, pipeline, and power generation. Depicted are three chain sling configurations.

Did you know

Registered Lifting Machinery Inspectors (LMIs) are persons registered by the Engineering Council of South Africa in terms of the Engineering Profession Act, 2000 (Act 46 of 2000), for specified categories with a defined scope of competence.

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LIFTING TACKLE

Webbing slings

Webbing slings are usually manufactured from polyester or nylon and thus offer numerous advantages over other types of slings. Firstly, because they are made from polyester, they are light and thus offer easy handling. Secondly, they are advantageous in that they wont cause injuries to their users and they can be used to hoist delicate cargo as they do not scratch. Webbing sling manufacturers offer many improvements on the product, with some slings being water, heat and UV resistant. There are also many variations, such as slings with metal or reinforced eyes and slings in double or single thickness sizes. Due to the material of the slings, friction does cause static electricity build-up, which could be detrimental to certain cargo types especially electronic equipment. It is for this reason that many manufacturers have developed anti-static web slings.

Hooks

When it comes to hooks, there are endless sizes types and shapes, each specifically designed to perform a certain job. There are foundry hooks, alloy-sling hooks and steel wire rope hooks to name just a few. Whether you use the hook for lifting or for tipping, there are two safety rules that all manufacturers enforce. Namely, always ensure the hook you are employing is of adequate strength to lift or tilt the load and secondly, always make sure the hook is properly engaged before beginning the job. In the case of a safety hook, always make sure that the safety clasp is facing away from the load or is not in a position where it will come undone by bumping into any chains or loads. Depicted on the right is a safety hook. It is different from other hooks in that it is completely closed, thereby ensuring that the rope or chain attached to it does not accidentaly come un-hooked.

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LIFTING TACKLE

Snatch blocks

A snatch block is essentially a pulley mechanism encased in metal. They have numerous lifting and pulling applications and as with most devices in the lifting industry can be dangerous if not lethal if not applied properly. According to research, snatch blocks and the amounts of pressure exerted through them are underestimated. It is warned that load exerted on a snatch block should never exceed its rating. The rule-of-thumb in the snatch box market is that you should buy the most expensive one you can afford. Although snatch blocks are used in many situations, they are especially common on boats and sailing ships, or where motorised aids are usually not available and the task must be performed manually.

Coupling links

A coupling link has a variety of uses however the most common is that of joining two link-chains together. The coupling is generally made of a round stock and parallel legs. A locking rod is inserted through the parallel legs, thereby locking the assembly together. The chain link forms a vital role in every industry that uses chains.

Shackles
A shackle is sometimes also referred to as a gyve. It is a U-shaped piece of metal secured with a clevis pin or bolt across the opening, or a hinged metal loop secured with a quick-release locking pin mechanism. They are most commonly used as a connecting link in all manner of rigging systems, from boats and ships to industrial crane rigging. For safety reasons, it is common to mouse a threaded shackle to keep the pin from coming loose. This is done by looping wire through the hole in the pin and around the shackle body. For pins that have a cross-hole in the threaded end, a cotter pin can be used. There are various shackle shapes and sizes on the market including snap shackles. D-shackles, headboard shackles, twist shackles and bow shackles.

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LIFTING TACKLE

Clamps

In the context of lifting equipment, clamps are generally used with lifting tackle and specifically with steel wire ropes. As illustrated, these clamps can be used for joining or creating special endings for steel wire rope, eg, the ends of slings. The clamps basically consist of a saddle and a U bolt and care must be exercised when using clamps which must conform to standards.

Under the hook auxiliary equipment identified in SANS 687 Spreader beams

Spreader beams are compression beams which separate two slings (or similar devices), that are picking up a load. See example in the adjacent picture. Lifting beams are beams which actually pick up the load from one or more lifting points under the beam which is positioned in such a way so as to hold the load in a specific or balanced position. The beam in turn is usually lifted from a single point or set of points on the top of the beam. These lifting points are connected to the crane hook.

Plate grabs

Lifting large pieces of sheet metal is no easy task. The problem becomes more difficult when the piece of sheet metal needs to be lifted up metres into the air. However, a device for just this application has been developed and comes in the form of a clamp. Clamps are available for either hoisting the metal sheet up and down or are available for moving the sheet metal horizontally. The clamps are available in various configurations with different jaw sizes and different load capabilities and many clamp manufactures state that the gripping force applied by the clamps is more than double the load being lifted.

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LIFTING TACKLE

Balanced fork attachment

In essence, a balanced fork attachment converts your forklift into a mini crane. It simply attaches to the cranes mast either by means of screws or with the assistance of a safety strap. The loads you are able to pick up are determined by the capabilities of the forklift and of the fork attachment. Various fork attachment load options are available.

Coils grabs

For every job, there is the correct tool and lifting coils is no exception. A coil grab is basically that a rig that allows you to safely and easily lift a coil of wiring or tubing. The coil grabs use telescopic legs that will fit snugly over the coil to ensure that it wont drop once being hoisted. Also, many of the coil grabs let you rotate the coil while hoisted meaning you can spool cabling or tubing on or off the coil while it is in the air.

Bar tong

These tongs are specifically designed to lift round or cylindrical loads such as pipes, tubes and bars. A conformal leg engages below the centre-point of the load where not only is the load cradled by the legs, but also securely clamped on the outside diameter. Each tong is designed for a specific size range and some tongs use multiple legs for lifting long, slender materials, thereby reducing deflection and improving handling. It is also possible to lift multiple cylindrical components as either stacked bundles or in parallel.

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LIFTING TACKLE

Lifting bins, buckets

When it comes to moving or lifting materials such as sand, stones and rubble, nothing will do it better than a bin or a bucket. Dozens of different shapes and sizes are available on the market it is just a matter of selecting the correct one for the job at hand. The disadvantage with a lifting bin or a bucket is that when clearing debris from a construction site, you often end up collecting loads of valuable soil in the bargain.

Lifting tray

A lifting tray is a seemingly simple device. It attaches to a lifting machine, thus allowing the load on the tray to be moved and placed where needed.

Lifting cages/cradles
Lifting cages are just that cages that allow workers and their equipment to be safely lifted to where the work needs to be done. The cage operator of a lifing machine can lift with safety as required. Various sizes are available, however most of them have one thing in common, that is that the cage is extremely simple to enter and exit, but at the same time is extremely secure to prevent accidental opening. Most cages carry clear operating instructions and handles, locks and the like are all clearly demarcated.

Lifting Receptical
Containers
With ISO containers weighing specified weights, lifting them manually is just not an option - no matter how many employees you have willing to show off their strength. For lifting a container onto a truck you need a container lifter. There are many variations of these, some of them attached to trucks, and some of them freestanding. The idea of a container handler is to move a full sized laden or full containers around a warehouse. These are found in the export and import materials handling depots.

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UNDER THE HOOK MACHINES

Under the Hook Machines

(no SANS 687 in progress)

Mechanical, electrical or hydraulic devices, manual or remote

Magnetic hooks
Magnetic lifters are versatile work handling devices that can be used to move a variety of ferrous metals, ranging from small bundles of rod or scrap to large, heavy blocks. When used to replace slings and chains, lifting magnets can improve overall productivity by allowing a single person to lift a load that may have required two or more people the old way. Magnets eliminate the need for drilling and tapping holes in parts so that eyebolts can be attached to move them. In many cases, these holes need to be filled and the surface needs to be refinished, adding cost to the product. An example of how a magnetic lift can positively impact productivity might involve a crate of parts that require machining. Magnets further save time by eliminating blocking and slinging. They also reduce waste. Because magnets wont spoil metal surfaces, they decrease the potential for the kind of product damage often caused by chains, hooks and other mechanical grabs. There are two basic types of lifting magnets: permanent magnets and electromagnets. Permanent magnets are exactly that; permanent. These magnets use permanently magnetized material to build up the magnetic field. One disadvantage is that permanent magnets have a restricted lifting capacity. Electromagnets employ electricity to charge the magnet and hold the material to the magnet face. Unlike permanent magnets, electromagnets require a constant power source. This can be viewed as either a detriment or an advantage, depending upon how the magnet is being used. A power failure can be catastrophic when using an electromagnet. On the other hand, the ability to vary the current being supplied to the magnet allows the user more flexibility than a permanent magnet affords.

Vacuum lifters
Vacuum lifters consist of a below-the-hook frame with a large vacuum pad or several smaller suction cups for grabbing large sheets, rolls, plates, or other smooth-surfaced products. They are driven by pneumatic, hydraulic, electric, or mechanical power. Pneumatic or air-powered vacuum lifters are equipped with air cylinders or motors that provide lifting action. There are many different types of vacuum lifters. Choices include heavy-duty lifters, vertical-horizontal lifters, coil lifters, batterypowered vacuum lifters, and products with mobile attachments. Battery-powered lifters are similar to electrically-powered devices, but have a rechargeable battery.

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CHAIN BLOCKS & LEVER HOISTS

Chain Blocks & Lever Hoists

(Supported by SANS 500, 1637 & 1640)

Chain blocks
Chain blocks are defined in the act as lifting machines and although they are usually regarded as portable tools, price and light weight are considered more important than durability. Consequently they are more likely to be dropped, badly stored and generally abused than their permanently installed predecessors. These changes need to be reflected in the in-service inspection regime, which aligns closely with that recommended for lever hoists, which have always been regarded as portable tools. Modern units are fitted with safety devices, and we are finding that more safety devices are being introduced as a result of safety awareness. The act is clear on what devices are required.

Lever hoists
Lever hoists and pullers have the advantage of being easy to transport, require minimum set-up, and are a practical option in confined spaces. They are suitable for different applications ranging from heavy-duty construction work to day-to-day maintenance and repair jobs. Older lever hoists do however suffer a major drawback and that is if the chain is drawn quickly over the load sheave while it is set for free running operation, the brake will automatically be applied and the free running movement terminated. Similarly, if a light load is suspended from the chain, the weight of the load may be insufficient to activate the brake with the result that the load will be wound down dangerously quickly. Newer versions have been developed and these problems have been eliminated.

Cable pullers
The cable puller has come a long way from its humble beginnings, which consisted mainly of blunt force by the operator. But with the advancement of technology, cable pullers are now offered in a variety of styles and range in capabilities. Easy to use, reliable and safe, cable pulling has never been more convenient. The cable puller is ideal in a range of industry segments, from heavyconstruction all the way down the chain to DIY home projects. As with all lifting or hoisting equipment, the cable puller is available in a variety of sizes, and with different load capacities. Many of them are manufactured from heavy duty steel with an automatic or notch-by-notch release mechanism.

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FORKLIFTS

Forklifts
(Supported by SANS 10388)

All fork lifts including attachments & special equipment

Counter balance

The counter balanced forklift is probably one of the most commonly used tools in the materials handling market. It can be found in just about any storage facility or factory. The forklift carries its load on the outside of its wheelbase and relies on a counterbalance weight and the weight of the engine to stop it from tipping over its front wheels. Many forklift trucks are available, each one designed to suit a certain application and to carry a certain load. The trucks vary from a 1-tonne pallet handler to heavy-duty 40 tonne diesel trucks used for large sea containers.

Side loaders

The side loader and four-way reach trucks are forklifts that are designed to carry their loads parallel to their direction of travel. They come in handy when long loads need to be transported such as pipes, and lengths of timber. Diesel side loaders are often used in rough terrain whereas the electric powered models are used indoors on smooth surfaces.

Rail or tyre type stacker & reach lift trucks

Reach trucks are most commonly used for the storage and retrieval of pallets in a warehouse. They differ from the standard counter balanced forklift in that they contain the load within their wheelbase. This ultimately results in them being able to operate in smaller spaces while at the same time, being able to lift to great heights. The main advantages of reach trucks is that they are very efficient in small spaces, are commonly available and are relatively simple to use.

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FORKLIFTS

Pedestrian controlled lift trucks

These forklifts are very common in warehouses and factories. They are designed to be a highly efficient method of storage as they operate in fairly narrow isles. Admittedly, they are not as robust or as fast as their reach truck counterparts, but their manoeuvrability makes them an ideal choice for many applications. The pedestrian stacker is commonly used to handle pallets with no bottom stringer. This is because the outrigger legs would get in the way of a pallet with bottom stringers.

Order picking lift trucks including all models

This truck is designed specifically for the manual handling of lessthan-pallet-load quantities in racking. The order picker design has fixed forks attached to a platform which elevates the load and the operator to facilitate manual loading and unloading from racking. Order pickers can operate in narrow or wide aisles. These forklifts are also very useful in cycle counting and physical inventory.

Pallet trucks
Powered Pallet Trucks (PPTs) are sometimes referred to as a Walkie, Walkie-rider or Rider motorised truck. They are basically motorised versions of the pallet jack. The PPT is designed for the operator to walk along with the truck as he or she moves loads. The PPT also includes a platform on which the controller can stand. PPTs are great for the frequent moving of loads over extended distances within warehouses and manufacturing operations. They are fast and highly manoeuvrable. Minimal controls result in short learning times although precision tuning does take some practice.

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The Importance of Regular Inspection

Because of the inherent risks associated with cranes, regular inspections and maintenance are imperative. Before starting a detailed inspection of the crane, carrying out a general survey of the crane and its surroundings may well point to possible problem areas to look out for during the actual inspection. At this time, it is advisable to ask how the crane is going to be used, and how the crane operation will interact with other activities on site.
operators manual and load charts.

Any powerlines?

his pre-inspection should be used to gather general information about the crane operators qualifications and the cranes certifications. Gauge the competency of the operator by observing this person in action, and question him about the operation of the crane, the inspection and maintenance records and ask to see the appropriate

During the initial survey, check on crane stability, any physical obstructions to operation, and how close the crane is to electrical power lines. The machine should set up level and be positioned for safe working. Are the outriggers being correctly deployed? Inspect the relationship of the load, the angle of the boom, and its radius to the centre of gravity of the load. The weight of the load should not threaten to topple the crane. Check on the structural integrity of the crane main components. In addition, check on all wire ropes, including stationary supports.

Electrical hazards

A common and very serious safety hazard encountered in crane operations is overhead power lines. The OSHA requirements limit crane operations to a minimum clearance of 3.05 metres. If potential loads are stored directly beneath electric power lines, a crane should not be used to handle these. Even if the electricity to the power lines has been switched off, mobile cranes should not be operated until the following steps have been taken: The power company or owner of the power line has de-energized the lines. The lines are physically grounded and appropriately marked as being safe at the site. Durable warning signs are installed at the operators station and outside the crane identifying the clearance requirements between the crane/load and electrical power lines. A qualified representative of the power company must be on site to verify that the power lines have been de-energized and properly grounded.

Load charts

Load Charts are the principle set of instructions for safe crane operations. The crane operator must have these in his or her possession, and show understanding, of the appropriate load charts related to the crane in use and the loads being lifted. Because cranes can lift loads and move them at great heights, the potential for serious accidents is always present. Accidents can be avoided by careful job planning. A safety plan must be developed for the job and must be explained to all involved Lifting Guide 2010

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in excessive downtime, increased maintenance costs, and the increased potential for accidents.

Inspection types Frequent inspection

The most common type of inspection is termed the frequent inspection. These are usually performed at the start of each shift by the operator. This involves walking around the crane and looking for defects or problems. The parts of the crane that have a direct bearing on its safe operation and whose status can change from day to day with use must be inspected every day. When possible, these components should be observed during operation for any defects that could affect safe operation. Frequent inspections should include, but are not limited to the following: Check that all exposed moving parts are guarded. Apart from the fact that exposed machinery is dangerous, a removed guard may indicate that a mechanic is still working on part of the crane. Visually inspect each crane component used in lifting, swinging, or lowering the load or boom for any defects. Inspect all wire rope (including standing ropes), sheaves, drums rigging, hardware, and attachments. Hooks with cracks, excessive throat openings of 15%, or hook twists of 10 or more, must be removed from service. Check that all swivels can rotate freely. Visually inspect the boom and jib for straightness and any evidence of physical damage, such as cracking, bending, or any other deformation of the welds. Look for corrosion under any attachments that are connected to the chords and lacing. Check carefully for cracking or flaking paint. This may indicate metal fatigue which often precedes a failure. On lattice booms, look for bent lacing. If it is kinked or bent, the main chord can lose substantial support in that area. When lacing is bent, the ends also tend to draw together which pulls the main chords out of shape. This precaution is especially important on tubular booms where every component must be straight and free from any dents. Damaged members must be cut out and replaced with lacing to the manufacturers specifications, procedures, and approval. With mobile cranes, inspect the tyres for damage and proper inflation. Inspect the cranes operating lines for either air or hydraulic fluid leaks. Check that the fuel, lubricating oil, coolant and hydraulic oil reservoirs are filled to proper levels. The crane must be equipped with a fully-charged fire extinguisher. The operator must know how to use it. Check all functional operating mechanisms such as: sheaves, drums, brakes, locking mechanisms, hooks, the boom, jib, hook roller brackets, outrig-

Drum brakes

in the lift. Before operations begin for the day, a walk-around inspection needs to be conducted to ensure that the machine is in proper working condition. Only qualified and properly designated people should operate the crane. Regular inspections are important, as they provide a means of detecting potential hazards or conditions that could contribute to a sequence of events leading to an accident. A thorough inspection programme can forecast maintenance needs or potential equipment failures or malfunctions. The lack of such a programme could result

Operating mechanisms, sheaves

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ger components, limit switches, safety devices, hydraulic cylinders, instruments, and lights. Check the turntable connections for weld cracks and loose or missing bolts. If bolts are loose, there is a good chance that they have been stretched. When checking the outriggers be sure that neither the beams nor the cylinders are distorted. Check that any welding is sound and not cracked and that both the beams and cylinders extend and retract smoothly and hold the load. Check the condition of the floats, and check that they are securely attached. Inspect and test all brakes and clutches for proper adjustment and operation. Always inspect the boom hoist lockout and other operator aids, such as anti-two-block devices (ATB) and load moment indicators (LMI), for proper operation and calibration. While the engine is running, check all gauges and warning lights for proper readings and operate all controls to see that they are functioning properly. Check for any broken or cracked window glass that may hamper the view of the operator.

Scope

The scope of the periodic inspection covers much of the same aspects of the frequent inspection. With the periodic inspection, however, the inspection is more detailed and may include magnetic or isotopic crack inspections. It should be noted that crane operators cannot be expected to be totally knowledgeable and proficient in the operation of the many diverse types of cranes available today.

Statutory Inspections

These are inspections and tests prescribed by legislation every six months. These functions must be done by an LME registered by the DoL who has in his employ a ECSA registered LMI and both should have the correct and same scope of approval and competence respectively.

Periodic inspections

The next more comprehensive level of inspection is the periodic inspection. Depending on the amount of use the crane is subjected, to this can take place once a month or once a year. The periodic inspec- Crane hook tion procedure is intended to determine the need for repair or replacement of components to keep the machine operating properly. Inspection records of the inspected crane must be maintained monthly on critical items in use, such as brakes, crane hooks, and ropes. These inspection records should include, the date of inspection, the signature of the person who performed the inspection, and the serial number, or other identifier. This inspection record should be kept readily available for review. The manufacturers maintenance and inspection records, forms/checklist, or equivalent should be used.

Hoist trolley

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Training for Safe Operation

There are a number of very real risks involved in operating a crane. Whether crane operators operate mobile or stationary cranes to lift, and place objects, potential danger is always present. Through proper training, crane operators will be able to operate a variety of cranes safely and efficiently. These range from gantry cranes used to move shipping containers, tower cranes mainly used on large building projects, overhead cranes in factories, or even mobile or truck-mounted cranes.

training may only be given by accredited training providers who are registered with the TETA and the trainers have to be qualified facilitators or assessors also registered with the TETA.

Basic computer skills needed

With new technology, cranes are becoming more computerised. Therefore, the new generation of operators will need to have some basic computer skills and have the ability to read, and interact, with a computer screen, In some cases, crane operator training can only be performed by an organisation that has the approval of the chief inspector. When this is the case, the operators must pass a theory and practical test before they receive a valid certificate of training, which entitles them to operate the crane on their own. They are required to be re-tested every two years to ensure they remain competent as crane operators.

efore climbing behind the controls, the operator needs to make sure that the crane is ready for use by checking the instruments and gauges.

Training essential

The law requires all crane operators to be formally trained. Training is carried out under the auspices of the Training Education Transport Authority (TETA). The training must meet education training quality assurance (ETQA) requirements for Provisional Accreditation, and have been recommended to the TETA Quality Assurance Standing Committee for approval of its status. Most of the larger organisations offer a bridging course after appointment. During this course, aspirant crane operators receive a broad knowledge of the general activities in which they might be involved. This in-service training is either done by a training officer, a foreman or an experienced senior operator. During this initial stage, crane operators will be under the supervision of a co-operator. Operator

Operators must judge distance and heights accurately while manipulating a number of complex controls
Not simple

Although the work of the crane may look simple to the outsider, certain aspects of the work is quite complicated. For example, if material is hoisted too quickly, the strain might result in a snapped cable or the sudden movement could cause the cargo to shift. As soon as the material is lifted from the floor, the operator has to manoeuvre the crane in such a way that the material is lowered onto a specific position. In addition, some cranes run on rails. This means that the operator also has to regulate the forward and backward movement of the crane on the rails. Moving a crane while it has a load suspended from its hook takes extra skill and good coordination.

Good hand-eye coordination

With an overhead crane, the bridge of the crane serves as a substitute for the boom on a tower crane. The hoisting platform and its suspended hook, as well as the cabin, can move backwards and forwards across the bridge. This means that the cabin has to be manoeuvred to a position right above the place where the load has to be picked up or deposited. Where a mobile crane has to be brought to a construction site, the operator must check the condition of the ground before setting up 2010

Safety training

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the crane. This may involve placing timber blocks or steel plates under the outrigger pads. Before attempting to lift a load, it is essential to check that the mobile crane is level on the outriggers. Every crane has a safe working load (SWL). The driver needs to be aware of what weight of material can be safely hoisted in each load and must check the cranes cabin instruments to make sure that the load is within safe working limits. This has to take into consideration the cranes capacity and the weather. For example, high winds can pose a danger to a suspended load.

Grade 10 Certificate. The Occupational Health and Safety Act and the Mine Health and Safety Act require crane operators to be at least 18 years of age and in good physical health.

Working with ground crew

While operating, the driver must observe and follow the signals given by doggers who direct the moving and positioning of the loads. The operator has to position the crane and its hook so that doggers can attach loads, by means of slings, shackles and chains. At times crane operators may have less than a clear view of what is happening on the ground. In these circumstances, ground crew will assist with the process of loading and unloading. Often, because of noise and distance, the worker on the ground shows the crane operator what to do by means of hand or flag signals, or by using a two-way radio or telephone.

A varied skill set

Although modern cranes have comfortable cabins ensuring maximum protection, outside the lifting work has to continue in all conditions. For this reason, it is essential to maintain the equipment by inspecting it for defects or wear. Ropes and winches must be lubricated, and worn cables replaced. Obviously, people who want to become crane operators should not be afraid of heights. They may be required to mount a vertical ladder to reach the cabin which is situated high above the ground. Furthermore operators must judge distance and heights accurately while manipulating a number of complex controls. This requires good hand-eye co-ordination. A responsible attitude towards the work is also important. Persons who easily become nervous or impatient can cause considerable damage by snapping cables or dropping material, thus endangering the lives of others. Prospective crane operators are also subject to a strict selection process prior to appointment. The minimum educational requirement is a Lifting Guide 2010

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MOBILE CRANES

Mobile Cranes
(Supported by SANS 19)

All mobile cranes and fixed adaptations of the superstructure of a mobile crane

Truck mounted cranes

These are mobile cranes either fitted with a lattice boom or a hydraulic telescopic boom, mounted on a conventional truck chassis. They are used as jobbing cranes and are limited to accessing places where there are good flat surfaces. They are not suited to rough terrain like construction sites.

Fixed or truck mounted knuckle boom cranes

A knuckle-boom crane or articulating crane is a hydraulically driven articulated arm fitted to a truck or trailer, and is used for loading/ unloading the vehicle. The numerous jointed sections can be folded into a small space when the crane is not in use. One or more of the sections may be telescopic. Often the crane will have a degree of automation and be able to unload or stow itself without an operators instruction. Unlike most cranes, the operator must move around the vehicle to be able to view his load; hence modern cranes may be fitted with a portable cabled or radio-linked control system to supplement the crane-mounted hydraulic control levers.

Pick and carry cranes

A pick and carry crane is usually fitted onto a rubber tired vehicle with a built in control station. Some times it is just too difficult or impossible to reach a spot, with conventional cranes. In such cases, a pick and carry crane can just be the right solution. Other features that make a pick and carry crane more powerful are its advanced hydraulic boom derricking and articulating operations of chassis. A pick and carry crane may also have a water-cooled diesel engine. The amount of weight that a pick and carry crane lifts may range from 9-12 tonnes or even more, depending upon the model. They are sometimes called yard cranes.

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MOBILE CRANES

Mobile harbour cranes

Traditionally, a cargo ship docks at the container terminal and off-loads the containers. Once these have been removed, the ship disembarks and re-docks at another berth, where the hold hatches are opened by more conventional cranes, and then the cargo is discharged into the hold with specialised devices. When this process is complete, the hatches are closed and the ship disembarks and re-berths at the container depot. Docking fees are paid to re-load its containers. The mobile harbour crane does all three functions in one, reducing docking time, money and turnaround time.

Crawler lattice boom cranes

Crawler lattice boom cranes are used for heavy lifts, mostly on sites where there are short distances between lifts, for example, at construction sites. They are slow moving, but can travel with loads. They are fitted with lattice booms consisting of lacings and stringers which are lightweight and strong. Another feature of the crane is that it travels on crawler tracks which makes set up quick.

Lattice boom cranes on tyre wheeled carriers

Lattice boom cranes on tyre wheeled carriers are similar to crawler cranes and are used for lifts including heavy lifts. After dismantling these cranes, they can be moved by their carrier, which is similar to an all terrain crane on normal high sped roads. They are fitted with lattice booms consisting of lacings and stringers which are lightweight and strong.

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MOBILE CRANES

Rough terrain and/or centre mount cranes

Rough terrain and/or centre mount cranes are cranes that have to be moved on low beds from site to site because they do not conform to road ordinance requirements. These cranes can work on rough sites in mud, snow and adverse conditions. They are highly manoeuvrable on site and are available up to 100 tonne capacities.

All terrain cranes

All terrain mobile cranes are used for lifting very heavy items, or for lifting items over great heights or large reaches. These are not for carrying, stationary operations. All terrain cranes can travel long distances at reasonable speeds conforming to axle loading requirements. Once on site, the crane can negotiate rough terrain similar to construction sites and open cast mines. They use telescopic boom configurations which can include lattice boom luffing fly jibs. The job does not come to them, but they go to it.

Tele handlers
A telescopic handler, or tele handler, is a machine widely used in the lifting industry. It is similar in appearance and function to a forklift but is more a crane than forklift, with the increased versatility of a single telescopic boom that can extend forwards and upwards from the vehicle. On the end of the boom the operator can fit one of several attachments such as a bucket, pallet forks, muck grab, or lift table. In some cases, it can even be converted into a crane.

Carry deck cranes

Carry deck cranes are designed for both indoor and outdoor jobsites and feature telescoping booms and a load deck for materials handling. Because of their low profile, they are able clear many overhead obstacles. Furthermore, their compact design allows for easy manoeuvrability in tight spaces, and they are thus the perfect alternatives when other cranes cannot fit.

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MOBILE CRANES

Truck mounted side loading container carriers

A truck mounted side loading crane is used for the loading, unloading and transport of ISO standard containers. The truck is usually fitted with balancing arms to prevent it from rocking over in the process of loading or unloading the container.

Excavators & loaders used as mobile cranes

Even though an excavator is designed for the clearing of debris at a building site, with the correct attachments, it can be transformed into a make-shift crane. Simply attaching a rope and hook to the end of the boom is not recommended though.

The lifting evolution

One of the things we need to do as humans is lift things. For cavemen, lifting the odd rock to dispatch a rabbit was not a problem, however, since the time of the Greeks, people wanted to lift objects weighing tonnes. And although Archimedes is sometimes credited with the invention of the lever, people had been using the humble lever for aeons before the Greek philosopher laid down the principles. However, the first evidence of early cranes comes from the ancient Greeks, who used devices called lifting tongs and lewis irons. About this time, the winch and the pulley were invented to ease the business of lifting things vertically. The Romans developed heavy lifting even further, and are credited with the first geared, powered crane. The power was provided by men working a tread wheel. Although still primitive, the Romans lifted some seriously heavy things. It is recorded the that the capital block of Trajans column weighs 53.3 tonnes. This piece of rock had to be lifted about 34 metres in the air, before being positioned.

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OVERHEAD & GANTRY CRANES

Overhead & Gantry Cranes

(Supported by SANS 10375) Did you know? Lifting machines cover everything defined in DMR, not only forklifts.

Overhead crane
An overhead crane, also known as a bridge crane, is a type of crane where the hook-and-line mechanism runs along a horizontal beam that itself runs along two widely separated rails. Often it is in a long factory building and runs along rails along the buildings two long walls. It is similar to a gantry crane. Overhead cranes typically consist of a hoist to lift the items, the bridge, which spans the area covered by the crane, and a trolley to move along the bridge.

Gantry cranes
A gantry crane is a type of crane which lifts objects by a hoist that is fitted in a trolley and can move horizontally on a rail or pair of rails fitted under a beam. Workstation gantry cranes are designed to lift smaller items around a working area in a warehouse or workshop, whereas rail-mounted gantry cranes are commonly found in steel factory applications such as steel yards, paper mills or locomotive repair shops. The rail-mounted gantry crane functions similarly to an overhead bridge crane, but has rails installed on the ground and gantry-style legs to support the crane. The picture shows a half gantry, half overhead crane.

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OVERHEAD & GANTRY CRANES

Free standing and/or permanently attached jib cranes

Free standing jib cranes are engineered to stand by themselves on a concrete foundation without building support. They allow for 360 rotation and can be base plate mounted, foundation mounted, or sleeve insert mounted. Standard capacities are from 1/2 to 5 tonnes. Other types of jib cranes include a mast type and wall mounted jib crane. Mast type is where the mast is supported at the top and bottom by the overhead building steel and floor. Wall mounted jib cranes only offer 200 of rotation and their design can be either cantilever or tie rod supported.

Goliath cranes
Goliath cranes are adapted to applications where overhead runways would be very long, costly to erect, and difficult to maintain in alignment. Where the installation is only temporary, a Goliath crane can be moved to a new location with less trouble or expenses than an overhead crane and its runway. Also, it is comparatively easy and inexpensive to extend the length of the runway and thus, increases the working area of the crane. Most gantry crane installations are outdoors. The initial cost of a Goliath crane, which may be double that of an overhead crane, must be equated against the additional cost of an overhead runway. The picture shows a cantilever overhang crane.

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TOWER CRANES

Tower Cranes
(Supported by SANS 522)

All top or bottom swivelling tower cranes

Tower cranes are a modern form of balance crane that consist of the same basic parts. Fixed to the ground on a concrete slab (and sometimes attached to the sides of structures as well), tower cranes often give the best combination of height and lifting capacity and are used in the construction of tall buildings. The base is attached to the mast which gives the crane its height. Furthermore, the mast is attached to the slewing unit (gear and motor) that allows the crane to rotate. On top of the slewing unit there are three main parts, namely the long horizontal jib (working arm), shorter counter-jib, and the operators cab. The long horizontal jib is the part of the crane that carries the load. The counter-jib carries a counterweight, usually of concrete blocks, while the jib suspends the load to and from the centre of the crane. The crane operator either sits in a cab at the top of the tower or controls the crane by radio remote control from the ground.

TOWER CRANE SERVICES

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REACH STACKERS & STRADDLE CARRIERS

Reach Stackers
(no SANS std. yet)

Mobile machines specially designed to move and stack containers, including the forklift counter balance types where a RCI must be fitted, whether the spreader is manual or automatic

A Reach Stacker is one of the most flexible handling solutions designed to operate in small or medium sized ports. Reach stackers are able to transport a container in short distances very quickly and pile them in various rows. Reach stackers have gained ground in container handling in most markets because of their flexibility and higher stacking and storage capacity when compared to lift trucks.

Straddle Carrier
(no SANS std. yet)

All mobile self propelled tyre type machines similar to gantry cranes

A Straddle Carrier is a non road-going vehicle for use in port terminals and intermodal yards used for stacking and moving containers. Straddles pick and carry containers while straddling their load and connecting to the top lifting points via a container spreader. These machines have the ability to stack containers up to four high and are capable of speeds up to 30 km/h with a laden container.

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CONTAINER CRANE

Container Crane
(no SANS std. yet)

Cantilever or fixed or on rail/s crane either inland or at a harbour

A container crane is a large dockside gantry crane found at container terminals for loading and unloading of containers from container ships. Container cranes consist of a supporting framework that can traverse the length of a quay or yard, and a moving platform called a spreader. The spreader can be lowered down on top of a container and locks onto the containers four locking points using a twistlock mechanism.

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SHIPS & WHARF SIDE CRANES

Ships Cranes
(no SANS std. yet)

All ship cranes including Scotch Derrick cranes

In medieval Europe, crane vessels which could be flexibly deployed in the whole port basin were introduced as early as the 14th century. In 1920, the 1898 built battleship USS Kearsarge (BB-5) was converted to a crane ship when a crane with a capacity of 250 tonnes was installed. Later it was renamed Crane Ship No.1. It was used, among other things, to place guns and other heavy items on battle ships under construction. Since then, ships cranes have come quite a way. Their applications are no longer limited to just placing weapons on battle ships, but are now also used in many major construction jobs around the world. As a definition, a crane vessel, crane ship or floating crane is a ship with a crane specialised in lifting heavy loads. The largest crane vessels are used for offshore construction. Conventional monohulls are used, but the largest crane vessels are often catamaran or semi-submersible types as they have increased stability. On a sheerleg crane, the crane is fixed and cannot rotate, and the vessel therefore is manoeuvred to place loads.

Wharfside Cranes
(no SANS std. yet) Wharf cranes were the backbone of the materials handling lifting industry in years gone by. It is difficult to formulate an exact definition for these cranes because they have evolved into modern state-of-the-art cranes. An example of this crane can be seen in the adjacent picture. They are used to travel on rails and load railway trucks which travel on rails underneath the cranes. Their lifting capacity has been increasing, but when they were in abundance, they generally picked up relatively small loads compared to todays standards.



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Falling from Height

Whether youre on a ladder at home, on scaffolding at a building site or window cleaning ten storeys up, if you slip, it takes three quarters of a second for the average human to react and by then its usually too late to grab onto something. According to the splat calculator we found on the internet, by then you will have already fallen three metres. Four seconds later you would have fallen 78 metres, at 211kph.

ad you been wearing a decent safety harness fitted with an energy absorbing lanyard and, most importantly, it had actually been attached to a reliable anchor point to arrest your fall, then youd have a good chance of coming out unscathed. Otherwise you just dont stand a chance against at least breaking several bones in your body if it happens to be your lucky day, or you pay with your life.

as that undertaken in connection with the erection, maintenance, alteration, renovation, repair, demolition of or addition to a building or similar structure, explains Arni. The regs also include the installation, erection, dismantling or maintenance of a fixed plant where such work includes the risk of a person falling from height. Risk assessments must be in place and a fall protection plan must be documented and enforced by anyone involved with work carried out in an elevated position. It is clear that anyone working at height must be protected from the potentially disastrous consequences of such work, Arni adds.

Ninety percent of the time the lanyard of the safety harness is dangling in the wind
In spite of the laws in South Africa, in the form of the OHS (occupational health and safety) act as well as the construction regulations, clearly stipulating that people working at height should be protected, you still regularly see workers high up on a tower, a billboard or a bridge without a safety harness. In too many instances the worker is wearing a harnesses, but is not attached to the structure. Ironically, while workers are donning a hard hat and even safety goggles, ninety percent of the time the lanyard of the safety harness is dangling in the wind.

The act

Attached

Although it is the employers responsibility to ensure that workers have the right PPE (personal protection equipment) and are trained to use the equipment, the employee also has a responsibility to take reasonable care of the health and safety of himself and others who may be affected by his actions or omissions. Most of the time we find that staff are only wearing the safety harness because the boss said so, Arni says. They tend not to attach the safety harness either because it slows them down, or they just ignore safety protocol and fail to re-attach their lanyard to a reliable anchor point and tie-off as they move around the structure. Working at height has the biggest number of fatalities while the lifting industry comes a close second, says Arni. When you consider that a fall from a height greater than 22 metres is considered fatal and the fact that people who fall from lower heights still die, it is definitely reasonable to protect workers from the consequences of working at height.

Arni Sommer

Budgeting

Construction

Arni Sommer talks about the safety harnesses they now produce locally. When it comes to the safety regulations there is a general misunderstanding around the term construction, he says. Most assume that construction is purely when youre putting up a building, but it actually extends way beyond that. If companies are not involved in laying bricks they think the construction regulations dont apply to them. In fact, the regulations define construction work

One of the biggest problems with safety equipment is that contractors dont budget for safety harnesses as such. They budget for other PPE such as hard hats, shoes and goggles, only to discover later that theyve forgotten about the harnesses, lanyards and fall arrest systems, never mind the necessary rescue equipment needed when someone has fallen, says Arni. Then they go and buy the cheapest harnesses and inadequate fall arrest equipment. South Africa has adopted the European norms and therefore a general guide is to look for equipment manufactured to either the EAN, CE or the Lifting Guide 2010



why the correct rescue procedures using dedicated rescue solutions is taught, says Arni. It is not the fall that kills, but rather the sudden stop, especially when using a static line or lanyard to arrest a fall of more than 3 metres. The dynamic energy absorber is a tear-webbing system that reduces the force of the fall to under 6 kNs before stopping the fall. This reduces the chances of causing damage to internal organs and internal hemorrhaging, as is the case in a static fall arrest!
Arni Sommer, Cel: 071-125-6177

A typical safety harness

(SABS) SANS EN standards, explains Arni. The act doesnt specify one specific standard. It just says that a harness or sling must be manufactured to a recognised technical standard and as far as is reasonably practicable, that the article is safe and without risk to health and safety when used.

Staff are only wearing the safety harness because the boss said so
Training
Together with selecting the correct equipment, from the bare basics of how to use the equipment, to advanced maintenance on the equipment and how to plan and handle a rescue operation is vital. The advanced course also deals with the legislation aspects around working at height as well as risk assessment of operations. An important aspect, that of suspension trauma, should also be covered, Arni explains.

Fall arrest

One of the most important components of a safety harness is the fall arrest system which has to include a proper energy absorbing element, otherwise the shock of the fall arrest can be damaging to the body and even fatal if not handled correctly. Thats

Safety harnesses must be manufactured according to a recognised standard

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AERIAL PLATFORMS

Aerial Platforms
(Supported by SANS 50280, 16368 & 18893. Also BS EN 61057 & Ansi A92.2) Working at height has the biggest number of fatalities while the lifting industry comes a close second. It is not the fall that kills, but rather the sudden stop, especially when using a static line or lanyard to arrest a fall of more than 3 metres.

Boom type (cherry pickers)

A cherry picker (also known as a boom lift, man lift, basket crane or hydraladder), is a type of aerial work platform that consists of a platform or bucket at the end of a hydraulic lifting system. It is often mounted on the back of a large vehicle such as a truck (in which case it may also be called a bucket truck). It can also be mounted on a flat-back pick-up van known as a Self Drive, or sometimes on a stand-alone trailer or self-moving platform. Cherry pickers were originally designed for use in orchards where they are still heavily used. It lets the picker pick fruit high in a tree with relative ease. Similar devices, also known as cherry pickers, are used to service telephone, cable television and electrical equipment on utility poles.

Specially insulated aerial platforms

An electrically-insulated aerial platform assembly is for use by a lineman on or around utility poles. The assembly usually consists of a work platform presenting an elongated, substantially flat upper work surface where a lineman may stand, sit or kneel, together with means for temporarily attaching the platform to the utility pole with the platform being electrically insulated from the pole during normal working conditions.

Scissor lifts (mobile or fixed)

A scissor lift is a type of platform which can usually only move vertically. The mechanism to achieve this is the use of linked, folding supports in a criss-cross X pattern. The upward motion is achieved by the application of pressure to the outside of the lowest set of supports, elongating the crossing pattern, and propelling the work platform vertically. The platform may also have an extending bridge to allow closer access to the work area (because of the inherent limits of vertical only movement). The contraction of the scissor action can be hydraulic, pneumatic or mechanical (via a leadscrew or rack and pinion system).

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SUSPENDED ACCESS PLATFORMS

Suspended Access Platforms (SAE)

(SANS 51808 & 10295 part 1 & 2)

Units that are hang from suspension anchors/points

Temporary Suspended Platforms

A temporary suspended platform is much the same as a building maintenance unit except for the fact that it is easily attached or detached to or from the building. They usually consist of aluminium cradles, of various sizes from which the workers can lower themselves down the buildings side. This cradle is attached to the building via ropes.

Building Maintenance Unit (Permanently Suspended Platforms)

Building Maintenance Units or BMUs are permanently installed units for maintenance workers to safely access all areas of a buildings faade for window cleaning, regular maintenance and minor repair work. BMUs can be manual, semi- powered or fully powered and are generally installed onto a tracked runway system that is in turn fixed back to the roof structure. Depending on the design of the BMU, either a dedicated cradle or a separate cradle set can be suspended from the jib.

(MEWP) Mobile Elevating Work Platform

A mobile elevating work platform is a mechanical device used to provide temporary access for people or equipment to inaccessible areas, usually at height. MEWPs are designed to lift limited weights (usually less than a tonne), distinguishing them from most types of cranes. They are usually capable of being fully operated (including setup) by a single person. MEWPS may provide additional features beyond transport and access, including being equipped with electrical outlets or compressed air connectors for power tools. There are distinct types of MEWPs, the key difference is in the drive mechanism which propels the working platform to the desired location. Most are powered by either hydraulics or possibly pneumatics.

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HYDRAULIC INDUSTRIAL LIFTING DEVICES

Hydraulic Industrial Lifting Devices

(SANS TBA)

All special industrial applications. (usually heavy lifting devices)

Hydraulic lifting machines have been in use for many years. Originally driven by water, hydraulic equipment has found endless uses in industry today. Because of the nature, versatility and compact nature of hydraulic equipment, more and more demand for special applications have arisen. To make things work more efficiently in small places and to develop the same or more force, hydraulic pressures have increased to normal working pressures of 700 bar.

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VEHICLE HOISTS

Vehicle Hoists
(SANS 71)

All hoists designed to lift vehicles of any capacity or design

4 posters
A 4 poster car lift is essentially very similar to a 2 poster car except for the one fundamental difference being that the 4 poster lift has four legs with which to lift a car or truck. It is for this reason that 4 poster lifts are generally used when it comes to lifting heavier vehicles such as trucks. They are also used when the truck or car needs to be lifted for extended periods of time. A drawback of the 4 poster lift is that it needs far mare space than the scissor or 2 poster lift. The ground underneath the lift also needs to remain clear at all times.

2 posters
2 poster lifts have advantages as well as a few drawbacks. They are much cheaper than their 4 poster big brothers. 2 poster lifts require a lot less room than the 4 poster and scissor lift designs, and lastly they are much more functional than the other makes as there is no platform to contend with when working on the vehicle. 2 poster lifts do however have one drawback and that is that they need to be permanently mounted to the garage or workshop floor.

Scissor lift type (excluding dock levellers)

Scissor lifts are a common piece of equipment in many garages and workshops where space is at a premium. Car scissor lifts are much the same as a pair of scissors, hence the term. Usually a car is driven on to the lift which is then raised up, allowing ease of access to the underside of the vehicle. The actual lifting and lowering is controlled by hydraulic power in most cases, although electric lifts are also an option. Scissor lifts are beneficial in that you dont need to mount them to your floor. They are completely mobile and can be taken out when needed or stowed away when not in use.

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VEHICLE HOISTS

Hydraulic type
At some point, all of us have seen a hydraulic lift in action. The most common place would be when you take your car to get its exhaust fixed or replaced. The basic idea behind any hydraulic system is very simple. The force that is applied at one point is transmitted to another point using an incompressible fluid. The fluid is almost always an oil of some sort and the force is almost always multiplied in the process. The end result is that very little force has to be applied in order to lift a heavy object such as a car or truck. A hydraulic system does however have to be continually maintained. Dirt and air-bubbles that end up in the hydraulic pipes or cylinders could wreck absolute havoc.

Tail Lifters
(SANS 1055)

All tail lifts fitted to a mobile vehicle

A tail lift is a mechanical device fitted to the back of a van or lorry, which is designed to facilitate the materials handling of goods from ground level or a loading dock to the level of the load bed of the vehicle, or vice versa. The majority of tail lifts are hydraulic or pneumatic in operation, although they can be mechanical, and are controlled by an operator using an electric relay switch. The use of a tail lift can obviate the need to use machinery such as a forklift truck in order to load heavy items onto a vehicle, or can be used to bridge the difference in height between a loading dock and the vehicle load bed. There are two main types of tail lifts available, namely column lifts and cantilever lifts.

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OTHER SPECIALISED CATEGORIES

Other Specialised Categories

As the lifting industry grows, more and more specialised machines are being added to the lifting machine list.

Side cranes

Most side cranes are lifting machines that are specially adapted bull dozers for pipe laying and similar operations. They have become very popular over the years because they can work in adverse conditions. Some models can lift in excessive of 70tonnes which is achieved by adjustable counter weights.

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Secondhand/Hiring
When projects end, crane owners might need to sell off equipment that is surplus to their requirements. These can be really good buys. However, keep your eyes open for the tarted-up piece of junk, being passed off as a good deal.
you expect, conduct a couple of simple checks. Start it up. Does the engine sound smooth and does it run without smoking? Do all the gauges and dials work? Check on the level of the engine oil and its condition. You can tell much from the general condition of a crane. If the wiring is not neat and the hydraulics show signs of leaking after a couple of minutes of operation, the crane may well have many more hours on it than the salesman is letting on. Dents and scrapes tell of neglect and careless operation.

Hiring the answer?

Unlike 30 years ago, hiring companies are in a very competitive market. So the equipment they hire out is mostly quite new and should offer good reliable service with no downtime. The big advantage of hiring is that instead of spending your capital all in one go, you can keep it in the bank, to be deployed more advantageously at some more opportune time.

aybe you need a crane urgently. Or you are planning to start in professional cargo handling using a mobile crane. Possibly, you are looking for an economical way to buy your first crane. Maybe due to uncertain economic conditions, you would like to keep the investment costs as low as possible.

Smiles not miles

Before you leap

If it is a truck-mounted crane, the condition of the tyres will speak volumes about the age of the mobile crane, and the type of use it has been put through. Look at the controls the levers and the foot pedals. If these are worn smooth, you might think twice about purchasing this crane. The crane should have all its maintenance records as well as paperwork such as load charts. If the crane is a legitimate sale, then the salesman will not mind if you give the former owner a ring. Why did the former owner sell it?

Before rushing off to your new crane dealer, consider that used cranes have the following main advantages over new cranes: immediate availability shorter delivery lead times lower purchase costs Most cranes, because of the nature of their duties, have great durability, dependability, economy and flexibility. However, to get the quality and service

Guarantees?

If you are buying an expensive capital item such as a crane, then there should be discussion about guarantees and over what period such guarantees should be in force. If you are not an expert in the field of cranes, then whatever you do, take a crane expert with you. He or she will at least be able to advise you whether you are buying the right machine for your requirements.

No maintenance worries

For someone needing a crane for a specific project, hiring means not having to worry about maintenance, or finding the right technical skills. It also means not having to layout large sums on spares. If your lifting needs should change, by not being tied by ownerhsip, the option to hire exactly the right lifting solution is almost immediately available. All of this allows the person who needs to use a crane to concentrate on their core business, rather than trying to be a crane operating company.
Used crane



Lifting Guide

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Inside Back Cover

Lifting Guide

2010



Outside Back Cover Raytoko

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