Safety in Tools and Tackles

by Sudipto Paul

 Hand operated
hand tools
Power operated
portable tools

Industri
al

Industri
al

Class of Tools

What do you think are the most

common injuries from working with
hand and power tools?
Electric shock
Flash burns
Falling
Hand and Eye injuries
Hearing loss
Crushing, cuts or
losing a body part
Ergonomic injuries

General Requirements for Portable Power

Tools
Dos

Donts

Tools, cords and accessories

must be inspected before its use.
Always wear Personal
Protective Equipment (PPEs)
including shielded safety goggles.
Be sure the power tools are
doubly insulated and grounded.
Keep power tools clean, sharp
and in good operating condition.
Immediately turn off and
unplug any tool that sparks,
overheats or causes an electrical
shock.
The user must be properly
trained to use the specific tool.
Follow all the written
instructions in the standard
operating procedure and the
warnings.
Use Guarding

Use a power tool without

wearing appropriate
personal protective equipment.
Overreach or use a power tool
while standing on a ladder. Plant
your feet firmly on the floor.
Try to fix a defective power tool
yourself.
Using a small tool for a big job
that requires heavy-duty tool.
Using power tools in areas with
chemicals or other flammable
liquids or wet surface.

Power tools can be dangerous

Hand-held power tools are lightweight,
portable and convenient to use. Because of
that, its easy to forget that theyre dangerous.
Unsafe use of power tools can result in:
electrical shock
fires or explosions
severe cuts, puncture wounds, or injuries
from flying debris
Its important to understand how your tool
works and how to prevent accidents.

Visual Photographs

Unplug power tools before

changing bits or blades.

Dont use small tool

for a small job.

Before you start work with a tool

Drill machine, saw machine, grinding machine and other power
tools come with written instructions. Look those over before
you plug in the tool. See your supervisor if you have any
questions.
Be sure your work area is clean. Oily rags, sawdust, papers and
other clutter can easily be ignited by sparks or heat.
Dont use power tools if your work area is wet or damp or if you
are outside in the rain. Operating a power tool with wet hands
or while standing in water can result in electrical shock.
Make sure the tool is turned off and unplugged from the power
supply before you inspect it or install bits or blades.
Carefully inspect the tool, its cord and any accessories before
each use. Look for dirt, rust, dull blades, loose parts,
malfunctioning switches, defective insulation or any other
damage. Dont use the tool if it needs repair. Report any
problems to your supervisor.

Personal Protective Equipments for

tools and tackles
Safety Helmet

Ear plug

Long Sleeved
shirt
Long pants

Safety Goggles
Dust/mist
respirator
Safety Gloves

General Requirements for Hand

Operated Hand held tools
Dos
Train/authorize each user for
specific tool.
Select the proper tool and the
proper PPE (usually hand gloves,
safety glasses etc) for the job.
Inspect the tools for defects
such as : sharpness of cutting
tool, burrs/cracks/chips, splinters
on the hand grip of tool.
Mushroomed heads on the
impact tools. (i.e., cutting edges
are sharp, struck head is not
mushroomed or chipped).
Discard tools which are bent,
cracked or chipped

Donts
Do not use the tool in
application for which it is not
intended or beyond the design
capability.
Do not carry edged or pointed
tools in the pockets.
Do not use a tool which is oily
or greasy. It may slip out of hand
causing injury.
Carry tools in your hands when
going up or down a ladder or
steep stairs.
Do not leave any tools
unattended in the passageway.
Suitable cabinets or covers shall
be provided for the hand tools.

Safety in Drilling machine at

Railway Siding,Joda

Safety in Drilling machine at

Railway Siding,Joda

Safety in Grinding machine at

Railway Siding, Joda

Safety in Grinding machine at

Railway Siding, Joda (Welding Set)

Safety in Carrying of Sleeper Using

Rail Trolley at Railway Siding, Joda

Safety in Carrying of Sleeper Using Rail

Trolley at Railway Siding, Joda

Safety in Carrying of Sleeper Using Rail

Trolley at Railway Siding, Joda

Clamping mechanism of Rail Trolley

Long Handle for
Holding the Rail
trolley

Clamping
arrangement of
sleeper

Wheel of Rail Trolley

Movement of Sleeper using Lifting

Tongs

Safety in Movement of Sleeper

using Lifting Tongs
Lifting Tongs

Safety in carrying and placing of

sleeper in position in between two
sleepers using lifting tongs

Jhama- A lifting tool for sleeper

using FX 150 crane

Jhama lifting
tool for 4
sleepers at a
time

Safety in Rigging and Material

Handling

Wire rope - Slings

6x19 Fibre Core

8x19 Fibre Core

6x19 IWRC

Exercise

U- Bolt (Bull dog) Clamp

Rules to use clamps

Saddle must be close to the
size of the cable

Spacing between clamps is

equal to 6 to 8 times the
diameter of cable

Bolts must be equally tight

25

Installation of U- Clips
Installation of U-Clips
U- Bolt (Bull
dog) Clamp

Diameter in
Inches

Minimum Number
of Clips

1/8 7/16

- 5/8

- 7/8

1 1/8 1

1 3/8 - 1

Thumb rule
SWL = 6*D*D
D = dia. of the rope
eg: 1/2 rope dia = 6 *1/2 *1/2 = 1.5 T
Note: Dia is in inches & capacity in Tons.
Factor of safety for wire ropes 5
Factor of safety for wire rope slings

Factor of safety for wire ropes when used for

carrying personnel- 10

SLING HITCHES AND

APPLICATIONS

BASKET HITCH
A basket hitch has twice
the capacity of a single
leg only if the d/d ratio
25/1 and legs of slings
are vertical.
At other angles, sea
table.

ANGLE

% OF SINGLE
LEG SLING
CAPACITY

200%

30

170%

45

140%

60

100%

CHOKER HITCH
The
choker hitch has 80% of the

capacity of a single leg only if the

corners are softened and the
vertical sling angle is smaller than
600
Use blocks to prevent angles
greater than 600

ANGLE OF
CHOKE

SLING RATED
LOAD
% OF SINGLE
LEG SLING
CAPACITY

1200 - 1800

80%

900 1200

65%

600 890

55%

Choker hitch

Wire rope slings Choker hitch

The capacity of a choker hitch is

Approximately 75% of the single leg

Choker hitch - Angle

Wire rope slings

Choker hitch capacity
reduction when angle of
choke less than 120
degrees
ANGLE OF
CHOKE

CAPACITY
% OF CHOKER
(ASME B30.9)

CAPACITY
% OF VERTICAL
(ESTIMATED)

1200 - 1800

100%

75%

900 1200

87%

65%

600 890

74%

55%

300 590

62%

46%

00 - 290

49%

40%

Basket hitch

Wire rope slings Basket hitch

The basket hitch has

twice a capacity of a
single leg if the legs
are vertical and the
sling is wrapped
around a load that is
big enough.

Chain sling

Chain sling Hardware

Use master links to
collect slings and to
connect to hook
Use grade 8(80)
fittings that match
the W.L.L of chain
and offer proper
securement

Synthetic sling

Synthetic web and round slings basket hitch

Basket hitch capacity is
double only if legs are
vertical

At 600 vertical angle the

capacity is equal to
single leg

Bridle
THE BRIDLE
Slings angle greatly affects the
sizing of sling and fittings at load.
30 degrees vertical is a good
angle
60degrees vertical is the
maximum angle
INCLUDE
D ANGLE
HORIZONT
AL SLING
ANGLE

LOAD

VERTICAL
SLING
ANGLE

Inspection of tools &

tackles

Inspection of tools & tackles

Wire rope - Slings

Inspection of wire rope slings removal criteria

Missing or illegible sling
identification
Excessive broken wires
Severe localized abrasion
or scraping
Kinking, crushing, bird
caging or any other
damage resulting in
damage to the rope
structure

Eye

Body
Mechanica
l splice

Inspection of Wire rope slings

Inspection of wire rope slings removal criteria
Eye
Evidence of heat damage
End attachments that are
cracked, deformed or
worn
Severe corrosion of the
rope, end attachments or
fittings
Other conditions,
including visible damage,
that cause doubt as to the
continued use of the sling

Body
Mechanica
MECHANIC
l splice
AL
SPLICE

Inspection of Wire rope slings

Inspection of wire rope slings removal criteria
Damage, corrosion, quality of workmanship

Remove from service

Inspection of Wire rope slings

Inspection of wire rope slings
Broken wires

Broken strands
remove from service

Broken wires
Remove from service

Inspection of Wire rope slings

Inspection of wire rope slings
Kinking

Remove from service

Inspection of Wire rope slings

Inspection of wire rope slings
Dogleg
Look for displaced
strand, if a strand
is significantly
dislocated,
remove from
service

Inspection of Wire rope slings

Inspection of wire rope slings
Dogleg

Remove from service

Inspection of Wire rope slings

Inspection of wire rope slings
Bird caging

Remove from service

Inspection of Wire rope slings

Wire rope slings Temperature

Inspection of tools & tackles

Storage of Wire Ropes

Ropes should be stored in coils or on reels in a clean, dry

place indoors.
If outdoor storage is necessary then their surfaces should
be covered to prevent the ingress of moisture or matter
injurious to the rope.
Periodical Examination and lubrication of their rope.
The rope should be kept away from heat and steam
The lime, sulphur and ash can cause corrosion pits.

Inspection of Synthetic slings

SYNTHETIC
WEB SLINGS,
NYLON OR
SLINGS
POLYSTER

ROUND SLINGS,
POLYSTER

Inspection of Web slings

Inspection of web slings
Cause for removal
Missing or illegible sling identification
Acid or caustic burns
Melting or charring of any part of the
sling
Holes, tears, cuts or snags
Broken or worn stiching in bearing
splices
Excessive abrasive wear

Inspection of Web slings

Inspection of web slings
Cause for removal
KNOTS IN ANY PART OF SLING
DISCOLORATION AND BRITTLE OR STIFF
AREAS ON ANY PART OF THE SLING, WHICH
MAY MEAN CHEMICAL OR ULTRAVIOLET /
SUNLIGHT DAMAGE
FITTINGS THAT ARE PITTED, CORRODED,
CRACKED, BENT, TWISTED, GOUGED OR
BROKEN
OTHER CONDITIONS, INCLUDING VISIBLE
DAMAGE, THAT CAUSE DOUBT AS TO THE
CONTINUED USE OF THE SLING

Inspection of Synthetic slings

Inspection frequency of
synthetic round slings
Initial:
Prior to initial use
Frequent:
Each day or shift before the sling is used
The periodic inspection:
Normal service
yearly
Severe service
monthly to quarterly
Special service
as recommended by a
qualified person

Inspection of Polyester slings

Polyester round slings removal from
service
Missing or illegible sling
identification
Acid or caustic burns
Evidence of heat damage

Holes, tears, cuts, abrasive wear or snags

that expose the core yarns
Broken or damaged core yarns
Weld splatter that expose the core yarns

Inspection of Polyester slings

Polyester round slings
Removal from service
Round slings that are knotted
Discoloration and brittle or stiff areas
on any part of the slings, which may
mean chemical or other damage
Evidence of heat damage
Fittings that are pitted, corroded, cracked,
bent, twisted, gouged, or broken
Other conditions, including visible damage,
that cause doubt as to the continued use of
the sling

Inspection of Nylon / Polyester slings

Nylon and polyester slings
Temperature

90C
0C
-40C

Shall not be used at

temperatures in
excess of 90c or
below -40c

Inspection of tools & tackles

Wire Rope Discard Criteria

10 randomly distributed broken wires in one lay length.

Five broken wires in one strand in one lay length.
Severe localised abrasion or scraping.
Deformations, or evident rope deterioration from corrosion
Thermal damage or core protrusion.
Cracked, deformed or worn end attachments.
More than 1 broken wire in vicinity of a swaged fitting,
including resin-poured sockets

55

Inspection of tools & tackles

Wire Rope Discard Criteria

Indication of strand or wire slippage in end attachments.

Defective or damaged fittings, ferrules or splices. No SWL
indicated on ferrule.
Loss of diameter not to exceed 10% for 6 strand, or 3% for nonrotating, of the nominal diameter.
Distortion- kinking, crushing, core collapse, knotting or other
permanent distortion.

56

Exercise

Inspection of hardware

Inspection of hardware
Inspection of hardware
Wear

10% or more reduction in any sectional dimension

indicates it has excessive wear, measure by
comparing to a section of fitting that has no wear,
or to the catalog dimensions
Make sure identification is legible

Inspection of hardware
INSPECTION OF
FITTING
DEFORMATION

ANY SIGNIFICANT PERMANENT

DEFORMATION, OR CHANGE IN
SHAPE, INDICATES IT HAS BEEN
OVERLOADED AND MUST BE
REMOVED FROM SERVICE

DUCTILE VS. BRITTLE

FAILURE

DUCTILE
FAILURE
SHOWS
DEFORMATION

BRITTLE
FAILURE
SHOWS
DEFORMATION

Inspection of hardware
DEFORMATION
HOOKS
ANY VISIBLE APPARENT
BEND OR TWIST FROM THE
PLANE OF THE UNBENT
HOOK
ANY DISTORTION CAUSING
AN INCREASE IN THROAT
OPENING OF 5% OR MORE,
NOT TO EXCEED 7MM

Inspection of hardware

Field marking of hooks quickcheck marksPlace reference marks only in

these two areas:
1. In the tip area
2. In shoulder area centered
on shank or eye

Use a round pointed punch,

not sharp or pyramid point

Inspection of hardware

Inspection of fittings Cracks and

sharp nicks

Any crack, sharp nick or gouge in the surface of

any fitting is cause for removal from service

Inspection of hardware

Inspection of fittings modification

Bold
substitutio
n
Welding of hook
Any modification of any fitting is
cause for removal from service:
Welding or heating
No substitution of parts
No bending

Inspection of hardware

Inspection of rigging hardware

removal criteria for threads

Excessive thread damage or wear of screw pins,

shank hooks and turnbuckles:
Remove from service if
threads damaged or
corroded for more than
20% of the length engaged
in ear of shackle or nut of
Engag
hook or turnbuckle
ed
Length
:

Inspection of tools & tackles

Web slings

Use only identified sling.

Never use a damaged sling.
Never make knots in a sling.
Never drag a slings from underneath a load that is
resting on it
Never use a sling with unprotected sharp edges.
Always ensure that lifting hooks or devices have smooth
edges that will not damage the eyes of the sling.
Damaged slings to be taken out of service immediately.
Any sling with cuts at the edge or damaged to stitched
seems must be rejected

Inspection of tools & tackles

Web slings

If slings are to be used in chemically abnormal

atmospheres or in constant high temperature then seek
usage advices before use
Do not store sling in direct sunlight OR near direct heat.
Never use a round sling that has a damaged outer
sheath.
Always observe the certified capacity of a sling.
Always inspect a sling before use.
When inspecting sling examine the full length for
chafe/cuts/seam damage.
Check working temperature range

Inspection of tools & tackles

Shackles

Check alignment of holes

Pin should be free to rotate
when nut is tight
Sound shackles, they must
have clear ring
Use split pin where required,
not welding rod
Dont use shackle where pin
can unscrew by rolling under
load.
Make sure pin is free, but not
loose, in tapped hole
No thread damage

Check for
Wear
Check for Wear &
Straightness
Check that the pin is
always seated
Check that shackle
is not opening up
When shackles are inspected highlighted points
in the above sketch shall be considered.
Shackle Pins shall not be replaced by a bolt.
69

Screw Pin shackle shall not be used

if Pin can roll and get unscrewed.

Incorrect

Correct

A shackle shall never be

loaded at an angle.
As shown in the above
sketch packing
shall be used to avoid this.

70

Inspection of tools & tackles

Chain pulley block

Chain pulley block Shall have end

hooks,
The two Hooks of Chain blocks are
the one which is used for clamping
and next one for lifting
Chain block Is a device for load
lifting and Horizontal Pulling Shall
not be done
The moving parts such as Gears
shall be properly guarded
Never Drop a Chain block From any
height

Inspection of tools & tackles

Chain pulley block

Before hanging the chain pulley

block on the structure ensure for
adequate strength for structural
member to withstand load.
Dont hang the block by tip of the
top hook on structure.
Dont hand the chain pulley block
on any of scaffold member as it is
not designed to take load.

Inspection of tools & tackles

Chain pulley block

When a block is hung to an

overhead beam with a help of
sling protect the sling against
the sharp edges.
The tip of the hook block
should have a safety latch.
Pulley blocks should have
identification mark and SWL
marked on them.
Loads in excess of SWL
should not be raised, lowered
or suspended.

Crane

Boom-limit switch & Boom cutoff

The most vital control which

does not enable the boom to
extend beyond the preset angle
and also further trips the
function

Safe load Indicator

Boom
angle

Load
Radius

HSE Dept. HCP & TPPC

Boom
length
Vertical
Height

Safe load Indicator and cut off Functions

The picture shows the Over

hoist indicator in normal
condition and also further the
indicator glows and trips off the
entire function

Conditions when a crane gets destabilized

HSE Dept. HCP & TPPC

Unequal Tyre Pressure

Certification of Cranes

Load test on cranes are to be done

by a competent person.
Never load the crane beyond SWL
Refer crane load chart before
operating.

Case Studies.

Case Studies.

Case Studies.

Case Studies.

Case Studies.

Thank You