1. Material Handling and Hand Rigging
Contren learning series #

2. 1.0.0 Introduction
Moving and placing heavy objects is a frequent occurrence in the industrial maintenance profession.
Everyone in this profession needs a knowledge of how to place rigging on a load to safely lift, move, and sit heavy objects.
Everyone will not be the crane operator, but everyone must know how to signal the operator.

3. 2.0.0 Rigging Hardware
Only hardware designed for lifting should be used.
We will discuss:
Hooks
Shackles
Eyebolts
Lifting Lugs
Turnbuckles
Beam Clamps
Plate Clamps
Rigging Plates and Links
Spreader and Equalizer Beams

4. 2.1.0 Hooks Used to attach to a sling or load.
Always inspect hook before use.
Replace if:
Throat is opened 15% over the original width.
Body is twisted 10 degrees from original plane.

5. 2.2.0 Shackles (Clevis)
Used to attach an item to a load or to attach slings or wire ropes together.
Important safety information:
The shackle pin (not the body) must always be hung on the hook.
Pin wear of 10% or more must be replaced.
Shackles pulled at an angle has reduced capacity.
Never use a shackle in a manner that allows the pin to be rolled under a load.

6. 2.3.0 Eyebolts
Attached to heavy equipment to give connection points for lifting.
Shoulder-less eyebolts can only be used for vertical lifting.
Use shoulder eyebolts for angled lifting connections.
Position the ring so that the lifting force is applied to the ring.

7. 2.4.0 Lifting Lugs
Custom-built for a specific machine for proper lifting.
May be welded, bolted, or pinned to the machine.

8. 2.5.0 Turnbuckles Used to adjust the length of rigging connections.
Typical ends: Eye, jaw, hook.
Hook ends have less load capacity than others.
Important safety information:
Do not weld on a turnbuckle.
Only one turnbuckle per leg.
Do not use jam nuts (unless supplied by factory).
Do not over-tighten. Use correct wrench size only.
Not for angular loading unless factory-specified.

9. 2.6.0 Beam Clamps
Used to connect lifting devices to structural beams so they can be lifted and positioned.
Two clamps may be used as long as the bridle sling angle does not exceed 25 degrees from vertical.
Replace clamp if jaws open more than 15% of original.

10. 2.7.0 Plate Clamps
Used to grip structural plate steel for attachment to lifting devises.
Screw plate clamps are considered to be the safer than the cam plate clamps.
Grip and lift only one sheet at a time.
Replace if evidence of any wear or deformation to body or teeth is seen.

11. 2.8.0 Rigging Plates and Links
Plates and links that are custom built for a specific component to be lifted.

12. 2.9.0 Spreader and Equalizer Beams
Used to support long loads during the lifting operation.
Tested at 125% of the rated capacity.

13. 3.0.0 Slings Common Sling Types: Wire Rope Synthetic Web and Round
Metal Mesh

14. 3.1.0 Sling Capacity Capacity depends on: Sling material and type
Hitch configuration and quality

15. 3.2.0 Sling Care and Storage Store slings on a rack off the ground.
Do not drive or walk over slings.
Thoroughly inspect slings before each use.

16. 3.2.1 Wire Rope Slings Inspect for:
Broken wires
Diameter reduction
Heat damage
Corrosion
Damaged ends and fittings
Rope distortion
Core protrusion
Unlaying of a splice
Discard if wear exceeds one-third of original diameter.
The D/d ratio affects the capacity of wire rope slings.
There are charts that give you the efficiency based on D/d.
 D 
- --d

17. 3.2.2 Synthetic Web and Round Slings
Inspect for:
Chemical burns
Melting
Holes, cuts tears, snags
Broken stitches in splices
Abrasion
Knots
Damaged fittings
Missing or illegible tag

18. 3.2.3 Metal Mesh Slings Inspect for: Discard if: Broken weld joints
Broken wires
wire diameter reduction
Discard if:
Wire diameter reduction is
25% - abrasion
15% - corrosion
10% increase in choker slot
10% increase in eye openings
15% reduction in web cross-section

19. 3.3.0 Chain Slings Recommended for:
Rough objects (ie: castings)
High temperatures
Not recommended for routine lifting
A chain link is a single bar of steel.
If one link breaks, the load falls,
Usually without warning.
If any portion is worn 15%, remove from service.
Chains must be annealed every 1-2 years.
After being annealed 6 times, destroy chain.
Use only Grade 8, or higher, chain.

20. 3.3.1 Chain Sling Storage Store chains on a rack off the ground.
Do not drive or walk over chains.
Thoroughly inspect chains before each use.
Lubrication of chains can be dangerous.
Slippery when handling.
Lubricates attract dust, causing abrasion.
Sometimes lubrication is necessary for storage in exposed environments.

21. 3.3.2 Chain Sling Care and Inspection
Inspect before each use.
Annual inspection (replace if:)
Wear – 15%, or more, anywhere
Stretch – 5% longer than original
Links – twisted, bent, cut, gouged, or nicked
Cracks – in any part of chain
Link Welds – any deformation
End Fittings – stretch, wear, twist, cut, opening
Capacity Tag – missing or illegible

22. 4.0.0 Tag Lines Typically are natural fiber or synthetic rope
Hand- held to keep load from swinging or twisting

23. 5.0.0 Block and Tackle Basic lifting device used for light loads
Capacity of simple b&t is equal to the load line (tackle)
Capacity of compound b&t is higher due to more sheaves; thus, multiple load lines
Compound
Simple

24. 6.0.0 Chain Hoists Lifting device for lifting light loads
Sometimes referred to as chain falls
For straight vertical lifting only
Never wrap the chain around the load
Always attach a choker to the chain

25. 6.1.0 Spur-Geared Chain Hoists
Lifting device for lifting light loads
For straight vertical lifting only
Most efficient type of manual hoist
Most commonly used

26. 6.2.0 Electric Chain Hoists Works just like a spur-gear hoist
Except than an electric motor is used instead of a pull chain

27. 6.3.0 Care of Chain Hoists Inspect before each use.
Check for adequate capacity.
Inspect load chain and hook.
Inspect sheaves.
Check for proper lubrication.
Assure that hoist is securely hung.

28. 7.0.0 Ratchet-Lever Hoists and Come-Alongs
Used for short pulls.
Ratchet-Lever Hoist
Uses a chain for load suspension
Vertical lifts only.
Not the same as a chain hoist.
Come-Alongs
Uses a cable for load handling
Horizontal pulling only
Fast Wind Handle
For spooling of chain
Ratchet Handle
For load handling

29. 8.0.0 Jacks Used to raise or lower equipment.
Short movements with good control.
Three types:
Ratchet jack
Screw jack
Hydraulic jack

30. 8.1.0 Ratchet Jacks Raises and lowers loads under 25 tons
Uses the lever-and-fulcrum principle
Raises or lowers one notch at a time
A pawl locks the load between lift strokes

31. 8.2.0 Screw Jacks
Can raise or lower loads heavier than the ratchet jack
Uses the screw-and-nut principle
Turning the screw raises or lowers the load

32. 8.3.0 Hydraulic Jacks Most useful general purpose jack
Uses hydraulic pressure
Slow, but very precise movements

33. 8.4.0 Inspecting and Using Jacks
Inspect before each use
Use the proper jack handle (no extensions)
Remove the jack handle when not using
Place on solid footing
Assure vertical lifting
Block and crib load as it is raised or lowered
Never exceed jack capacity

34. 9.0.0 Tuggers Electric or pneumatic wenches
Used for lifting, lowering, and pulling
Assure adequate capacity
Assure secure anchoring

35. Cranes
Cranes are a valuable resource for handling heavy equipment and structural components.
Overhead cranes
Gantry cranes
Mobile cranes

36. Overhead Girder Crane

37. Gantry Crane

38. Jib Crane

39. Mobile Crane

40. Job-Site Safety ?

41. Crane Operations

42. 10.1.0 Verbal Modes of Communication
Type of communication depends on the requirements of the situation:
Portable radio (walkie-talkie)
Frequency noise or crowding can be disruptive
Background noise can interfere

43. 10.2.0 Non-Verbal Modes of Communication
Flags and whistles have been used.
Hand signals are the most common form of crane communication.
ASME B30.5 Consensus Standard of Hand Signals

44. 10.2.0 Non-Verbal Modes of Communication
If a mobile crane is being moved without the direction of a rigger, the operator must use the crane’s horn to signal:
STOP – one (1) audible signal
FORWARD – two (2) audible signals
REVERSE – three (3) audible signals

45. 11.0.0 General Rigging Safety
The rigger must be aware of all hazards, including those that are unavoidable:
Weather – wind, rain, snow, etc.
Slippery surfaces
Unguarded areas (adjacent to worksite)
Remember that most accidents result from human error.

46. 11.1.0 Personal Protection Hard hats Safety glasses Ear plugs Gloves
Steel toe boots
Barricades

47. 11.2.0 Equipment and Supervision
Employer is responsible for ensuring that all hoisting equipment is operated by experienced and trained personnel.
As a rigger, you are responsible for selecting the correct rigging and lifting equipment, using it correctly, and directing the crane movements safely and effectively.

48. 11.3.0 Basic Rigging Precautions
Determine the weight of the load and rigging.
Verify load limits for hoisting equipment.
Examine all equipment and rigging.
Discard, and report, all defective equipment.
Stay weather-conscience; be prepared to stop.
Be alert for factors that can reduce equipment capacity.
Keep loads plumb if at all possible.
Avoid sudden snatching, swinging, and stopping.
Avoid rapid acceleration and deceleration.

49. Barricades
Always use barricades to isolate the swing area of a lift.
Be sure you understand your company’s barricading policy before you start.

50. Load-Handling Safety
As a rigger, you are the ‘eyes’ of the crane operator.
Be confident of the full path of the lift before you start.
Watch area outside the swing.
Watch the path of the rear (counterweight) area of the crane.

51. 12.0.0 Working Around Power Lines
Sometimes, it is necessary to lift close to energized power lines (proximity work).
Charts are available stating how close you can get to a power line of a given voltage.
0-50 kV 10 ft
kV 25 ft

52. Look Up and Live

53. 13.0.0 Site Hazards and Restrictions
Know the site before you start.
There are many site hazards:
Underground utilities
Water, gas, oil, electrical, telephone, sewer, drainage, tanks.
In the air:
Electrical and telephone poles, wires, and towers.
On the ground:
Structures.
Soft ground that will not support the weight.

54. Emergency Response
Learn your company’s emergency response procedures before you start.
React quickly.
React correctly.

55. 14.1.0 Fire If at all possible, lower the load and secure the crane.
In either case, evacuate the area.
Call 911.
Attack fire only if feasible.
Judgment is crucial in evaluating proper responses to fire emergencies. Be sure someone on site is capable.

56. 14.2.0 Malfunctions During Lifting Operations
Mechanical malfunctions can be serious.
A failure could cause the crane to tip over, a boom to collapse, etc.
These are unlikely but be alert for them.
If a malfunction does occur, try to lower the load and secure the crane.
Tag the crane out of service.

57. 14.3.0 Hazardous Weather Be aware of changing weather conditions.
Be prepared to cease operations and take shelter if hazardous weather is approaching.
Lightning sensors are used in some areas to detect lightning strikes up to 20 miles away.

58. 14.3.1 High Winds and Lightning
High winds and lightning are the two most dangerous weather hazards to crane operations.
Because of the boom and load in the air, high winds can tip over a crane.
Because the boom is tall and made of metal, it attracts electrical energy.

59. 15.0.0 Using Cranes to Lift Personnel
OSHA 29CFR regulations:
Although not prohibited, personnel lifting with a crane is discouraged and only used when no other means is suitable.

60. 15.1.0 Personnel Platform Loading

61. 15.2.0 Personnel Platform Rigging
All wire-rope bridle legs must be attached with shackles or master links.
All hooks must have safety latches and be closed.
Safety factor: rigging must be rated at 5 times the intended loading.
Personnel, equipment, and materials necessary to perform work is the only items permitted on the platform.

62. 16.0.0 Lift Planning Some companies require a written lift plan.
Plan includes information on crane, load, and rigging.
Even without a written plan; the crane, load, and rigging must be inspected and the entire lift must be planned before you start.

63. Lift Plan Data
A tremendous amount of data is required to complete a Lift Plan.
Be sure that all the information is recorded.

64. 17.0.0 Crane Component Terminology
It is important that you know the names of the basic components of a crane.
A complicated lift or an emergency may require you to swiftly give information or warnings about a particular area of the crane. This would not be the time to describe what the component looks like.