Rigging Handbook

RIGGING HANDBOOK PTB‐13‐HB‐0001

RIGGING HANDBOOK

Content
1. Lifting Equipment Regulations
2. General Lifting Procedure
3. Selection and Use of Lifting Gear
4. Electric Overhead Travelling Cranes
5. Hand Chain Blocks
6. Hand Operated Chain Lever Hoist
7. Lifting and Pulling Machines
8. Power Operated Blocks
9. Winches Use for Lifting
10. Travelling Girder Trolley
11. Beam Clamps
12. Slewing Jib Cranes
13. Runways
14. Mobile Gantries
15. Jacks
16. Chain Slings
17. Wire Rope Slings
18. Flat Woven Webbing Slings
19. Round Slings
20. Fiber Rope Slings
21. Shackles
22. Eyebolts
23. Lifting Beams, Spreader and Frames
24. Plate Clamps

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LIFTING EQUIPMENT REGULATIONS

Overview

The regulations for the use of lifting equipment the Provision and Use
of Work Equipment Regulations 1998 (PUWER) and the Lifting
Operations and Lifting Equipment Regulations 1998 (LOLER). Both are
accompanied by approved codes of practice (Anceps) and guidance.
PUWER applies to all equipment provided for use at work and LOLER
is additional for lifting. Therefore, for lifting equipment, both sets of
regulations apply.
The requirements of the legislation can be summarised as follows:
(1) The equipment is safe and suitable for its purpose
The manufacturer must identify the hazards associated with the
equipment he makes and eliminated them or reduce the risk to
an acceptable level. To show he has done so he affixes the CE
marks to the equipment and issues a EC Declaration of
Conformity. If safety depends upon the installation conditions, it
should be thoroughly examined after installation to ensure that it
safe.

Employers have a general duty to provide their employees with
suitable and safe equipment.

(2) The equipment is maintained in a safe condition
All equipment should be inspected at appropriate intervals to
ensure that health and safety conditions are maintained and any
deterioration detected and remedied in good time. It should also
be thoroughly examined by competent person and a record kept
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of the result. Any equipment found to be unfit for a further
period of service should be withdrawn. It is good practice to
check equipment each time before use. Some equipment also
required regular preventive maintenance. When repairs affect
load bearing parts, the equipment should be thoroughly
examined and, if appropriate, tested before further use.

Employees should corporate by making equipment available for
inspection thorough examination and maintenance.

(3) Records of conformity, test, examination etc. are kept
All equipment should have a “birth certificate” to show that,
when first made available for use, it complied with the relevant
requirements. For new equipment this will be an EC Declaration
of Conformity** plus a manufacturer’s certificate if called for by
the standard worked to. It may also include a report of thorough
examination following installation.

When equipment is tested and / or examined in service, a record
of the results should be kept. The records should be cross
referenced to enable the history of the equipment to traced.

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GENERAL LIFTING PROCEDURE

Some basic information about load balance and stability
Before lifting, it is essential to ensure that when clear of the ground,
the load will adopt the intended attitude and remain securely
attached to the lifting machine without overloading any of the lifting
gear. This means that the load must be both balanced and stable.

Balance
In most lifts, you will want the load to be level when clear of the
ground. To do this position the hook of the lifting machine vertically
above the center of gravity (C of G) of the load.

The legs of the sling(s) should be distribute as evenly as possible
according to the lifting points available. The angle which each leg
makes with the vertical affects the proportions of the load which will
be imposed on it so all legs should be, as far as practicable, at the
same angle.

If the load tilts on lifting, the loads in the sling legs will be unequal.
This effect is especially significant when the angle between the legs is
small.
If a rigid load is lifted on four or more lifting points it may be found
that only two or three legs take the majority of the load with the
remaining legs providing a relatively small balance force. If this the
case, larger capacity slings will be required.

Stability
In this context, stability means resistance to topping. An object with a
narrow base and a high C of G will need less force to topple it than
one with a wide based and a low C of G.

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As the height of the C of G increases relative to the width of the base,
a point will be reached where the object will fall over unless it is
supported by external means. At his point, the object is regarded as
being unstable. A similar situation exists with a suspended load.

It is essential when singing a load to ensure that it is stable. A load will
be inherently stable if the lifting gear is attached ABOVE the C of G
and properly COPSULE section 1 appendix 1.3 for more detailed
guidance.

When it is intended to ‘turn over’ the load in the air or position it at an
inclined attitude, special consideration should be given to the
questions of balance and stability to ensure that at all stages of the
operation the load remains balanced, stable and securely attached
without overloading any item of lifting equipment.

On occasions, particularly when using a single leg sling, it may be
necessary to lift a load such as a pipe or drum with the sling
positioned a short distance away from the center of gravity. The load
when lifted will then take up a tilted position but will be inherently
stable.
Before you start you need to know the following:
About the load:
 What constitutes the load?
 Is it in one piece or likely to fall apart?
 Is it strong enough to support itself from the lifting points or
does it need support to be lifted?
 Are there any special problems e.g. delicate loads, very hot,
cold, corrosive or sharp load?
 Are there lifting points and if not how can the lifting gear be
attached?
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 What does it weigh? (This is ESSENTIAL – do not guess – if in
doubt over estimate)
 Where is the centre of gravity (C of G)?
 Is it fixed down or free to be lifted?
 If it is fixed will it be stable when the fixings are released or will
it need support?
About the lifting machine:
 Is there a suitable lifting machine which can be positioned

above the C of G of the load? (To be suitable it must, in
particular, be of sufficient capacity are not so fast as to make it
difficult to control and position the load, and it must permit any
sideways movement required)
 If there isn’t a suitable lifting machine, is there a suitable lifting
point from which a lifting machine can be attached? (To be
suitable it must, in particular, be of sufficient strength bearing
in mind any other loads imposed on it, be vertically above the C
of G of the load and permit such sideways movement as is
required.)
 If there isn’t either a suitable lifting machine or lifting point, is
there access for a portable structure?
About the site:
 Is there a clear and safe path to the landing site or are there
exposed persons or obstructions in the way?
 Are there any special environmental problems e.g. very
hot/cold or wet, the presence of fumes, solvents, acids or other
chemicals?
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 Is the landing site level and strong enough to take the load?
(Watch out for excessive floor loadings, soft ground and hidden
weak spots such as ducts and drains.)
 Does the load have to be turned or orientated before landing?
 Has the landing site been prepared or do you need packing,
supports, tools, etc.?
The basic 9 points procedure is as follows:
(1) Cooperate with others
Ensure you have checked with other personnel that:
 You have the authority to erect any structure or lifting
machine required.
 You have the authority to make the lift,
 You can clearly communicate with the crane driver and any
assistance and have an agreed code of signals,
 You will not conflict with other activity in the area or under
the path of the load.
(2) Select and install the lifting structure and / or lifting machine
If there is an existing lifting machine, ensure that
 It is of adequate capacity
 It is not so fast to make it difficult to control and position
the load.
 It provides adequate headroom and height of lift;
 It can be positioned so that the hook is over the C of G of
the load;
 It permits any sideways movement required.
In addition, if you have to provide this equipment specially for
the job, ensure that
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 It has been properly installed and, if appropriate, tested
and / or thoroughly examined by a competent person after
installation.
(3) Select the lifting gear
Decide on the lifting gear required ensuring that:
 If the load is not strong enough to support itself, additional
support is provided
 The load will stay together and loose pieces cannot fall off;
 The safe working load of the lifting gear takes account of
both the weight and the mode of use;
 The load is not damaged by the lifting gear;
 The lifting gear is not damaged by the load;
 The lifting gear is not damaged by the environment;
 The load can be controlled in the air – use a tag line if
necessary.
(4) Check the lifting gear
 Check the lifting gear to ensure it is fit for use.
(5) Assembly the lifting gear
 Position the lifting machine hook vertically above the C of
G.
 Attach the lifting gear ensuring that all pieces are free to
align correctly.
 Hoist to take up the slack, keeping fingers, toes etc. clear
and check that the gear is correctly positioned.
(6) Make a trial lift
 Ensure the load is not fixed down, keep fingers, toes etc.
clear and make a trial lift i.e. lift just clear of the ground.
 Ensure the load is level and secure. If not, lower it,
reposition the listing gear and try again.
(7) Lift and travel the load
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
Lift and travel the load to the landing site, carefully
avoiding obstacles and people and warning exposed
persons to clear the area.
 Check the landing site is prepared and lower the load,
stopping just clear of the ground.
(8) Make a trial landing
 Check the position of the load and packers/supports etc. to
ensure the load will be supported without trapping the
slings.
 Gently lower until landed but do not allow the lifting gear
to go slack.
 Ensure the load is safe and will remain stable when the
gear is removed ad if not, lift it clear again and reposition
supports, packers etc. and try again
 Stack off the fear and remove it by hand.
(9) Make a trial landing
 Check the gear and return it to safe storage, placing into
quarantine any item that is damaged.

Remember!
9 points procedure!

 Corporate with others
 Select structure and machines
 Select lifting gear
 Check lifting gear
 Assemble lifting gear
 Make a trial lift
 Lift and travel the load
 Make a trial landing
 Clear up
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SELECTION AND USE OF LIFTING MACHINES AND
SUPPORTINGS STRUCTURES

When selecting a lifting machine consider:
 What does the load weigh?
 What is the size and shape of the load?
 Is the hazardous, fragile etc?
 What height does the load have to be lifted?
 Is the load to be lifted, jacked or pulled? (It may be necessary
initially to raise the load by jacking to gain sufficient access for
other lifting equipment to be employed in the final lifting
and/or moving operation)
 Is it necessary to move the load and if so in which direction and
over what distance?
 Is the equipment to be used for just the one jib or it will be
used again.
 Is a suitable suspension point available or is it necessary to
provide one?
 If a structure is required, can it be attached to the building or
must it be free standing?
 What headroom is available?
 Are there any obstruction which my impede the operation
 Is the working area spacious of confined?
 Is there a suitable electrical supply available?
 Is there a suitable compressed air supply available?
 Is the job indoor or outside?
 Is the area a hazardous area or are there any environmental
problems which may affect the equipment of the operative?
 Does the operative need to be in a remote position?
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 Is any special measure necessary to comply with regulations or
other safety requirements?
Remember!
Choose the lifting machine carefully
In particular, it must be suitable for:
 The weight and type of load
 The movement required
 The means of power available
 The environment
TYPES OF LIFTING MACHINE AND SUPPORTING STRUCTURE.
Pulley Blocks
For the lightest of loads, it may be possible to use a single pulley block
arrangement. Pulley blocks are used in association with fiber rope or
wire rope, and the effort can be either direct from the operative onto
the rope or by the winch. The mechanical advantage is depended on
the number of fall of rope in the system.
It must be realized that, when used without a winch, the operative
carrier a proportion of the load and is effectively the brake as pulley
blocks are not self‐sustaining. It is strongly recommended that such
arrangement are restricted to the highest loads and avoided if
possible.
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Pulley blocks are more commonly used in association with winches,
where the winch provides the effort and self‐sustaining feature, thus
enabling heavier load to be lifted. A feature of pulley blocks which
must not be overlooked is the resulting load imposed on the
supporting structure. This load comprises the weight of the pulley
blocks and rope, the load including any sling etc. used to connect the
load, the applied effort used in raising and sustaining the load and the
effects of friction at the sheaves. See the guidance on the use of
pulley block on page 63.
Hand Operated Chain Blocks
Hand operated chain blocks are self‐sustaining lifting machines
providing an easy means of lifting or lowering a load with acceptable
operative effort. Most are designed for vertical lifting but some are
designed to facilitate use at an angle. In practice, all hand chain can be
used at an angle within certain parameters provided appropriate
precautions are taken. For further information, see section 3 of
COPSULE. They may be used with girder trolleys to move suspended
loads along runways.
They are relatively light in weight and easy to install, so suit temporary
applications. Being operated by a hand chain, they can be high above
the operative or the operative may be on a different level to the load.
They are popular for maintenance purposes and ideal where there is
no power. The larger capacities may require more than one operative.
Hand Operated Chain Lever Hoists
Hand operated chain lever hoists are a self‐sustaining lifting machine
providing a simple means of raising loads through short distances.
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They are designed to operate in any position, making them suitable
for pulling as well as lifting. They may be used with girder trolleys to
move suspended loads along runways. They are ideal for applications
requiring frequent repositioning and are often used in a maintenance
work, the erection of structures and positioning of machinery etc.
Wire ropes grip/pull lifting machines
These are lever operated machines which use a gripping action to haul
a wire rope. They are self‐sustaining and may be used for both lifting
and pulling applications. They may be used in conjunction with pulley
blocks either to increase the mechanical advantage or to divert the
line of pull. Don’t forget the resulting load imposed on the supporting
structure. See the guidance on the use of pulley blocks on page 63.
The wire rope passes through the machine and can be stored on a
special coiler separate from the machine. This makes them ideal for
extremely high lift. They are frequently used for maintenance and
construction work.
Winches
Self‐sustaining winches are often used in association with pulley
blocks, either to increase the mechanical advantage or to divert the
line of pull. They provide a means of lifting or pulling loads from a
fixed point. They can require less headroom that either hand or power
operated blocks and the operative may be remote from the load. They
are therefore ideal for use in confined spaces. There is a wide range of
hand operated winches and both electric and pneumatic power
operated winches.
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Winching speed can vary so ensure it suits the application. Don’t
forget the resulting loads imposed on the supporting structure. See
the guidance on the use of pulley blocks on page 63.
A type of winch known as the suspended mounting hand operated
winch or pole hoists, is available and is often associated with man‐
carrying rescue applications. However, it also has some advantages
for lifting loads.
Power Operated Blocks
Power operated blocks are self‐sustaining and may be used with
girder trolley to move suspended loads along a runway. Whilst most
may be used for either temporary or permanent applications, some
design are only suitable for permanent installations. Both electric and
pneumatic powered type are available and the control can be remote
from the block. Some have more than one speed. Single speed blocks
may be too fast for applications where precise positioning is required.
Travelling Girder Trolleys
Travelling girder trolleys provide an easy way of moving a suspended
load along a runway track. They are available as push travel, hand
chain travel or power travel versions. They may be separate from the
lifting machine, which may be suspended by its top fitting from the
trolley load bar, or built into the machine as an integral item.
Runway
Runway fitted with a trolley and lifting machine provide a relative
simple means of lifting and moving a suspended load but only along
the line of the runway track. They are usually a permanent installation
P2TIM‐TB 14


but can be temporary. The traditional runway is a standard “I” section
beam but there are now several proprietary section available. Runway
may from parts of the building structure, be built onto the building
members or be built into self‐supporting structures.
Mobile Gantry
A mobile gantry provides an alternative to a permanent runway and is
ideal where an occasional application call for both lifting and limited
movement of the load in a single plane. It is, in effect, a runway
mounted on its own free standing supporting structure. Whilst the
structure is portable, and is usually mounted on wheels or castors for
ease of positioning, they are generally unsuitable for movement under
load. They are intended to be positioned over the load which ca then
be raised, moved along the track and lowered.
Various types of mobile gantry are available and design range from
heavy duty gantries intended for permanent erection to light duty fold
away designs intended for one off lifting operations. Capacities vary
with the design so consult the manufacturers to establish the
available range.
Slewing jib cranes
Slewing jib cranes provide, in affect a runway which slews. When
fitted with a trolley and lifting machine, loads may be lifted and
moved to any position within the arc of coverage. The jib may be
mounted onto a suitable building column, wall or similar structure or
be built into its own self‐supporting column.
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They are ideal for use where loads have to be swung out over the
edge of a loading dock etc. or in a machine shop to lift items in and
out of machine tools etc.
Slewing jib cranes are usually custom built from standard component
to suit specific applications and are rarely suited to temporary
applications. Light duty jibs may be found to be too “bouncy” for
applications which require precision positioning.
Overhead Travelling Cranes
An overhead travelling cranes provides lifting and movement of the
loads in all directions. They range from small manually moved beam
with a hand chain blocks to massive bridge structure which
incorporate specially manufactured crab units. They are ideal where
repeated lifting and movement of loads anywhere within the area of
coverage is required.
Because they require permanent tracks, overhead travelling cranes

are rarely suitable as a temporary installation. Depending on how they
are controlled, the speed may be excessive for some applications.
However, because they can be easily positioned, they also be used as
a sky hook from which to suspend a more suitable lifting machine.
Also some light duty cranes may be found to be too ‘bouncy’ for
application which require precision positioning.
Although no specific information is given in respect of overhead
travelling cranes in this guide, the guidance offered in respect of
travelling trolleys, hand operated chain blocks and power operated
blocks may be applied where appropriate. See also BS 7121‐1‐2006
Code of practice for the safe use of cranes, General.
P2TIM‐TB 16


Tripods and Shearlegs
Where only a simple suspension point is required but no suitable
purpose made suspension point or building member is available, a
tripods or a set of shearlegs may be suitable. They provide a fixed
suspension points for a lifting machines but they are not suitable
where any sideways movement is required. Any attempt to swing the
load to one side can easily cause the tripods or shearlegs to overturn.
They are usually constructed from tube or light sections and have
three, or occasionally four, legs with hinge at the top where the
suspension point is. Alternatively, they may have provision for a which
to be mounted on the legs with a top sheave or which the rope
passes. They are free standing and the legs may have feet or point at
their bases.
Tripods and shearlegs are generally available in height up to 6 meters
and the legs are arranged so that the span of the feet when erected is
one third of the height. Capacities is usually range from 500 kgs to 5
tones. In most cases they are easily erected by one or two people.
No specific information is given in this guide and the manufacturer
instruction should be sought and followed.
Jacks
Some loads lend themselves to being jacked up rather than slung and
lifted from above. Jacks are often used to raise load a short distance
to enable lifting gear to be attached. They are also used where load
have to be lowered precisely into their final position, such as plant
installation.
P2TIM‐TB 17


They require floors or supporting member which are able to
withstand the forces through the jack base when the load is raised.
This is usually a smaller area than the contact area of the load and
therefore greater forces are imposed. Strong support packing to
follow behind the jack is also required. Although some mechanical
jacks are available, the majority are hydraulic.
Safe use of Lifting Machines and Supporting Structures
Having selected suitable equipment, it is important that it is properly
installed/erected and fit for use, it is also important that the people
using the equipment understand how it is designed to be used and
follow a procedure which ensures they remain in control of the loads
at all times throughout the operation. The following gives general
guidance on these matters but as a first step always ask for, and
ensure you obtain, keep and follow, the manufacturer’s instructions.
Follow the GENERAL LIFTING PROCEDURE on page 5. In addition, note
the following points:
Installation/Erection of the equipment
If the equipment has been in storage, a check should be made to
ensure that no damage or deterioration has occur whilst in store.
Ensure that the structure from which a lifting machine is suspended is
adequate for the load it is intended to carry.
Use of existing structure to support a Lifting Machine
Often such structure is primarily designed for other purposes, e.g. a
building from which a runway is suspended. It is important to ensure
P2TIM‐TB 18


that they are adequate for the purpose of lifting but, because of other
loads which may be imposed, proof loads testing alone is not
adequate. The following is recommended:
Runways: A structural engineer or other suitable qualified person
should do a theoretical check on the structure and provide
written confirmation that the structure is adequate. The runway
track should be designed, tested and certified in accordance with
the requirement of BS 2853 and should together with all
connections to the supporting structure, be periodically
thoroughly examined.
Other Lifting Points: As with runways, a suitable qualified person,
should do a theoretical check provide written confirmation that
the lifting point is adequate. The connection between the lifting
machine and the structure should be properly designed for lifting
purpose, tested and certified e.g. a beam clamp. All connection
should be thoroughly examined that the appropriate intervals.
Marking: All runways and approved lifting points should be clearly
identified and marked with their safe working loads. Both former
and current supporting structure design standard, such as BS 449
and Eurocode 3 respectively, require specific allowances for
dynamic loading which are greater for power operated lifting
machines. It is recommended that the power operated machines
are not used or runways or lifting points designed only for manual
operated equipment. To avoid confusion, it is recommended that
the SWL marking should include the word ‘MANUAL’ or ‘POWER’
as appropriate.
P2TIM‐TB 19


Floor or Ground Loading for Free Standing Lifting Equipment
For any free standing lifting, ensure that the surface on which it stand
will take both the total weight the local loading under the supports.
This is often left to the rigger or slinger to decide but, if there is any
doubt, the matter should be referred to a suitable qualified person.
Beware of hidden dangers, such as underground pipes, drains and
cables. The use of floor spreader plates, to distribute the imposed
loads over a larger surface area, should always be considered. Also
watch out for deflection of floor spans which might tilt the equipment
and alter the radii or make it unstable particularly if the equipment
can move under load.
If the load to be landed on the same surface, ensure it does not cause
a local overload as it might stand on a smaller area than the lifting
machines.
Use of Pulley Blocks
With pulley blocks, the imposed on the supporting structure and the
equipment which connect the pulley block to the structure is
increased by the hoisting effort. The increase in load is as given in
table 2.
Number of sheaves
Top Blocks 1 1 2 2 3 3
Bottom Blocks 0 1 1 2 2 3
Load on Top 2,08 1,56 1,39 1,3 1,25 1.22
Fitting = load
lifted x Factor
Assuming 8% per sheaves for friction
Table 2. Loads Imposed by Sheaves Blocks
P2TIM‐TB 20


Use of Travelling Trolleys
Check the track is sufficiently level at all loads up to maximum that the
trolley, machine etc. will not run away under gravity.
When fitting a trolley onto an “I” section track, ensure it is correctly

adjusted for the width of beam, that the wheels align, are in fully
contact with the track and that anti‐tilt devices are correctly set.
Check also that end slopes are in place are effective and contact the
trolley stop plates and wheel treads and not the wheel flanges.
Use of Lifting Machine
With a hook suspended lifting machine, the top hook should be fitted
with a safety latch to prevent displacement and the support should fit
freely into the seat of the hook and not exert any side thrust upon the
point or latch.
After erection, check that the lifting chain or rope hangs freely and is
not twisted or knotted. This is a especially important with power
operated chain blocks. Take care with multi falls blocks in case the
bottom hook has been turned over between the falls, imparting a
twist to the chain or rope
The height of lift should be checked to ensure that the hook will reach
its lowest point without the chain or rope running fully out. Ensure
any limits are correctly set and functioning. Ensure the brake is
operating correctly especially if the equipment has been in storage a
long time.
P2TIM‐TB 21


Connecting the Electrical Power Supply
The electrical power supply and feed system should be of correct size
and type for the machine and installed by a qualified person to the
Electricity at Work Regulations 1989 and the supplier’s instructions.
For travelling machines with a cable supply, ensure the cable is long
enough to allow the machine to travel to its furthest point without the
cable coming under tension. It is good practice to leave the earth wire
longer than the other so that if an accidental force on the cable pulls
the wires from their terminals, the earth wire will be the last to be
disconnected.
Before connecting the power supply, insulation resistance polarity and
earth continuity test should be carried out, care being taken not to
damage any low voltage circuits or electronic devices.
After connecting the power supply, check that all motions work as the
controls indicate, e.g. when the ‘down’ button is pressed, the machine
lowers and vice versa. This is a special important in case of plug in
connections as the passing at the socket is not guaranteed. If the
direction of motion is incorrect, disconnect the mains supply and
reverse two phases. Do not change the controls as the limit switches
may not function.
Connection the Compressed Air Supply
The air feed line should be of the correct size and provide the required
pressure and delivery rate specified by the manufacturer of the
machines. It should be installed by a qualified person in accordance
with the supplier’s instructions.
P2TIM‐TB 22


The air must be dry and depending on the source, this may require
the incorporation of a filter to remove moisture. Many lifting
machines also require the air to be lubricated.
For travelling machines, ensure that the supply hose is long enough to
allow travel to the furthest point without undue stress on the hose
and connections.
Maintenance
A routine preventive maintenance programme should be drawn up.
For power operated machines, this can be combined with
maintenance of the associated power supply/air supply and control
equipment (see PUWER 1998 Regulation 5).
Some Essential Precautions when using Lifting Machines
 Do not use a lifting machine to people unless it has been
designed or specially adapted for that purpose or the hazards
associated with lifting people have been addressed in some
other way.
 Do not raise, lower or suspend a load greater than the marked
safe working load.
 Exception for machine designed to pull as well as lift, always
ensure the line of lift is vertical.
 Do not use the load chain or wire rope to form a sling, i.e. it
must not be wrapped around the load and backed hooked or
choke hitched.
 Never load the point of the hook. The sling should be located in
the seat of the hook and the safety catch closed.
 Do not crowd the hook with slings. Use a shackle to join the
slings first.
P2TIM‐TB 23


 Avoid shock loading. If the machine has dual speed, start the lift
in slow speed before going to full speed.
 Most manually operated lifting machines, and especially lower
capacity ones, are designed for operation by one person is
required, it is likely that either the load exceeds the safe
working load of the machine and/or it is in need of
maintenance. Whichever is the case an unduly high operating
effort requires investigation before the lift proceeds. This
guidance is not intended to preclude using more than one
person to operate the machine, which may be found
advantageous but is to indicate the degree of operating effort
normally required.
 Most power operated lifting machines are fitted with an
overload devices designed to protect the lifting machine. This
may be mechanical, electrical, or thermos electrical if the lifting
machine fails to lift the load, it is likely that the load exceeds
the working load and should be checked before resetting the
controls.
 Never change the motion direction of an electrically powered
machine without first allowing the motor to stop. Quick
reversal of direction causes shock loading and heavy current
surges.
 Avoid unnecessary inching as this causes burning and pitting of
contact and could burn out the motor.
 Do not leave an unattended load suspended from a lifting
machine unless absolutely essential in which case ensure that
the danger area is cordoned off.
 Except where special provision is made, do not allow anyone to
pass under or ride upon the load. The area should be kept clear.
P2TIM‐TB 24


 With a push travel trolley, move a suspended load by pushing
rather than pulling wherever possible. To move an un‐laden
machine, pull on the bottom hook.
 Never attempt to move a power operated machine by pulling
on the pendant control or a supply cable or hose.
 Avoid load swing as this may endanger the operative and result
in increased loading on the lifting machine and its supporting
track or structure. End stops are final safety device only.
 Avoid excessive or intentional use of limit devices. They are a
safety feature intended to protect the lifting machine.
 No person other than a Competent Person or someone under
the supervision of Competent Person should attempt to
dismantle the lifting machine or replace load bearing
components.
 Ensure the travel path is clear and free from obstruction before
operating the lifting machine. The operative must always have
a clear view of the hook path to avoid accidental hook
engagement or collision.
 Always make a trial lift so the load is just clear, then check the
integrity of the lifting machine and method of slinging. Only if
the load is stable and balances should the lift proceed. See page
5 for information on load balance and stability.
Storage and Handling
When not in use, lifting machine should be returned to storage or
parked in a safe position such as at the end of runway. When parked
the hook should be raised out of the way of people in the area. Ensure
any hanging loops of chain etc. do not present a danger.

P2TIM‐TB 25


SELECTION AND USE OF LIFTING GEAR

Factors influencing Choice of Lifting Gear
Obviously anyone faced with lifting a grand piano will select a
different type of sling (probably one constructed from man‐made
fibre webbing) from that chosen for lifting hot metal ingots (probably
a chain sling). However, lifting gear is not just about slings. Some loads
are best lifted with accessories such as lifting beams or clamps or may
need a removable lifting point such as an eyebolt. In practice many
lifting arrangements will use a combination of two or more pieces of
lifting gear.
A word of warning about the quality of lifting gear. It may be tempting
to make up your own of lifting gear from whatever is available but this
is a dangerous practice. Chain wire rope, fibre rope, webbing,
shackles, eyebolts, turnbuckles, etc. come in a wide variety of design
and grades and only a few are designed for and suitable for lifting. To
the uninitiated they may look the same but they are not. Equally
important is the way slings are terminated. Knots in rope etc. causes
stresses that are avoided by proper terminations. Wire rope grips
sometime known as Buldogs Grips, are not suitable for making the
termination of slings. Chain should only be joined or shortened by
propose designed components. Beware also of equipment intended
only for lashing purposes as this is rarely suitable for lifting.
The following factors are not necessarily in order of importance, nor
do they represent an exhaustive list, but are some of the
considerations appropriate to selecting lifting gear. Users are advising
P2TIM‐TB 26


to consults a LEEA member if in any doubt as to the suitable of the
lifting gear for any lifting purpose, environment, etc. In making a
selection, a balance will be struck between various, sometime
conflicting, consideration and the final decisions may be one of
several compromise solutions.
Don’t forget!
 Only use good quality lifting gear
 Never use homemade lifting gear
 Sometimes life may depend on it!

When selected the lifting gear consider:
 What contributes the loads?
 Is it in one piece or likely to fall apart?
 Is it strong enough to support itself or does it need support to
be lifted?
 Are there any special problems? E.g. the load is delicate, very
hot, cold, corrosive, sharp, etc. or there are similar
environmental problems.
 Are there lifting points and if not how can the lifting gear be
attached?
 What does it weight?
 Where is the centre of gravity (C of G)?
 What allowances must be made for the lifting mode?

P2TIM‐TB 27


If the load is not in one piece, consider:
 Lifting the parts separately
 Using the lifting gear to hold the parts together, e.g. a bundle of
tube held by a double wrap and choke hitch
 Holding them together by other means, e.g. load binder
If the load is not strong enough to support itself consider:
 A lifting beam
 A cradle
If there are a special problem, e.g. the load is delicate, very hot, cold,
corrosive, sharp, etc. or there are similar environmental problem
consider:
 Whether a particular type of lifting gear is more suitable. See
page 93 for more information on the various sling types.
 Whether special packing or protection is required to avoid the
load being damage by the lifting gear.
 Whether the lifting gear may be damaged by the load or the
environment.
If there are lifting points, consider:
 Whether they are intended for the whole load or just a
component, e.g. eyebolt in a motor
 What sort of terminal fitting will mate with the lifting points?
 Whether the lifting points may be used at an angle or just
vertical
If there are no lifting points, consider:
 Whether removable lifting points can be used, e.g. eyebolts in
existing tapped holes
 Whether other accessories suited to the load can be used, e.g.
plate clamps, case grabs, pallet forks, pipe hooks
P2TIM‐TB 28


 Whether the slings can go through or wrap around the load.
If the weight is not known, consider:
 Whether the information might be available elsewhere e.g.
packing/delivery notes, product handbooks, component
drawings.
 Whether the load can be weighed e.g. take delivery vehicle to a
weigh bridge
 Whether the load can be estimated – it usually can. A skilled
estimator can get within 10% so allow for some error.
If the position of the C of G is not known, consider:
 Whether the information might be available elsewhere e.g.
packing/delivery notes, product handbooks, component
drawings
 Whether the position of the C of G can be estimated – it usually
can. The estimate may not be exact but the trial lift will allow
you to check and adjust if required
All lifting slings are designed for use in one or more modes. The
maximum load that can be lifted varies with the mode. (see page 28
for information on the allowances to be made and table 3 for a
summary).

Multipurpose Slings
Slings of various types are without doubt, the most commonly used
lifting gear. They may be used on their own or in combination with
other lifting gear such as lifting beams, shackles or clamps. They are
very versatile and in the hands of a skilled slinger, can be used safely
in a wide variety of arrangements. However, to use them safely the
slinger needs a good understanding of the characteristic of the various
P2TIM‐TB 29


types of sling, the way they are rated, the geometry and mode of use
the rating assumes and the effect of deviating from the assumed
conditions. Finally, the slinger needs to know the difference between
good slinging practice and bad. The following deals with those
matters:
Remember!
Choose the lifting gear carefully. In particular, it must be
suitable for:
 The weight and type of load
 The available lifting points
 The position of the C of G
 The mode of use
 The environment
SLING TYPES
Chain slings
Grade 8 mechanically assembled slings are now the most common.
Grade 4 is also available but is normally assembled into sling by
welding. Grade 8 is, for the same SWL, much lighter than grade 4 and
there is a wide range of fittings to specific purposes. Grade 4 can be
more suitable in some environments particularly hot or corrosive, but
specialist advice must be sought. Chain slings are more durable than
other type in an abrasive environment.
P2TIM‐TB 30


Wire rope slings
Wire rope slings can be made from a variety of rope constructions.
The termination is usually by a ferrule secured eye (FSET) with or
without thimbles, but it can also be hand spliced. Wire rope slings are
relatively economics, particularly for the higher capacities and longer
length. Having a degree of rigidity, they can also be pushed through or
under load.
They have the disadvantage that they are susceptible to kinking if
bent round too small a radius and care is needed to avoid hand
injuries from broken wires.
Other wire slings
Slings are also made from wire coil in the form of a belt and from
plate small diameter wire rope. These have the advantage of
spreading the weight over a larger surface of the load.
Fiber rope slings
Fibre rope slings are made from both natural and man‐made fibre
ropes. Size for the ascending order of strength is as follows
Sisal > manila > polyethylene > polypropylene > polyester > polyamide
(nylon).
Nylon is approximately two and a half times as strong as manila grade
1 of the same diameter. Polypropylene ropes will float.
P2TIM‐TB 31


Natural fibre ropes are liable to rot and mildew in damp conditions
and are not recommended for use in chemical environments. Man‐
made fibre ropes have varying resistance to chemicals as follows:
‐ Polyamide (nylon) is virtually immune to alkalis but it is attacked
by moderate strength acids. It also losses up to 15% of its
strength when wet.
‐ Polyester is resistant to moderate strength acids but is damaged
by alkalis.
‐ Polypropylene is affected little by acids and alkalis but is damaged
by solvents.
All fibre ropes are prone to deterioration at high temperatures. Man‐
made fibres rarely show a sharp melting point; they will either soften
over a range of temperatures or they will char or decompose before
melting.
Webbing slings
Webbing slings are manufactured in a similar variety of material as
man‐made fibre ropes. They are light in weight and can be made in
various widths, which is an advantage when trying to avoid local
damaged to a load. They can also be fitted with sleeve as added
protection to the slings of the load. They have a similar resistance to
chemicals and temperature as the man‐made fibre ropes.
SLINGS CONFIGURATIONS
There are five basic configurations i.e. single leg, two legs, three legs,
four legs, and endless. Single leg sling can be a reevable form. For
P2TIM‐TB 32


loads such as wooden cases, drums, long pipes, logs, etc. special slings
are available and recommended.
METHODS OF RATING LIFTING SLINGS
When a multi legs sling is used with the sling legs at an angle, the load
in each leg will increase as the angle increase.
It should be noted that in the UK the angle was traditionally measured
as the included angle  (alpha) between the legs of the two leg sling
and between the opposite legs of a four leg sling. As three legs slings
do not have an opposite leg, it was taken for these as twice the angle
to the vertical. This has led to some confusion so the new generation
of European standard all measure the angle between the leg and the
vertical table  (beta). Until the older equipment is all phased out,
both systems are likely to be found.
For the sling to be used safely, an allowance must be made for the
angle and this is achieved by rating the sling in one of two ways. The
two methods of ratings are ‘the uniform load methods’.
The uniform load method is the simpler option, having inherent safety
advantages, permitting only one working load limit up to an angle to
the vertical  (beta) up to 45o (included angle  90o) and reduce
working load limit at the angle to the vertical  between 45o and 60o
(included angle  between 90o and 120o). This information is marked
on the slings and the need to estimate angles is kept to a minimum.
This is the method which should be used for all multipurpose slings.
P2TIM‐TB 33


The trigonometric method allows the working load limit to vary as the
angle between the sling legs varies. This method was the one
traditionally used in the United Kingdom and provided the maximum
utilisation of the sling’s capacity, but has been gradually superseded
over the last 30 years. For multi‐purposes applications, the operatives
require tables showing the safe working loads at various angle for
each size of chain, rope etc. This method also requires the operative
to judge the angle accurately so has the inherent danger that if he
should misjudge it, the sling may be overloaded. It is strongly
recommended that this method should only be used for sling
designed for a single purpose.
It should be clearly understood, however that whilst equipment

designed to be used under the trigonometric method may be rerated
according to the uniform load method, the reverse is NOT always
possible and may be dangerous. It is therefore recommended that to
avoid confusion, all items of a given type (e.g. all chain slings) at the
location should be rated by the same method.
RATING ASSUMPTIONS AND DEVIATIONS FROM THE ASSUMED
CONDITIONS
Both method assume certain conditions of use which ensure that no
part of the sling is overloaded. It is important to understand that
although the weight to be lifted may be within the maximum lifting
capacity of the sling, using it in the wrong way can overload part of
the sling. Some deviations from the assume conditions are prohibited
such as loading a hook on the tip. Others are permitted provided on
appropriate allowance is made. With multipurpose sling, the designer
P2TIM‐TB 34


has little if any information about the intended use so the onus to
make such allowance falls on the user.
The assumed conditions fall into two categories: the geometry and
the mode of use.
Geometry
It is assumed that all legs of the sling are in use and are at more or less
the same angle  to the vertical. It is also assumed that the sling legs
are symmetrically disposed in plan i.e. for three legs slings, all
included angle  (delta) between the legs in plan are equal, for four
leg slings, the opposite included angle 1 and 2 between adjacent
legs, in plan, are equal. See figure 1.

  
 

   

Figure 1. Geometry of Three and Four Leg Slings
 (alpha) = included angle between diagonally opposite legs
 (beta) = angle of sling leg to the vertical
 (delta) = included angle between legs in plan (three legs)
1 and 2 = opposite included angle between adjacent legs in plan
(four leg)

P2TIM‐TB 35


As a general guide, the loading can be assumed to be symmetric if all
the following conditions are met:
(a) All sling legs are in use
(b) The load is less than 80% of the marked SWL
(c) None of the sling legs exceeds the maximum permitted angle 
to the vertical for marked SWL
(d) Sling leg angles  to the vertical are all at least 15o
(e) Sling leg angles  to the vertical are all within 15o to each other
(f) In the case of three and four leg slings, the plan angles  are all
within 15o of each other
If the slinging geometry does not comply with the assumptions or the
general guide above, then the load will not usually be evenly
distributed amongst the legs. The amount of load that will be imposed
on an individual leg depends upon the following:
(1) The number of legs in the sling, or in use
(2) The angle between each of the legs and the vertical
(3) The distribution of the legs in plan view
(4) The total load being lifted
The relation between these factors is complex, especially for three
and four leg sling. What happens as these factors vary can be
identified in general term although to quantity the effect requires
complex calculation?
If not all the legs are in use, then the safe working load of the sling
must be reduced. The amount by which it should be reduced can be
calculated exactly but it is rather complex as a number of factors need
to be taken into account. As easy way of ensuring that the sling is
P2TIM‐TB 36


never overloaded is to reduce the working load from that marked o
the sling according to the number of legs in use e.g.
A 4 leg sling with 2 legs in use, REDUCE SWL = ¾ i.e. ½ x SWL MARKED.
A 3 leg sling with 2 legs in use, REDUCE SWL = 2/3 x SWL MARKED
This inevitably means that in some cases the sling will be under‐
utilized. If maximum utilization is required, then reference should be
made to person who understands the factor involved and therefore
perform the necessary calculations.
If the angle  between each of the legs and the vertical is not the
same, the loading in the leg with the smaller angle to the vertical
increase. Ultimately if one leg is vertical it will take all the load.
Unequal angles to the vertical may occur because of the position of
attachment points on the load, particularly with an irregularly shaped
load. However, it often happens because the load tilts when lifted due
to position of the centre of gravity being misjudged. The effect is
significant, and becomes greater as the included angle  between the
legs decreases. There is some reserve of strength to counter this but
as a guide,  multi leg sling should not be used with an included angle
 of less than 30o ( less than 15o to the vertical) or a difference in
angles to the vertical of more than 12o (i.e. equal to 6o of tilt) without
an allowance being made.
For three and four leg slings the problem becomes three dimensional
in that the distribution of the legs, when viewed in plan, also effects
the share of the load imposed on each leg. The sling geometry of
three and four leg slings is as follows:
P2TIM‐TB 37


Three leg slings: With a three leg sling, it is assumed that viewed in
plan, the legs are at 120o to each other. If two of the legs are closer
than that, the third leg will receive a greater share of the load.
Ultimately, if tow of the legs is side by side, i.e. at zero angle to each
other, then they will receive only half the load between them leaving
the third leg to take the other half on its own and thus be overloaded.
Four leg slings: With a four leg sling, it is assumed that, viewed in plan,
the legs are symmetrically disposed, the lower attachment points
making the corners of a rectangle. Ideally, the nearer the rectangle is
to a square the better., but this is by no means essential. However,
the smaller the angle between the legs the greater the effect of
unequal angles. On a four leg sling, the unequal effect can occur
across either or both of the horizontal axes, i.e. along the length of
the rectangle and/or across the width of the rectangle.
The four leg sling is also affected by the rigidity of the load. Even if all
the legs have the same angle to the vertical and are symmetrically
disposed in plan, small differences in the lengths due to
manufacturing tolerances or the positions of attachment points may
prevent the load being equally distributed. The uniform load method
of rating takes some account of this by rating a four leg sling at the
same working load limit as a three leg sling of the same size and
grade. However, if the load is very rigid, the majority of it may be on
only two diagonally opposite legs with the other two providing
balance. In such cases, the sling should be de‐rated to two‐thirds of its
standard rating.
P2TIM‐TB 38


Mode of use
Single leg and multi‐leg slings are for use with the leg or legs in a
straight pull, i.e. the legs are not bent around the load, choked, back
hooked or otherwise prevented from taking up a straight line under
load.
Endless chain and wire rope slings are rated for choke hitch but for
historical reasons the standard rating for textile slings assumes a
straight pull. (Note also that very large capacity endless wire rope
slings are also usually rated in strength pull).
In all cases, it is also assumed that any edges around which the sling
passes have a large enough radius to avoid damage to the sling. For
chain and wire rope endless slings, the rating takes account of the
chain and wire rope being bent around itself on the bight.
The way the sling is used may vary from this assumed conditions, and
this may be desirable, offering a more secure way of attaching to
certain loads. The options, together with the appropriate mode
factors to be applied to the standard ratings, are given in table 3.
Sling use in combination
Sling may be used in combination with other slings and lifting gear.
For examples two round slings with shackles to connect them to the
load. The combined safe working load of the arrangement must take
account of the angle of the slings by applying an angle factors to both
the slings and the shackles. The angle factors are given in table 4. The
factors for eyebolts are different and are given in the special section
on page 42.
P2TIM‐TB 39


Remember that, as for multi leg slings, if the slings are not at the same
angle then will not receive an equal share of the load. Remember also
that, if the slings are choked or use in some mode other than in in
line, the appropriate mode factors in table 3 will apply in addition to
the angle factors.
Two other points should be noted. First, if the slings are not the same
in the capacity, they will not be able to take the same share of the
load. Second, if they are not of the same type, the way they tighten up
and extend as the tension is applied may vary and alter the intended
geometry of the arrangement.

MODE FACTORS
Maximum load to be lifted = mode factor x SWL marked on the sling
Key: NP = non preferred, NA = not applicable
1 2 3 4 5 6 7 8 9
Material Single leg Single leg Single leg Single leg Single leg Endless in Endless Endless
in line choke basket back halshed line choked basket 0‐
hooked 90o
Chain 1 0,8 1,4 1 NP NP 1 1,4

Wire rope 1 0,8 1,4 1 1,6 NP 1 1,4
Webbing 1 0,8 1,4 NA NP 1 0,8 1,4
Fibre rope 1 0,8 1,4 1 1,6 1 0,8 1,4
Round sling NA NA NA NA NA 1 0,8 1,4

Table 3. Summary of Mode Factors

P2TIM‐TB 40


Sling Angle Load Angle
(SAo) Factor
90o 1.000
85o 1.004
80o 1.015
75o 1.035
70o 1.064
65o 1.104
60o 1.155
55o 1.221
50o 1.305
45o 1.414
40o 1.555
35o 1.742
30o 2.000
(25o) 2.364
(20o) 2.924
NOTE:
(15o) 3.861
Sling Angles (SAo) below 30°
(10o) 5.747
(5o) 11.490 should be avoided.

Table 4. Summary of Angle Factors

Notes to table 4
(1) The factors for eyebolts are different and are given in their
special section on page 42
(2) * This assumes that all the slings are of the same SWL. If
they are not the factor should be applied to the lowest
SWL. The factor also applied to any other gear used in
line with the sling e.g. shackles
P2TIM‐TB 41


(3) ** Combination should be used in this range unless the
upper ends of the slings or gear are joined by a shackle or
link. If they are placed directly onto the hook of the lifting
machine, they will load the hook incorrectly.
(1)
(2)
30o
(3)
(4)
Figure 2. Examples of the Application of Mode and Angle Factors
(1) Single bow shackle
Used with its axis vertical so no reduction required
Capacity = SWL marked

(2) Pair of single leg chain sling of the same SWL
Angles of sling leg to the vertical = 30o so factor selected
from the range 0 < 45o
Capacity of pair = 1.4 x the SWL marked on one sling

(3) Single shackle
Angle to the vertical = 30o so factor selected from the
range 0 < 45o
P2TIM‐TB 42


Capacity = 0.7 x SWL marked

(4) Single collar eyebolt
Angle of line of pull to the vertical = 30o
Factor selected from the separate factors for eyebolts on
page 42
Capacity = 0.4 x SWL marked

(5) Single Round sling
Angle to the vertical = 30o so factor selected from the
range 0 < 45o
Also make allowance for choke hitch from table 3 on page
41
Capacity = 0.7 x SWL (in choke hitch); = 0.7 x 0.8 x SWL (in
straight pull)

Remember!
Check your rating allowances
Allow for:
 Number of legs in use
 Rigidity of the load
 Lack of symmetry of the legs
 Angles to the vertical
 Mode of use
P2TIM‐TB 43


GOOD SLINGING PRACTICE
Good slinging practice must ensure that the load is as safe and secure
in the air as it was on the ground and that no harm is done to the
load, lifting equipment, either property or persons.
Follow the GENERAL LIFTING PROCEDURE on page 5. In additions
notes the following points:
 Do not exceed the SWL or rated angle of any equipment
 Take account of the geometry and mode of use
 The sling must not be twisted or kinked in any way
 Attach the sling securely to the load and machine and
position the sling hook to face outwards
 Never load the point of a hook
 Do not hammer, force or wedge slings or accessories into
position, they must fit freely
 Any choke angle must not exceed 120o and any basket 90o
 Do not hammer down a choke to increase the grip on a
bundle. Use a double wrap and choke instead.
 Use packing to prevent damage to the sling from corners
or edges and to protect the load. See below for guidance
on packing.
 When attaching more one sling to the hook of the
machine, use a shackle to join the slings and avoid
overcrowding the hook. This is a good practice whatever
the angle of the sling and essential at included angles over
90o i.e. over 45o to the vertical.
 Place the hook of free legs back onto the master link and
take care to ensure that empty hooks do not become
accidentally engaged.
P2TIM‐TB 44


 Ensure the load is balanced and will not tilt or fall
 Ensure the load is free to the lifted.
 Keep fingers, toes etc. clear when tensioning slings and
when landing loads
 Check that there is no overhead obstacle such as power
line
 Except where special provision is made, do not allow
anyone to pass under or ride upon the load. The area
should be kept clear.
 Never drag slings or other lifting gear over floor, etc. It can
damage the sling or gear.
 Never attempt to drag a trapped sling from under a load. It
can damage the sling and may topple the load.
 Never use a sling to drag a load
 Never use sling in contact with chemicals or heat without
the manufacturer’s approval.
 Never use damage or contaminated slings
 On completion of the lift check all equipment and return to
proper storage.
Packing
Adequate packing between sling and load is necessary. The object of
packing are:
(1) To provide an adequate radius around which a sling may
pass without unacceptable loss of load carrying capacity
(2) To assist the sling in gripping the load
(3) To prevent damage to the load itself
With regards to (1) above, it is important to realize that when a sling
bent around a corner, its strength will be considerably reduced. Whilst
P2TIM‐TB 45


a small radius will prevent the cutting action of a sharp edge. IT WILL
NOT PREVENT THE LOSS OF STRENGTH DUE TO THE SLING WILL BE
LOADED IN THIS WAY.
For example, a chain sling passing around a corner may have one or
more links loaded in bending, which could result in premature failure
of the chain. (see figure 4)
In the case of wire rope sling, too small a radius would result in
permanent kink (see figure 4) and some of individual wires being
overloaded. Although in both of these example failure may not occur
immediately, permanent damage will have been done which may
subsequently result in failure.
Various material is suitable for packing. Whatever is used must be
capable of taking the crushing force which will be imposed upon it,
and it should be position to make best use of its strength.
Where a particular load is lifted regularly, purpose designed re‐

useable packing may be found economical but for general purposes,
the operative should have available a good selection of material
according to the nature of the work (e.g. timber blocks, rubber,
sections of vehicle tyres, conveyor belts, etc.)
When positioning packing, it is essential to ensure that it will stay in
place throughout the lift, as packing which falls or flies out will be
hazards in itself as well as imposing shock load upon the lifting
equipment. It may therefore be necessary to provide some
independent means of securing the packing in place.
P2TIM‐TB 46


The amount of packing required varies according to the particular job
and in a guide of this type it is not possible to cater for every situation.
The illustration below provides some example of good and bad
practice.

Figure 3. Good standard – Adequate radius – No kinking
Figure 4. Bad Practice

P2TIM‐TB 47


Remember!
Adequate packing:
 Maximize the strength of the sling
 Prevent the load damaging the sling
 Prevent the sling damaging the load
 Assists the sling to grip the load

P2TIM‐TB 48


ELECTRIC OVERHEAD TRAVELLING CRANES
The following is based on Section 2 of COPSULE
Selecting the Electrical Overhead Travelling Crane
The majority of lifting operations will utilize an existing crane in these
circumstance the selection process will therefore be one of checking
whether the available crane is suitable for lifting operation.
Consideration should be given to the followings:
 Lifting capacity is required
 Whether start and finish positions of the load lie within the
area covered by the crane. A crane should never be used to
drag a load
 Whether the height of lift is sufficient for the lifting operation
taking account of the height required for the lifting accessories
 The speed of the various motions and whether they are
appropriate to the degree of precision required to position the
load.
 Whether the load has to be manipulated or oriented in anyway
and the facility required to do so.
 Whether the nature of the load presents a hazards or the load
needs to be handled with particular care. It so a specific risk
assessment is required. Crane is not intended for lifting people
 The method of communication between the slinger or
banksman and the crane operative
 Whether the possible operating positions allow the operative a
clear view of the load at all time
 Using Electric Overhead Travelling Crane Safely
P2TIM‐TB 49


 Check the crane before use – do not use a defective crane.
 Ensure that the lifting operation is adequately planned and
supervised. This is a legal requirement in LOLER
 Never use an electric overhead travelling crane to lift people
without doing a risk assessment and taking necessary
precautions.
 Never use an electric overhead travelling crane to raise, lower
and suspend a load greater than marked safe working load.
 Ensure that the load directly under the crane. The line of pull
should always be vertical, never side lift or drag a load.
 Never load the point of the hook. The load of lifting accessories
should be located in the seat of the hook and the safety catch
closed.
 Never crowd the hook fittings. To prevent overcrowding with
multiple slings, connect them with a shackles of adequate
strength.
 Always start with a trial lift. The load should be raise just clear
and the lift halted whilst the stability, balanced and security of
the load is checked.
 Ensure that the crane is not subjected to shock loading. When
using cranes with speed control, commence the lift at slow
speed before progressing with full speed.
 When travelling, crane should be taken to prevent the load
swinging unduly.
 Avoid operating the along travel and cross travel controls
simultaneously unless necessary for the lifting operation.
 Avoid running the crab, hoist or crane into the end stop as this
will cause the load to swing unsafely, put shock loading on the
crane and its supporting structure. End stop are a final safety
device only.
P2TIM‐TB 50


 All new cranes and many older designs are fitted with overload
safety devices to protect the crane. Should the crane fail to lift
the load, it is probable that the load exceeds the safe working
load. This should be checked before resetting the controls.
 Never reverse any motion without first allowing the motor to
stop. Quick reversal of direction causes shock loading and
heavy current surges.
 Avoid unnecessary inching. Excessive inching could burn out the
contacts and motors.
 Avoid excessive or intentional use of motion limit devices, they
are a safety feature intended to protect the crane.
 Never override load limiter, hoist limits or travel limits.
 Ensure the travel path is clear and free from obstruction before
operating the crane. The operative must have a clear view of
the load path at all times. If necessary, stop all motions to allow
the operative re‐position to a better vantage point before
proceeding.
 When operating the crane in closed proximity to the load, stand
clear before initiating a travel motion so as to avoid being
trapped.
 Never allow to anyone a ride on or be beneath a suspended
load.
 Do not leave suspended load unattended
 Never place a pendant control on a load unless it has been
deactivated by pressing the stop button. The pendant’s weight
can operate a push button.
 Never set down or leave a remote control station unattended
however briefly before pressing the stop button or deactivated
it.
 Always return remote control station to the designated storage
place after use
P2TIM‐TB 51


 After use return the crane to its parking position and raise the
hook to a height where it will not present a hazard
Don’t forget!
 Never use crane to lift people without a risk assessment
 Never exceed the SWL
 Never load the point of the hook
 Never crowd the hook
 Never reverse a motion before the motor has stopped
 Never override load limiters, hoist limits or travel limits
 Never place a pendant control on a load unless deactivated
 Never set‐down a remote control, however briefly, unless
deactivated

In service inspection
Regularly inspect the crane. For crane in daily use it is good practice to
make a pre‐use inspection at the start of each shift or working day.
For cranes user infrequently it should be done before use on each day
of use.
The pre‐use inspection is to test the functionality of the crane and
visually check for any obvious defect and should include but not be
limited to the followings:
Functionality:
 Operation of emergency stop control
 Operation of all crane motion controls
P2TIM‐TB 52


 Operation of electrical isolator switch
 Operation of motion limit switches
 Operation of any anti‐collision devices
 Operation of brakes
 Operation of audible warning where fitted
Conditions:
If any of the following defects are found, refer to competent person:
 Illegible or unclear marking of SWL or controls
 Damage to the crane structure
 Sign of rope wear, broken wires or kinks,
 Under no load the falls of rope cross over each other
 Wear or damage to sheaves, the hook block, hook and safety
latch
 Any unusual noises or erratic movement during operation
 Damage to the control pendant and associated cables
 For remote controlled cranes, damage to the seal of remote
control stations particularly around button or joystick and
damage to the casing which might enable dirt, water or other
contaminants to enter and which can cause false commands
 For crab control cranes, any damage to the means of access,
the cab or the controls
 For crab control cranes, damage to or absence of any
emergency equipment such as firefighting or emergency
egress equipment.
 For crane with cross bridge walkway any loose material or
equipment which the crane motion might cause to fall
 Damage to the supporting structure, gantry beams, rails or
tracks including end stops
P2TIM‐TB 53


 For portal and semi portal cranes any debris or other track
obstructions
Loose material on walkways
SWL not clear
Rope worn, broken
wires, kinks, fails
crossed
Damage to control
pendant and cross
Debris or other track
bridge cables
Damage to sheaves, obstruction
hook block, hook,
safety latch Damage to structure /
gantry beam, rail, end stops

Figure 5. Electric Overhead Travelling Crane Inspection Points
Damage to the seals
around button
Damage casing
Figure 6. Remote Control Inspection Points
P2TIM‐TB 54


Maintenance
The employer has a duty under PUWER to maintain the electric
overhead travelling crane in good condition and safe for use. The
degree of maintenance required will vary dependant on the type and
duty of the particular cranes. Detailed maintenance information
should be provided by the crane manufacturer or supplier. Note that
the requirements for maintenance, inspection and examination are
separate issues although in some cases they may be carried out
concurrently.

P2TIM‐TB 55


HAND CHAIN BLOCKS
The following is based on Section 3 of COPSULE.
Using hand chain block safely.
 Check the block before use – do not use defective block
 For hook suspension, ensure the support fits freely into the
seat of the hook. If the hook is not fitted with safety catch
mouse the hook to prevent displacement
 For trolley suspension, ensure the trolley is correctly set for
the beam width
 Check the chains are not twisted, particularly with a multi‐
fall block
 Check that the bottom hook will reach the lowest point
required without running the chain fully out.
 Never replace the load chain with a longer one without
consulting the supplier
 Never use undue effort to force the block to operate.
 Never allow oil or grease to come into contact with the
brake
 Never use the load chain as sling

Don’t forget!

 Never overload the block
 Never use undue force

 Never use the load chain as a sling
 Never modify unless authorized
 Never lubricate the brake
P2TIM‐TB 56


In‐service inspection

Regularly inspect the block. If any of the following defects are found
refer to a Competent Person.

Chain
 Signs of wear, particularly on the bearing surfaces inside the
crown of the links
 Links are bent, notched, corroded or stretched
 They do not hang freely or articulate freely
 The slack end anchor is insecure or the slack end stop is missing

Block body and fittings
 Visible damage or distortion of hook, trolley or block frame
 Missing safety catches
 Missing or damage covers
 Illegible marking
Hook distorted Missing/damage
safety catch
Marking illegible
Frame distorted
Chain is worn, links, bent,
Missing/Damage covers
notched, corroded or
stretched. Lack of articulation

Figure 7. Hand Chain Block Inspection Points

P2TIM‐TB 57


Operations
 The load slips
 The load chain jumps or makes a cracking noise during lifting or
lowering
 Excessive operating effort is required
 The brakes lock on or off
Maintenance
Follow any specific maintenance instruction issued by the supplier but
in particular keep the load chain lubricated and check the operation of
the brake.
The brake must be kept free of oil, grease, etc.

P2TIM‐TB 58


HAND OPERATED CHAIN LEVER HOISTS
Using chain Lever Hoists Safety
 Check the hoists before use – do not use a defective hoist
 Ensure the support fits freely into the seat of the top hook. If
the hook is not fitted with safety catch, mouse the hook to
prevent displacement
 Check that the chain is not twisted particularly with multi‐fall
hoist
required without running the chain fully out
 Never replace the load chain with a longer one without
 Never extend the lever or use undue effort to force the lever
hoist to operate
 Never allow oil or grease to come into contact with the brake

Don’t forget!

 Never overload the hoist

 Never lubricate the brake

P2TIM‐TB 59



Regularly inspect the lever hoist. If any of the following defects are
found refer to a Competent Person.

Chain
 Signs of wear – with link chain particularly on the bearing
surfaces inside the crown of the links – with roller chain
particularly on the pins indicated by slackness between the
links
 They do not hang freely or articulate freely

Hoist body and fittings
 Visible damage or distortion of hook, lever or body
Figure 8. Chain Lever Hoist Inspection Points
P2TIM‐TB 60


Operations
 The load slips
 The load chain jumps or makes a cracking noise during lifting or
lowering
 The brakes lock on or off

Maintenance
Follow any specific maintenance instruction issued by the supplier but
in particular keep the load chain lubricated and check the operation of
the brake. The brake must be kept free of oil, grease, etc.

P2TIM‐TB 61


LIFTING AND PULLING MACHINES
(using a gripping action on the wire rope)
Using Wire Rope Grip/Pull Machines Safely
 Check the machine and any pulley blocks before use – do not
use a defective machine or block
 Use only the correct rope for the machine
 Coil and uncoil the rope carefully to ensure it does not kink
 Ensure the machine is free to align with the rope and the rope
is free of any obstruction
 Ensure the anchorage point is adequate for the load taking
account of the effect of any pulley blocks
 Use only the operating lever provided with the machine or
cause safety pins to shear
 Never use kinked or damaged ropes or ropes with broken wires
 Never use grip/pull machines if the rope is twisted or trapped
 Never use the rope as a sling
Don’t forget!
 Never overload the machine
 Never use kinked or damaged ropes
 Never operate the raising and lowering levers at the
same time
 Never use the rope as a sling
P2TIM‐TB 62


Regularly inspect the grip/pull machine. If any of the following defects
are found refer to a Competent Person.

Machine body and fittings
 There is visible damage or distortion of terminal fittings, the
operating lever or the casing
 The shear pins are distorted or broken
 Massing safety catches
Figure 9. Wire Rope Grip/Pull Lifting Machine the Inspection Points
Pulleys
 The sheaves are not matched to the rope i.e. check group
profile, sheave diameter and SWL
 There is visible damage or distortion of the pulley frame,
sheave or terminal fitting
 Signs of wear in the sheave bearing or axle pin
P2TIM‐TB 63


 Insecurity of any component particularly the axle pin.

Rope
 An incorrect rope is fitted
 The rope is kinked, worn, corroded or has broken wires
 The rope termination is damaged, cracked or pulled
Figure 10. Pulley Blocks Inspection Points
P2TIM‐TB 64


Figure 11. Wire Rope Inspection Points
Operations
 The load slips
 The operation is jerky
 The rope will not progress through the machine but ‘hunts’
back and forth

Figure 12. Correct and Incorrect Methods of Uncoiling Wire Rope

P2TIM‐TB 65


Maintenance
Follow the specific maintenance instruction issued by the supplier. In
particular, keep the machine well lubricated Lack of lubrication will
result in a jerky movement or failure to operate. It is impossible to
over lubricate grip/pull machine.

P2TIM‐TB 66


POWER OPERATED BLOCKS
Using Power Operated Blocks Safely
 Check the block before use – do not use a defective block
 For hook suspension, ensure the support fits freely into the seat
of the hook. If the hook is not fitted with a safety catch, mouse
the hook to prevent displacement
 For trolley suspension, ensure the trolley is correctly set for the
beam width
 Check that the chains or rope are not twisted, particularly with
a multi‐fall block
required without running the chain or rope fully out.
 If the block has more than one speed, always start in the slow
speed
 Avoid unnecessary inching of the load
 Never change motions without first allowing the motor to stop
 Never replace the load chain or rope with a longer one without
 Never use the load chain o rope as sling
Don’t forget!
 Never overload the block
 Avoid unnecessary inching
 Never change motions before the motor stop
 Never use the load rope or chain as a sling
P2TIM‐TB 67



Regularly inspect the block. If any of the following defects are found

Chain
 Signs of wear, particularly on the bearing surfaces inside the
crown of the links
 It does not hang freely or articulate freely

Wire Ropes
 Signs of wear or visible broken wires, kink or corrosion
 Under no load the falls of rope cross over each other

Machine body and fittings
 Visible damage or distortion of hook, trolley or hoist frame
 Electrical connection are insecure
P2TIM‐TB 68


Figure 13. Power Operated Chain Block Inspection Points
Electrical connection
Frame distorted are insecure
Wire rope is worn,
has visible broken
wire, kinks or
corrosion. Rope fails
cross over each
other
Missing/damage covers

Figure 14. Power Operated Wire Rope Block Inspection Points

P2TIM‐TB 69


Operations
 Block will not lift
 The load slips
 The motion controls are reversed
 Overruns when the control is released
 The limits switches do not function

Maintenance
Follow any specific maintenance instruction issued by the supplier.

P2TIM‐TB 70


WINCHES USED FOR LIFTING
Using Winches Safely
 Check the winches before use – do not use a defective winch
 Ensure the anchorage and suspension points are suitable for
the full loads that will be imposed taking account of the effect
of any pulley blocks. Do not use timber bearers.
 Ensure the correct rope is fitted, that it is of adequate length
and the winch drum can accommodate it.
 Ensure is wound in the right direction. If the direction of
rotation is indicated, the winch must raise the load when
turning in that direction. Never try to raise load in the opposite
direction to that indicated
 Do not over wind the rope on or off the drum. At least two turn
must always remain on the drum but some manufacturers
design for more and their recommendation must be followed
 Endure the sheaves are correct for the size and type of the
rope, that fleet angles are not too great, the rope is not twisted
and the rope path is clear
 Check that the operating handles are secure
 With manual winches, use only the slow speed to raise/lower
loads. With power operated winches, select a speed
appropriate to the specific lifting operation
 Never use the pawl to arrest descending loads
 Never use the rope as sling
 Ensure oil, water, or other foreign matter does not come into
contact with line brakes.
P2TIM‐TB 71



Regularly inspect the winch. If any of the following defects are found
Don’t forget!
 Never overload the which
 Never raise load in the opposite direction to
that indicated
 Never over wind the rope off the drum
 Never use the load rope as a sling
 Never use the pawl to arrest a descending load
 Never lubricated the brake

Winch frame and fittings
 The winch frame is corroded, damaged or distorted
 The rope rum flanges are chipped or cracked
 The rope anchorage is damages
 The ratchet/pawl is damaged, worn or corroded
 The brake is worn or slipping
 The gears are worn, damage or not positively locating
 There are loose or missing bolts, keys or other fixings
P2TIM‐TB 72


Ratchet/pawl damaged, Handle damage
worn or corroded. Gears
worn or not locating
Marking illegible
Brake is worn/ Rope incorrect type or
slipping wound wrong way, worn,
kinked, corroded, has
Frame distorted visible broken wires or
damaged termination

Figure 15. Hand Winch Inspection Points
Electrical connections Brake is worn/
insecure slipping
Guards missing
Gears worn
not locating
Rope drum flanges
Frame distorted/ damage. damaged. Rope
Bolts or other fixings loose anchorages damaged
Figure 16. Power Winch Inspection Points
Pulleys
 The sheaves are not matches to the rope i.e. check groove
profile, sheaves diameter and SWL
P2TIM‐TB 73


 There is visible damage or distortion of the pulley frame,
sheave or terminal fittings
 Signs of wear in the sheaves bearings or axle pin
 Insecurity of any components particularly the axle pin
Visible damage or
distortion of the frame,
Fasteners insecure sheaves or suspension
Sheave groove profile,
Marking illegible diameter and SWL not
matched to the rope
Bearings or axle
pin worn

Figure 17. Pulley Block Inspection Points

Wire rope
 An incorrect rope is fitted
 The rope is kinked, worn, corroded, or has broken wires
 The rope termination is damaged, cracked or pulled
 The rope is worn in the wrong direction

Operations
 The load slips
P2TIM‐TB 74


 The rope does not wind evenly
Maintenance
Follow any specific maintenance instruction issued by the supplier.

P2TIM‐TB 75


TRAVELLING GIRDER TROLLEYS
Using Trolley Safely
 Check the trolley before use – do not use a defective trolley
 Ensure the wheel profile is suitable for the track
 Check the trolley width is correctly set for the track and the
suspension point is central to the runway
 Ensure track is fitted with positive ends stop which engage onto
the tread, not the flange of the trolley wheels
 Never force or wedge the suspension hook of blocks onto the
suspension point
 Never side load a trolley as this will cause them to tip and may
damage the track or cause the trolley to detect from the track
and fall
 Push rather pull loads suspended on push/pull trolley
Don’t forget!
 Never overload the trolley
 Never use if incorrect adjusted
 Never side load the trolley
 Never use without end stops

P2TIM‐TB 76


Regularly inspect the trolley. If any of the following defects are found
 Loose or distorted side plates, load bar or suspension eyes
 Wear or damage to the wheel treads ends flanges
 Insecure wheels and axle pins
 Damage or worn hand chain
 Damaged controls
 Worn or chipped drive gears
Check spacers are evenly
Damaged wheel treads, flanges
distributed so that load
& gears. Insecure axle pins.
bar is central
Side plate
loose/distorted
Anti‐tip missing
or not adjusted
Hand chain damaged Load bar loose/
Marking illegible distorted or not central

Figure 18. Travelling Girder Trolley Inspection Points

Maintenance
Maintenance may be combined with that of the block but should
ensure that the trolley is clean and that moving parts are regularly of
P2TIM‐TB 77


lubricated. Keep the running surface of wheels are contact surface
track free of any contamination including lubricants
P2TIM‐TB 78


BEAM CLAMPS
Using Beam Clamps Safely
 Check the clamp before use – do not use a defective clamp
 Ensure the beam is adequate to the load, in good condition and
suitable for the application
 Check the clamp is of the correct profile and size, or correctly
adjusted for the beam width and that it seats correctly on the
beam flange
 Never use beam clamp which are unidentified or uncertified for
lifting application
 Never replace bolts, shackles, etc. without consulting the
supplier
 Never force or wedge hook for lifting machines into the
attachment eye or fitting
 Never side load a beam clamp without the authority of the
supplier
Don’t forget!
 Never overload the clamp
 Never use if incorrect adjusted
 Never use uncertified clamp
 Never replace parts without authority
 Never side load without authority
P2TIM‐TB 79


Regularly inspect the beam clamp. If any of the following defects are
 Distortion, cracks corrosion or other damaged
 Wear of clamping screw threads
 Insecure fixing
 Illegible markings
Fixing bolt incorrect/
thread worn
Clamp incorrect size,
distorted, threads worn
Body distorted or
cracked. Particularly
check the inside of bends
and holes
Figure 19. Fixed Beam Clamp Inspection Points
Frame distorted/cracked
Fixing bolt incorrect/
thread worn
Fixing insecure Marking illegible

Figure 20. Adjusted Beam Clamp Inspection Points

P2TIM‐TB 80


Maintenance
Beam clamp should be cleaned and any moving parts lubricated at
appropriate intervals unless the supplier’s specific instructions
indicate otherwise

P2TIM‐TB 81


SLEWING JIB CRANES
Using Jib Cranes Safely
 Check the jib cranes before use – do not use a defective jib
crane
 Take the load gently to avoid shock loads. Similar care is
needed when lowering load as sudden loading/unloading may
cause the jib arm to whip
 Push rather than pull the load when slewing the jib arm
 Do not let the trolley crash into the travel stops as the load will
swing outward increasing the radius and therefore the
resultant load on the jib crane
 Never attempt to drag loads along the ground
 Never place ladder against, or climb on, unrestrained jib arms
Don’t forget!
 Never overload a slewing jib
 Never use without ends stop
 Never let the load swing outwards
 Never attempt to drag load
 Never climb on unrestrained jib

P2TIM‐TB 82


 Any structural defects, damaged, distortion or crack welds
 Loose or missing bolts
 Damaged or missing runway end stops
 Difficult in slewing or jib arm slews on its own
 Difficult in moving trolley or trolley moves on its own
Structural defects,
welds cracked,
End stops are
distortion
missing/damaged
Bolts are missing
Marking illegible
or loose
Jib slews on its own or trolleys
moves on its own
Figure 21. Slewing Jib Crane Inspection Points

Maintenance
The maintenance requirements may be combined with those of the
listing machine. Lubricate bearing and pivot points. Where the slewing
motion is obtained by manual gears of powered drive, the gear
wheels and drives must be kept in good order and lubricated. Bolts
and fixings should be checked to ensure they are tight and if
necessary re‐torqued. The running surface of the track should be
clean and keep free of debris etc.
P2TIM‐TB 83


RUNWAYS
Using Runway Safely
 Check the runway before use – do not use a defective runway
 Ensure the runway is clearly identified and marked with the
SWL
 Ensure the runway has positive ends stops which engage onto
the thread and the flange of the trolley wheels
 Do not side load the runway or attempt to drag loads
 Pull rather than pull on suspended loads
 Do not let the trolley crash into the travel stops as the load will
swing thus increasing the resultant loads on the runways and
structures
 In the case of runways fitted with more than one lifting
machine take care to avoid collision or any one span of the
runway becoming overloaded due to the proximity of the lifting
machines
 Never attach additional steelwork or suspend pipes, cables, etc.
from runways.
Don’t forget!
 Never overload a runway
 Never use un‐certified runway
 Never use without end stops
 Neve attempt to drag loads
 Never swing loads to the side or beyond the end of
the track
P2TIM‐TB 84


 Any structural defects, damaged, distortion, corrosion, or crack
welds
 Damaged or missing runways end stops
 Track not level or running face uneven
 Difficulty on moving trolley or trolley moves on its own
Maintenance
lifting machine. Bolts and fixings should be checked to endure they
are tight and if necessary re‐torqued. The running surface of the track
should be clean and kept free of debris, etc. Ends stop must be in
place, correctly set and secure.

P2TIM‐TB 85


MOBILE GANTRIES
Using Mobile Gantries Safely
 Check the mobile gantries before use – do not use defective
gantries
 If it has been dismantled, ensure it is correctly erected and that
all bolts, pins, etc. are in place.
 Ensure the surface on which the gantry is placed is level, even
and capable of taking the imposed loads. Where necessary use
floor plate to achieve this. Beware of hidden danger such as
buried pipes, cables, etc.
 Position the gantry so that the lifting machine is directly over
the load and the beam is line with the direction of travel
required.
 Where fitted, apply brakes, parking jacks or wheel locks before
attempting to raise the load
 Avoid swinging load. The centre of gravity of the load should
always be under the runways centre line or the gantry may
topple over.
 Never rotate loads unless the centre of gravity will remain
under the centre line of the runway beam
 Never attempt to move a gantry whilst under load
 Disconnect power supply etc. before attempting to move the
gantry for a new position
 Never use vehicle, winch, etc. to low a gantry. They can easily
topple over if not move with care
 Never place ladder against, or climb on, unrestrained gantries
P2TIM‐TB 86


Don’t forget!
 Never overload a mobile gantry
 Never move a gantry under load
 Never attempt to drag load
 Never swing load to the side or beyond the ends of
the track
 Never climb on an unrestrained gantry
welds
 Loose or missing bolts, locking pins, etc.
 Damaged wheels, jacks or ineffective brakes

Maintenance
lifting machine. Bearing and screw jacks should be lubricated. The
running surface of the track should be clean and kept free of debris,
etc.
P2TIM‐TB 87


End stops are missing/damaged
Structural
damaged
Markings
illegible
Wheels, jacks or brakes
damaged or ineffective

Figure 22. Mobile Gantry Inspection Points

P2TIM‐TB 88


JACKS
Using Jacks Safely
 Most jacking operations require the use of several jacks. Care is
needed as it is not possible to raise or lower jacks in perfect
unison. This results in uneven loading with the load being
transferred from one jack to another. It can be more hazardous
when lowering as the jack being lowered transfers its share to
the other jacks. The capacity of the jacks should adequate to
account for this.
 Check the jacks and packing before use – do not use the
defective jack or inadequate packing
 Ensure the surface on which the jack is placed is level, even and
capable of taking the imposed loads. Where necessary use floor
plate to spread the load over a wider area. Avoid hidden danger
such as buried cables, pipes, and ducts which may affect the
load bearing capability of the floor
 Ensure the load is capable of withstanding the forces imposed
by jacking operation
 Use packing capable of withstanding the load without crushing
 Ensure the jack is positioned so the load is applied to the jack in
correct plane. Never load a jack off centre
 The head of the jack should be full, firm contact with jacking
point of the load. Use packers if necessary to prevent the head
of the jack from slipping
 Lift and lower in small stages following up with support packing
to minimise the risk of a load falling or all the loads coming
onto a single jack. Do not raise the load higher than necessary
P2TIM‐TB 89


 Ensure the load is kept level within the limit of operation
 Never overextend the jack
 Never leave a load supported on jacks unless they are
specifically designed for that purpose. Use packing, screw
collars, trestles, etc. which are capable of withstanding the
imposed load without crushing
 Never reach under, work or climb on a load supported by jacks.
 Always keep hands end toes clear.
Don’t forget!
 Never overload a jack – beware with multiple jacks –
lowering one can overload another
 Never use uneven surface
 Never leave a load supported on jacks – use support
packing
 Never reach under or climb on a load supported by
jacks
 Never over extend a jack
Regularly inspect the jacks. If any of the following defects are found

General
welds
P2TIM‐TB 90


 Track not level or running face uneven
 Difficulty on moving trolley or trolley moves on its own
Maintenance
lifting machine. Bolts and fixings should be checked to endure they
are tight and if necessary re‐torqued. The running surface of the track
should be clean and kept free of debris, etc. Ends stop must be in
place, correctly set and secure.

P2TIM‐TB 91


CHAIN SLINGS
This following is based on Section 14 of COPSULE.
Using Chain Sling Safely
 Check the sling before use – do not use a defective sling.
 Remember to allow for the mode of use when selecting the
sling.
 Ensure the master link fits freely onto the lifting machine.
 Do not force or wedge sling or fitting into position; they must fit
freely.
 Position of the hook of multi‐leg slings to face outward form
the load.
 Do not lift on the point of any hook.
 Back hook free legs to the master link to avoid lashing legs
which might accidentally become engaged or otherwise be a
hazard.
 Ensure that the chain is not twisted of knotted.
 Never shorten a sling leg other than by means of an integral
chain clutch.
 Do not use chain sling at temperatures above 2000C or below
minus 400C or in contact with chemicals, particularly acids* and
acid fumes, without consulting the supplier.

*HSE Guidance Note PM 39 _ Hydrogen Embrittlement of Grade 8
Chain.

P2TIM‐TB 92


Don’t Forget!
 Never overload chain sling – allow for angles and
mode of use
 Never lift on the point of a hook
 Never force or hammer into position
 Never use chain twisted of knotted
 Never attempt or shorten except with an integral
chain clutch.

Figure 23. Correct and Incorrect use of a Chain Clutch

In‐service Inspection
 Regularly inspect chain slings. If any of the following defects are
found, refer to a Competent Person:
 Wear, distortion, cracking, corrosion, discolouration due to
heat or other damage to any part of the sling;
P2TIM‐TB 93


 Ineffective or missing safety catches;
 Illegible markings.
Maintenance
Maintenance requirements are minimal. Keep chain slings clean and
protect from corrosion.
Marking illegible Master link
Coupling components
distorted or cracked or
Chain links bent, pins insecure
notched, corroded,
stretched or lack
articulation
Hooks distorted Safety catches
missing / damaged
Figure 24. Chain sling Inspection points

P2TIM‐TB 94


WIRE ROPE SLINGS
Using Wire Rope Slings Safely
 Check the sling before use – do not use defective sling.
sling.
 Ensure the master link fits freely onto the lifting machine.
 Do not force or wedge slings or fittings into position; they must
fit freely.
 Position the hooks of multi‐leg slings to face outward from the
load.
 Back hook free leg to the master link to avoid lashing leg which
might accidentally become engaged or other otherwise be a
hazard.
 Ensure that the wire rope is not twisted or kinked.
 Ensure that the effective diameter of pins, hooks, etc. upon
which soft eyes fit is at least 2 x the wire rope diameter.
 Use packing to protect the wire rope from sharp edges and
small radii.
 Position the splices and endless slings in the standing part of
the sling away and hooks and fittings.
 Never join wire rope slings made from different lay directions
of rope together as this will cause them to unravel thus
seriously affecting their capacity.
 Never attempt to shorten, knot or tie wire rope slings.
P2TIM‐TB 95


 Do not use wire slings at temperatures above 1000C or below
minus 400C or in contact with chemicals without consulting the
supplier.
Don’t Forget!
 Never overload a wire rope sling – allow for
angles and mode of use
 Never join wire ropes of opposite lay
 Never use ropes twisted or kinked
Regularly inspect wire rope slings. If any of the following defects are
 Wear, distortion, cracking, corrosion, discolouration due to

heat or other damage to any part of the sling;
 Signs of movement at splices or ferrules;
 Broken or cut wires;
 Kinks (some permanent setting due to previous are around a
load is acceptable but check carefully for other signs of local
damage);
 Protrusion of core;
 Ineffective or missing safety catches;
P2TIM‐TB 96


Master link distorted
Marking illegible
Thimbles distorted
Wires cut or broken Signs of movement
at ferrule or splice
Rope kinked or
core exposed Safety catches
missing or damaged
Hooks distorted
Figure 25. Wire rope sling inspection points

Maintenance
Maintenance requires are minimal. Keep wire slings clean and protect
from corrosion. Use non‐acidic lubricant.

P2TIM‐TB 97


FLAT WOVEN WEBBING SLINGS
This is based on Section 16 of COPSULE.
Using Flat Woven Webbing Slings
 Check the sling before use – do not use defective sling.
sling.
 Check that the sling engages correctly with fittings and the
lifting machine, ensure smooth radii are formed.
 Do not twist or cross slings and do not overcrowd fittings.
fir freely.
 Position the sling so that the load uniformly spread over its
width and use packing to protect the sling with sharp edges.
 Position the bight for a choke lift at the natural (1200) angle to
avoid heat from friction.
 Ensure that stitching is in the standing part of the sling away
from hooks and other fittings.
 Never attempt to shorten, knot or tie flat woven webbing
slings.
 Never expose flat woven webbing slings to direct heat or
flames.
 Do not use flat woven webbing slings at temperatures above
800C or below 00C without consulting the supplier.
 Never use flat woven webbing slings which are cut or which
have loose or damaged stitching.
P2TIM‐TB 98


Don’t forget!
 Never overload a webbing sling – allow for angles and
mode of use
 Never attempt to shorten, knot or tie a webbing sling
 Never use around sharp edges without protection
 Never expose to direct heat
NOTE: The material from which the webbing sling is manufactured
may be identified by the colour of the label or printing on the label:
Polyester = Blue, polyamide (Nylon) = Green, Polypropylene = Brown
and the sling may also be dyed with a colour code to indicate the SWL
in straight pull.
Regularly inspect flat woven webbing slings. If any of the following
defects are found, refer to a Competent Person:
 Damaged, chaffed or cut webbing;
 Damaged or loose stitching;
 Heat damage (if due to friction this will appear as a hard shiny
area on the surface);
 Chemical damage;
 Solar degradation;
 Damaged or deformed end fittings;
P2TIM‐TB 99


Eye or eye reinforcement
damaged, chafed or cut
Marking illegible
Webbing damaged,
frayed, signs of
chemical attack or
Heat damage including solar degradation
hard shiny areas due to
friction
Webbing cut
Figure 26. Flat woven webbing sling inspection points

Maintenance
Maintenance requirements are minimal. Webbing slings maybe
cleaned with clean water and allowed to dry naturally. Remember
weak chemical solutions will become increasingly stronger by
evaporation.

P2TIM‐TB 100


ROUND SLINGS
The following is based on Section 17 on COPSULE.
Using Round Slings Safety
 Check the sling before use – do not use a defective sling.
sling.
 Check that the sling engages correctly with the fittings and the
lifting machine, ensure smooth radii are formed which allow
the sling to assume its naturally flattened from under load.
fit freely.
 Keep labels away from hooks and fittings.
 Use packing to protect the sling from sharp edges.
 Never attempt to shorten, knot or tie round sling.
 Never expose round slings to direct heat or flames.
 Do not use round slings at temperatures above 800C or below
100C without consulting the supplier.
 Never use round slings with cut or damaged outer covers.
P2TIM‐TB 101


Don’t Forget!
 Never overload a round sling – allow for angles and
mode of use.
 Never attempt to shorten, knot or tie round sling
 Never use around sharp edges without protection
 Never expose to direct heat.
NOTE: the material in which the round sling is manufactured may be
identified by the colour of the label or printing on the table: Polyester
= Blue, polyamide (Nylon) = Green, Polypropylene = Brown. The outer
sleeve of the sling will also be colour coded to indicate the SWL in
straight pull.
Regularly inspect round slings. If any of the following defects are
 Damaged or cut outer cover;
 Damaged stitching;
 Exposed inner core;
P2TIM‐TB 102


 Heat damage (if due to friction this will appear as a hard shiny
area on the surface);
 Chemical damaged
Stitching damaged or
Core exposed
Outer cover cut
or damaged
Cover shows signs of
Marking
chemical attack or
solar degradation
Figure 27. Round Sling Inspection points
Maintenance
Maintenance requirements are minimal. Round slings may be cleaned
with clean water and allowed to dry naturally. Remember weak
chemical solutions will become increasingly stronger by evaporation.

P2TIM‐TB 103


FIBRE ROPE SLING
Using Fibre Rope Sling
 Check the sling before use – do not a defective sling.
sling.
 Check that the sling engages correctly with fittings and the
lifting machine and ensure smooth radii are formed.
 Do not force or wedge or fittings into position; they must fit
freely.
 The diameter of components placed in a soft eye must be at
least the diameter of the rope but not so large that the two
parts of rope at the splice form an included angle greater than
300.
 Position the splice of an endless sling in the standing part of the
rope away from the load, hook or point of choke.
 Use packing to protect the sling from sharp edges.
 Position hooks of multi‐leg slings facing outward from the load.
 Never attempt to shorten, knot or tie fibre rope slings.
 Never expose fibre rope slings to direct heat or flames.
 Do not use fibre rope slings at temperatures above 800C or
below 00C without consulting the supplier.
P2TIM‐TB 104


Don’t Forget!
 Never overload a fiber rope sling – allow for
angles and mode of use
 Never attempt to shorten, knot or tie a fiber
rope sling
 Never use around sharp edges without
protection
 Never expose to direct heat.
Regularly inspect fibre rope slings. If any of the following defects are
 Signs of wear, cuts, or abrasion;
 Splices pulling or coming undone;
 Heat damaged
 Chemical attack
 Rot or mildew in natural fibre rope sling;
 Damaged fittings and thimbles;
P2TIM‐TB 105


Splices puling or
coming undone
Marking Illegible
Rope worn, cut,
abraded, shows signs of
rot or mildew, chemical
attack, heat damage or
solar degradation
Figure 28. Fibre Rope Sling Inspection points
Maintenance
Maintenance requirement are minimal. Fibre rope slings may be
cleaned with clean water and allowed to dry naturally. Remember
weak chemical solutions will become increasingly stronger by
evaporation.

P2TIM‐TB 106


SHACKLES
The following is based on Section 19 0f COPSULE
Using Shackle Safely
 Check the shackle before use – do not use defective shackles. In
particular, ensure the pin is the correct one in terms of type, fit
and grade of material.
 Select the type of shackle and pin most suitable to the
application.
 Remember to allow for the mode of use.
 Shackles should be fitted so that the body takes the load along
its centre line and is not subjected to bending.
 When connecting several sling legs, position, them in the bow
of the shackle to avoid forces that tend to spread the shackle
jaw.
 Ensure the load on the pin is central. Use spacers if necessary.
**
 Ensure the pin screwed fully into the shackle eye.
 Check the thread is fully engaged with the body but is not too
long so that tightening causes the body to deform.
 With bolt and nut type pins, ensure the nut jams on the inner
end of the thread and not on the eye of the shackle. The bolt
should be free to rotate with minimal side float. The split cotter
pin must be fitted before making a lift.
 Avoid applications where movement can unscrew the pin e.g.
when used with a sling in choke hitch. Position the pin away
from the moving part or use a nut and bolt type pin which can
rotate without unscrewing.
 Never replace the pin with a bolt.
P2TIM‐TB 107


Don’t Forget!
 Never overload a shackle – allow for the angle of use
 Never load out of line – the load should be central and
square on the pin.
 Never replace the pin with a bolt
 Never use in a way that would unscrew the pin.
** Caution
BS and ISO Standard shackles are designed and rated for the pin to
accept a central point load. Other commonly available types are
designed and rated for the load to be evenly distributed over the full
width of the pin. Unless the basis for rating is clearly stated it should
be assumed that the jaw must be fully filled and the load evenly
spread across the shackle pin width.
Regularly inspect shackles. If any of the following are found, refer to a
Competent Person:
 Distorted, worn, stretched or bent body or pin;
 Damaged or incomplete thread forms;
 Nicks, gouges, cracks or corrosion;
P2TIM‐TB 108


Body distorted or has visible nicks, cracks or gouges
Marking Illegible
Screw threads
damaged or incomplete Wrong pin fitted, pin
bent or of incorrect fit
Figure 29. Shackle Inspection Points

P2TIM‐TB 109


EYEBOLTS
The following is based on Section 20 of COPSULE.
Selecting the Correct Eyebolt
Eyebolts to BS 4278 are available in three standard types, eyebolt with
link, collar eyebolt and dynamo eyebolt. Select the eyebolt to be used
and plan the lift taking the following into account:
Types of eyebolt
Eyebolt with link – suitable for all general purpose applications.
Collar eyebolt – suitable for most general duties (A collar eyebolt
fitted with a link is not the same as an eyebolt with link and must not
be treated as such.)
Dynamo eyebolt – suitable only where a truly axial load is guaranteed.
Capacity
When used at an angle or in pairs it is necessary to reduce the SWL by
the factors given in table 5.
ANGLE FACTORS
Maximum load to be lifted = angle factor x SWL for a pair of eyebolts
Included angle α between the sling legs
Type of eyebolt 0 < α ≤ 300 300 α ≤ 600 600 < α ≤ 900
Eyebolt with link 1.0 0.8 0.63
Collar eyebolt 0.63 0.4 0.25
Table 5. Angle Factors and Eyebolt Used in Pairs
P2TIM‐TB 110


Using Eyebolts Safely
 Check the eyebolt before use – do not use a defective eyebolt.
 Check the thread of both the eyebolt and hole, ensure they are
compatible, fully formed, of sufficient length, undamaged and
clear of any debris which may prevent proper engagement.
 Ensure the contact surface around the hole is flat, clean,
perpendicular to the thread axis and big enough to support all
the eyebolt collar.
 Tighten the eyebolt down firmly by hand. The collar must sit
evenly on the contact surface. Do not use tommy bars, grips or
wrenches to tighten eyebolts.
 With collar eyebolts used in pairs, the eyes must be in the
correct plane. Use shims but do not machine the collar or even
tighten. See figure 32.
 A hook of similar capacity may be engaged directly to the eye of
a dynamo eyebolt or the link of an eyebolt with link. Collar
eyebolt must be fitted with a shackle or link to accept hooks.
The hooks must fit freely so do not wedge or force them into
position.
 Never reeve a sling through the eyes, links or shackles fitted to
be eyebolts used in pairs as this will impose a severe resultant
force onto the eyebolts.
 Dynamo eyebolts are only suitable for axial loading. Never use
dynamo eyebolts for angular loading.
 When using eyebolts with multi‐leg slings, use eyebolts with
links or collar eyebolts taking care to de‐rate the for angular
loading.
P2TIM‐TB 111


 Where a single eyebolt is used, use a swivel or swivel hook to
prevent the eyebolt unscrewing if the load rotates.
Don’t Forget!
 Never overload an eyebolt – allow for angle of use
 Never over tighten an eyebolt
 Never load a dynamo eyebolt at an angle
 Never use collar eyebolts out of the permitted alignment
 Never reeve a sling through a pair of eyebolts
 Never use in a way that would unscrew the eyebolt
Regularly inspect eyebolts. If any of the following defects are found,
refer to a Competent Person:
 Any signs of distortion to the eye, shank or link;
 Worn, damaged, or incomplete threads;
 Nicks, gouges, cracks, corrosion;
P2TIM‐TB 112


Marking Illegible
Weld Cracked
Link distorted or

cracked Eye Distorted

Screw threads worn,
damaged or incomplete
Underside of collar not flat
Shank Bent

Figure 30. Eyebolt Inspection Points – Eyebolt with Link
Marking Illegible
Eye Distorted
Screw threads worn,
damaged or incomplete

Shank Bent
Figure 31. Eyebolt Inspection Points – Dynamo Eyebolt
Maintenance
Maintenance requirements are minimal. Keep eyebolts clean, protect
from corrosion and thread damage. Do not attempt to straighten bent
eyebolts or re‐cut threads.

P2TIM‐TB 113


LIFTING BEAMS, SPREADERS AND FRAMES
Using Lifting Beams and Spreads Safely
 Lifting beams may incorporate various loose and detachable
items of lifting gear. Refer to the separate requirements for the
safe use of those items.
 Check the lifting beam before use – do not use a defective
beam.
 Many lifting beams are designed for a specific purpose and
should not be used for other purposes without consulting the
supplier. This will include the size of a hook from which they are
suspended.
 The weight of the beam, together with its attachments, must
be added to the weight of the load when calculating the total
load that will be imposed on the crane hook. The self‐weight
should be clearly marked on the beam.
 Ensure that the SWL on the individual lifting points is not
exceeded. Extra care is needed where these are adjustable or
where there is a choice of lifting points.
 Ensure the load remain stable and that the beam remains at its
intended attitude during use. Particular care is required if the
lifting points are below the centre of gravity of the load.
 Use tag lines to control the load.
 Do not allow the beam to foul the underside of the crane, or
any other obstruction, when raising or transporting loads.
Remember that with a double girder overhead crane the upper
limit switch may allow the hook to raise up between the girders
but the lifting beam will foul them.
P2TIM‐TB 114


 Refer to the requirements of BS 7121: Part 1 when using beams
with cranes in tandem.
Don’t Forget!
 Never overload a lifting beam – only use it in the way it is
rated
 Never lift from below the C of G without checking for
stability
 Never allow the beam to foul underside of the crane –
remember the upper limit may allow the hook to rise
between the main beams
 Never forget the self‐weight of the bema or spreader – it is
part of the total load
Regularly inspect lifting beams. If any of the following defects are
 Beam distorted, damaged or corroded;
 Worn, lose or missing bolts or cracked welds;
 Attachments points worn, damaged or distorted, holes and
eyes worn or elongated;
P2TIM‐TB 115


Figure 32. Lifting Beam and Spreader Inspection Points
Maintenance
Maintenance requirements are minimal for lifting beams. Ensure that
bolted joints are sound and that corrosion damage is prevented. Refer
to the individual maintenance requirement for associated loose gear
and attachments.

P2TIM‐TB 116


PLATE CLAMPS
Selecting the Plate Clamp
There are three basic types of plate clamp but the facility they offer
may vary wit make. Refer to the manufacture’s instruction to see
what they are suitable for.
Types of plate clamp
Vertical plate clamp – designed to lift vertical plates but some
designed are also suitable for lifting plates from horizontal to the
vertical.
Horizontal plate clamp – designed to be used in pairs to lift horizontal
plates only. Some are in the form of a specially shaped hook without a
cam, others have a cam which grips the plate. They are used in
conjunction with a sling which must be of the right type to ensure that
the geometry and therefore the gripping forces are correct.
Universal plate clamp – really development of the vertical plate clamp
they can be used for either horizontal or vertical plates and to rotate
them. They may also permit angular loading in the plane of the plate.
Using Plate Clamps Safely – General
 Check the clamp before use – do not use a defective plate
clamp.
P2TIM‐TB 117


 Ensure that the clamps are suitable for the thickness of plate to
be lifted. Never exceed the maximum or minimum thickness for
which the clamps are designed.
 Put the clamp on the plate as far as it will go.
 Do not use clamps at an angle to the edge of the plate or for
lowering from vertical to horizontal, or vice‐versa, unless they
are designed for that purpose.
 Keep oil, grease and similar contaminates away from jaws
which use a friction grip material to hold the plate.
 Never use plate clamps on hard or polished plate unless they
have been specially designed for that purpose.
 Take great care to ensure the plate is fully supported before
attempting to release the clamp.
 Keep all person clear of the danger zone and remember that a
falling plate can ‘glide’ sideways. A large thin plate is likely to
glide further. Also the higher it falls from, the bigger the danger
zone.
Using Plate Clamps Safely – Vertical and Universal Types
 Some designs of clamp, particularly those with a moving cam
action jaw where the initial grip is provided by a spring, have a
minimum load and minimum plate thickness they can safely lift.
Wherever possible refer to the manufacturer’s instructions but
in the absence of specific guidance the load should not be less
than 20% of the SWL and the plate thickness not less than 20%
of the maximum.
 Some designs of plate clamp are suitable for lifting plates from
the horizontal to the vertical and inclusion of a pendant chain
to provide articulation between the clamp and lifting hook is
essential. However, the use of pendant chains should always be
P2TIM‐TB 118


considered to prevent the hook weight being imposed on the
clamp as this might cause the clamp to be released.
 Position the clamp correctly. Place the clamp over the centre of
gravity of the plate. If the plate is long and has tendency to
bend, use two clamps equally disposed about the centre of
gravity in conjunction with a spreader beam.
 Take care to ensure no one clamp takes more than its SWL.
 Ensure the clamp is fully locked or tightened onto the plate
before lifting.
 Under no circumstances should packing be placed between the
plate and the jaws nor any attempt to lift more than one plate
in the clamp.
 When using the universal type, check the manufacturer’s
instruction for the limitations on the angles.
Don’t Forget!
Vertical and Universal Type
 Never overload a clamp – if more than one is used, ensure
each can take its share
 Never exceed the permitted maximum or minimum
thickness
 Never use beyond the permitted angles
 Never use on hard or polished plate unless designed for
that purpose
 Never try to lift more than one plate
 Never place packing between the plate and the jaws.
P2TIM‐TB 119


Using Plate Clamps Safely – Horizontal Type
 Always use horizontal plate clamps in pairs with the correct
type, size and length sling and reeved in the manner for which
they are designed. Some of these clamps are designed to be
used with and endless loop of chain whilst others are for use
with a two leg sling. Under no circumstances must an endless
loop be substituted for a two leg sling or vice‐versa as this will
alter the geometry and therefore the gripping forces on which
the clamps rely for their safe operation.
 If the plates are likely to sag transversely, clamps which grip the
plate by a cam must be used.
 Position the clamps correctly. Place the clamps over the centre
of gravity of the plate. If the plate is long and has tendency to
bend use two or more pairs of clamps in conjunction with a
spreader beam, equally disposed about the centre of gravity, to
minimize the sag. Ensure the clamps face each other to balance
the horizontal clamping forces.
 Take cate to ensure no one clamp takes more than its SWL.
 Put the clamps onto the plate as far as they will go.
 If the sling is adjustable to accommodate, various widths of
plate ensure it is adjusted to give the correct geometry.
 Never attempt to rotate from the horizontal to the vertical or
vice‐versa with this type of clamp

P2TIM‐TB 120


Don’t Forget!
 Never overload a plate clamp
 Never use a single clamp – always in pairs
 Never exceed the permitted maximum or minimum
thickness
 Never substitute an endless loop for a two‐leg sling or vice
versa
 Never exceed the permitted range of sling leg angles
 Never use the cam‐less type if the plate can sag
 Never attempt to rotate from the horizontal to the vertical
with this type of clamp.

Regularly inspect the plate clamp. If any of the following defects are
 Wear, damage, or distortion to fixed and moving jaws;
 Frame opening out of cracked;
 Insecure, worn or bent pins, bolts, etc.;
 Worn friction grip material;
 Damaged, bent or unsatisfactory acting locking lever;
 Tight, bent or damaged clamping threads etc.;
 Corrosion;
P2TIM‐TB 121


Figure 33. Horizontal Plate Clamp Inspection Points
Maintenance
Plate clamps should be cleaned and any moving parts lubricated at
appropriate intervals, unless the suppliers’ specific instructions
indicate otherwise. In the case of clamps with smooth jaws lined with
a friction material, care must be taken to ensure no lubricant comes
into contact with the friction material.
WARNING: Teeth of jaws must not be re‐sharpened or re‐cut unless
this has been specifically approved by the maker.
P2TIM‐TB 122

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