bridge and gantry crane drivers guide 0001

WorkCover. Watching out for you. New South Wales Government

BRIDGE AND GANTRY

CRANE DRIVERSA GUIDE FOR POWER CRANE DRIVERS

GUIDE 1997

DisclaimerThis publication may contain occupational health and safety and workers compensation information. It may include some of your obligations under the

various legislations that WorkCover NSW administers. To ensure you comply with your legal obligations you must refer to the appropriate legislation.

Information on the latest laws can be checked by visiting the NSW legislation website (www.legislation.nsw.gov.au) or by contacting the free hotline

service on 02 9321 3333.

This publication does not represent a comprehensive statement of the law as it applies to particular problems or to individuals or as a substitute for

legal advice. You should seek independent legal advice if you need assistance on the application of the law to your situation.

WorkCover NSW

1CONTENTS PAGE

1. CERTIFICATE OF COMPETENCY FOR BRIDGE AND GANTRY CRANES 2

2. TYPES OF BRIDGE OR GANTRY CRANES 3

3. FEATURES OF BRIDGE OR GANTRY CRANES 5

4. CONTROLS 8

5. HOIST LIMIT SWITCHES 10

6. BRAKES 12

7. SAFE OPERATION 13

8. MAINTENANCE SAFETY PROCEDURE 17

9. SLINGING AND SAFE WORKING LOADS 18

10. WEIGHT OF THE LOAD 25

11. RULES TO FOLLOW WHEN SLINGING AND HANDLING A LOAD 26

12. STACKING 35

13. PERSONAL PROTECTIVE EQUIPMENT 37

14. COMMUNICATION 39

15. FLEXIBLE STEEL WIRE ROPE 41

16. SHEAVES AND DRUMS FOR FLEXIBLE STEEL WIRE ROPE 46

17. CHAIN 50

18. FLAT WEBBING AND ROUND SYNTHETIC SLINGS 53

19. FIBRE ROPE 55

20. ACCESSORIES 56

APPENDIX (i) Areas and volumes 59

APPENDIX (ii) Tables of masses 63

APPENDIX (iii) First aid 65

APPENDIX (iv) Terms used in this guide 66

APPENDIX (v) Sample assessment questions 67

21. CERTIFICATE OF COMPETENCY FOR BRIDGE AND GANTRY CRANES

To gain a certificate of competency for a cabin controlled bridge or gantry crane you must pass an

assessment for a Bridge and gantry crane certificate conducted by an assessor registered by the Workcover

Authority.

Before taking the assessment you must obtain a log book and learn the competencies required to pass the

assessment. Applicants must be at least 18 years old to gain a certificate.

It is illegal to operate a cabin controlled bridge or gantry crane without a Bridge and gantry crane

certificate or a log book (under the supervision of a certificated driver).

A cabin controlled bridge or gantry crane driver must know:

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It is the responsibility of the applicant to make sure that a bridge or gantry crane of the correct class is

available for the assessment at their workplace or has permission to use a crane at another location.

If you operate this type of crane and sling loads in connection with the operation of this type of crane you

will require a Dogging certificate in addition to being competent in its operation. See A guide for dogging

available from the WorkCover Authority.

32. TYPES OF BRIDGE AND GANTRY CRANES

Bridge and gantry cranes can be:

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Most bridge and gantry cranes are controlled by a pendant push button control suspended from the

crane structure.

Cabin controls are used for a wide range of applications particularly where it is not possible to have a

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kept away from the intense heat of the molten steel transported by the cranes.

Bridge cranes

Bridge cranes are commonly used inside factories for a wide range of jobs. They run on overhead rails

usually attached to opposing factory walls.

4Gantry cranes

Gantry cranes have two upright supports (portals) which move along two ground based rails. The height

of the portals depends on the maximum hook height. Gantry cranes are used in factories and in outdoor

storage yards such as railway and shipping storage areas.

Semi-portal cranes

Semi-portal cranes have a single portal running on a ground based rail while the other end is attached

to an overhead rail. They are usually used where there is an outdoor storage yard running parallel to an

enclosed factory.

Container handling cranes

Container handling cranes can be either a bridge or a gantry crane. They are used to handle containers at

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container by twist locks.

53. FEATURES OF BRIDGE OR GANTRY CRANES

The bridge

Each crane has a bridge which extends across the crane structure from rail to rail. It sits on an end

carriage that has a set of track wheels which run on a rail on either side of the building.

Working load limit

The working load limit (WLL) can be found printed on the bridge. It is the responsibility of the driver to

know the WLL of the crane. In many cranes this will be printed as the safe working load (SWL).

Long travel

Long travel is the direction of travel of the bridge along the rails.

Cross travel

Cross travel is the movement of the crab (see below) from one side of the bridge to the other.

The crab

The crab is the cross travel unit from which the hook is lowered and raised. The crab houses the hoist

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sits on rails attached to the bridge. The power for the crab comes from a bus bar or cable on the

bridge structure.

The hook block

The hook block is used for raising and lowering the hook. It can be single or multi-roped.

6The sheaves

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sheave (where fitted). The rule of thumb is that the diameter of a sheave must be about 20 times the

diameter of the rope.

The depth of an open sheave must be 1.5 times the diameter of the rope.

Where the rope is contained in the sheave the minimum depth of the sheave must equal the diameter

of the rope.

The driver must make sure that any sheave showing signs of wear could damage the rope which is

replaced and squeaking sheaves are inspected and greased repaired.

The control cabinet

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the contactors.

The resistor banks

The resistor banks are usually located on the crane bridge or in a well ventilated area. They dissipate heat

from the unused electrical current.

Live wires collector gear bus bars

There are two types of power supply AC and DC. Each is usually supplied by collector gear from live

wires or insulated bus bars running alongside the crane and runway.

The main isolating switch

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crane from the power source. It is used for maintenance or in an emergency.

It is usually located near the ladder to the service platform or the crane cabin.

Look for a switch with a bright yellow background with black writing.

Buffer stops

Buffer stops are fitted to absorb the impact from a collision at either end of the long travel.

Earth wire

The earth wire connection takes any electrical leak to earth. It must be visible and near to the permanent

wiring connection to the bus bar.

The cabin

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7The pendant control

The hand-held pendant control is usually suspended from the bridge on a strainer wire which can be

moved from one side of the crane to the other. The controls are normally push button.

Pendant controls usually have:

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They may also have a creep speed control.

The directional compass

Each crane must have a directional compass under the bridge of the crane. The compass helps pendant

control drivers with the pendant directional controls. Note: The compass is aligned with the crane travel

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84. CONTROLS

Cabin controls

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travel movement and the raising and lowering of the hook.

Pendant controls

9Remote controls

Remote controls are usually worn on a belt around the waist. When using a remote control it is important

to be in a position to review the load and the travel path.

Remote controls can be either infra red or radio controlled. Both infra red and radio controlled remote

controls have a limited range.

lnfra red controls must be pointed towards the crane during operation or the crane will stop.

10

5. HOIST LIMIT SWITCHES

Limit switches prevent over-winding and over-lowering of the hook block. The upper limit prevents the

hook block coming into contact with the rope drum and sheaves.

The lower limit will keep two full turns of rope on the drum when the hook is in its lowest working

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driver before the beginning of each shift.

11

Upper limit switches

Most cranes have two upper limit switches to prevent overwinding:

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Some older cranes are fitted only with a whole current self-resetting upper limit switch.

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before it reaches the whole current non-self-resetting limit switch.

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A qualified electrician must be called to reset a non-self-resetting upper limit.

The whole current self-resetting upper limit switch is used where there is no other upper limit switch. It

will self-reset once the lower control is activated.

The lower limit switch

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Riding the limits

Crane drivers must be careful about using the limit switches as a method of stopping the load at the

maximum height. The contacts can burn out if this is done to excess.

12

6. BRAKES

All bridge and gantry crane brakes work using the same principle:

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When the power is turned on the solenoid pushes the brake off allowing the drum or shaft to turn. When

the power is turned off two springs or a counterweight apply the brakes to the drum or shaft.

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Cabin controlled cranes have a long travel footbrake for easing the load smoothly to a stop. Pendant

control cranes have automatic brakes.

13

7. SAFE OPERATION

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sudden stops.

Do not move a load over a busy work area without giving warning. Watch out for any unexpected

movement or obstructions while a load is moving. Do not carry passengers or allow anyone to interfere

with a load.

Raising and lowering

The driver must use the same control setting to lower the load as needed to raise the load. If the load

needed No 3 setting to be smoothly raised then lower the load with No 3 setting.

Do not use a lower setting to lower a load than was needed to raise the load.

Some cranes have a creep lower speed for accurate positioning while lowering loads.

Some cranes have two hooks from the same crab. Do not change hooks while the first hook is still under

load. Some operations use both hooks such as tipping hot metals ladels and skips.

Starting and stopping

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crane slowly by returning the control to the OFF position step by step. Rapid acceleration can cause the

contacts to arc and burn.

Chasing the hook

Crane drivers must learn to chase the hook (take the swing out of the load as it is brought to a halt).

To chase the hook:

1. Stop the movement of the crane before the final stopping place. The load will swing forward.

2. Move the crane quickly to be above the load at the furthest extent of the swing of the load

and stop again.

14

Do not plug

Do NOT bring the load to a halt by plugging the controls. Plugging is continuously pushing and releasing

the control button. This will run the motor too slowly to activate the cooling fan and can burn out the

motor and overheat the contacts.

Electrical faults

Electrical faults are the greatest hazards associated with bridge and gantry cranes. If there is an electrical

fault call an electrician.

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an electrician.

If a worker receives an electric shock while holding the hook or load and is unable to let go:

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15

Pre-checks prior to turning on the main switch

1. Make sure there are no maintenance signs.

2. Make sure there is no obvious damage to the crane.

3. Check mains switch box for danger tags.

4. Check the main isolating switch for danger tags.

5. Check for any maintenance crew working on the crane.

6. Check that collector wires have not been blown or knocked off the insulators.

They must not have ladders or any other gear resting on them.

7. Check spreaders (container loading gantry cranes) for:

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8. Check wires and anchorages for defects.

Pre-checks inside the cabin and with the pendant control

1. Check the WLL (or SWL) stamped on the bridge of the crane.

2. Unlock emergency switch and switch power on.

3. Check control panel lights. (Cabin only)

4. Check for fire extinguisher. (Cabin only)

5. Make sure that you can identify each of the buttons on the pendant and that they operate freely

without sticking.

6. Check that the pendant strainer wire is properly attached and that the pendant moves freely across

the crane without undue force.

7. Drive and then stop the crane a few times in each direction to check the brakes for adjustment and

operation of the crane for the job.

8. Test the operation of the working limit switches.

9. Where possible have a full view of the load and the general work area.

16

10. Make sure that the runways and the general work area are clear of obstructions.

11. If the load hook is fitted with a safety catch make sure it is working properly.

12. Make sure that the hoist rope is free of kinks or obvious broken wires.

13. Make sure that the rope passes easily through all the running sheaves.

14. Check for any obvious mechanical problems.

15. Make sure that the runways and the general work area are clear.

Cross travel motion

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begin to swing as soon as it is hoisted.

Do not stand directly beneath the load or allow anyone else to do so.

Long travel motion

The bridge must always be brought directly over the load. It is not possible to position the hook block

directly over the load unless this is done.

The bridge will always drift after the power has been removed. Cabin controlled cranes have a foot pedal

brake to stop the bridge. It is important to learn to anticipate the amount of drift and use the brake as

smoothly as possible.

Hoist motion

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Only continue to hoist if the load is in balance. The person who has slung the load must check the

balance of the load for the operator of a cabin controlled crane. Hoist slowly until the load is clear of the

floor and then increase speed smoothly until the load is at the required height.

When lowering the load gradually reduce the speed as the load nears its target.

Reduce to the lowest speed and then inch the load down. Follow the doggers directions if you are

driving a cabin controlled crane.

17

8. MAINTENANCE SAFETY PROCEDURE

Maintenance procedures vary according to the type of crane. Follow the specific maintenance safety

procedures as laid down for your workplace.

Before carrying out maintenance the main switch must be opened and tagged by every worker who will be

working on the crane. This process isolates the crane from the power source while maintenance workers

are on the crane.

When all the tags have been removed from the main switch visually inspect the crane and call out to

make doubly sure that there is no worker still on the crane before reactivating the power.

Where there is more than one crane operating and one crane must be isolated for maintenance:

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isolation switch.

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drivers cabin.

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across to the other rail.

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to observe.

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Above signs on each side.

18

9. SLINGING AND SAFE WORKING LOADS

The working load limit (WLL) of a sling is the maximum load that can be lifted by that sling

making a straight lift.

The load factor for a straight lift = 1.

The lifting capacity decreases as the angle between the legs of the sling attachment increases.

Different methods of slinging will also alter the lifting capacity.

For example:

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Below are the various methods of slinging with their load factors.

SWL tables are available for all types of slings and rope. Make sure that you consult the correct table

before lifting.

You must know the load factors for each method of slinging shown on page 21.

A working load chart for 6 x 24-1570 Grade Galvanised steel wire rope

Rule of thumb methods for calculating the WLLs of flexible steel wire rope, chain and fibre rope.

Please note that these methods only give approximate answers.

19

Flexible steel wire rope (FSWR)

To calculate the WLL in kilograms of FSWR square the rope diameter (D) in millimetres (mm) and

multiply by 8.

Formula: WLL (kgs) = D2 (mm) x 8

For example: Rope diameter (D) = 12mm

WLL (kgs) = D2 (mm) x 8

= D (mm) x D (mm) x 8

= 12 x 12 x 8 = 1152 kgs

WLL (t) = 1.15 tonnes

The above equation can be reversed to calculate the diameter (D) in millimetres of FSWR needed to lift a

given load. To do this divide the load (L) in kilograms by 8 and find the square root of the result.

Formula: D (mm) = Load8

For example: Load = 1152 kg

D (mm) = 1152 8

= 144

= 12

Therefore an FSWR sling of at least 12mm is required to lift a 1152 kg load.

Chain

The WLL of chain is determined by the grade (G).

Do not use a chain to lift if it does not have a manufacturers tag that gives details of the WLL.

Return it to the manufacturer for WLL assessment and re-tagging.

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Formula: WLL (kgs) = D2 (mm) x G x 0.3

For example: $IBJOEJBNFUFSNN$IBJOHSBEF5JFHSBEF

WLL = D2 (mm) x G x 0.3

= D (mm) x D (mm) x G x 0.3

= 10 x 10 x 80 x 0.3

= 2400 kgs

WLL (t) = 2.4 tonnes.

Fibre rope

To calculate the WLL of fibre rope in kilograms square the rope diameter (D) in millimetres (mm).

Formula: WLL (kgs) = D2 (mm)

For example: Diameter = 25mm

WLL (kgs) = D2 (mm)

WLL (kgs) = D (mm) x D (mm)

= 25 x 25

= 625 kgs

WLL (t) = 0.625 tonnes.

20

Flat webbing and round synthetic slings

Flat webbing and round synthetic slings are labelled with the WLL. Do not lift if the label is missing.

Return to the manufacturer for testing and relabelling. Synthetic slings are colour coded (see table below).

Indicator stripes - each stripe represents 1 tonne WLL - safety factor 8: 1

Label for a flat webbing synthetic sling

21

Single sling

Basket hitch

Endless sling or grommet

Comparing methods of slinging and load factors

22

Load factors and slinging

In the examples below all the load and reeve factors are for FSWR. The arithmetic is set out so that

calculations can be easily worked out on a calculator.

1. To calculate the maximum weight of load that can be lifted multiply the WLL of the sling(s) by the

angle factor by the reeve factor.

Formula:

Max load = WLL (of sling) x angle factor

x reeve factor

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legs is 60 and they are reeved around a square load. This means a load factor of 1.73 for the angle and

another factor of 0.5 for the reeve.

Sling WLL 8 tonne

Angle factor 1.73

Reeve factor 0.5

Therefore:

Max load = 8 x 1.73 x 0.5

= 6.92 tonnes

6.9 tonnes is the maximum weight that can be lifted.

2. To calculate the WLL of multi-legged slings needed to lift this load divide the weight of the load by

the load factor.

Formula for a calculator:

WLL = weight load factor

Formula can be written:

WLL = weight

load factor

23

For example: The weight of the load to be lifted is 20 tonnes and the angle between the two legs of a

multi-legged sling is 60. This means that the load factor is 1.73 for the angle.

Weight 20 tonnes

Load factor 1.73

Therefore:

WLL = 20 1.73

= 11.56 tonnes

Therefore use a sling with a lifting capacity greater than 11.56 tonnes.

3. To calculate the WLL of a sling needed to lift this load divide the load by the angle factor and divide

by the reeve factor.


WLL = weight angle factor reeve factor


WLL = weight

angle factor x reeve factor

For example: Two slings have a 60 angle between them and are both reeved around a 4 tonne square

load. This means a load factor of 1.73 for the angle and 0.5 for the reeve.

Weight 4 tonnes

Angle factor 1.73

Reeve factor 0.5

Therefore:

WLL = 4 1.73 .5

= 4.62 tonnes


24

4. To calculate the WLL of the sling needed to lift this load divide the load by the angle factor and

divide by the reeve factor.


WLL = weight angle factor reeve factor


WLL = weight

angle factor x reeve factor

For example: Two slings have a 60 between them are reeved around a 20 tonne round load. This means

a load factor of 1.73 for the angle and 0.75 for the reeve.

Weight 20 tonnes

Angle factor 1.73

Reeve factor 0.75

Therefore:

WLL = 20 1.73 0.75

= 15.41 tonnes


5. To calculate the diameter (D) in millimetres (mm) of FSWR needed to lift a load of 5 tonnes as a

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Formula: D (mm) = Load 8

Formula can be written: D (mm) = Load8

D (mm) = 5000 8

= 625

= 25

Therefore a 25mm diameter FSWR is needed for the lift.

25

10. WEIGHT OF THE LOAD

Do not lift if the weight of a load is not stamped on the load or the delivery docket and it is not

possible to calculate the weight.

It may be possible to calculate the weight of a load from the weighbridge certificate from the

delivery vehicle.

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heavier when wet. In foundries when large castings are raised from a mould there can be suction created

by the sand adding substantially to the weight. Pipes are often weighed down by sludge. Fuel and water

tanks may not always be empty. Check for this.

When lifting a load for the first time watch the lifting equipment carefully for signs of strain in case the

stated weight is incorrect.

26

11. RULES TO FOLLOW WHEN SLINGING AND HANDLING A LOAD

A simple rule of thumb for a good safe working to angle

Make sure that the horizontal distance between the points of attachment of the load does not exceed the

length of the slings.

This will ensure that the angle between the two legs of the sling does not exceed 60.

Multi-legged slings

The recommended maximum angle between the two legs of a sling is 90. The recommended maximum

angle between the vertical and a leg of a sling is 45. At the absolute maximum angle of 120 the WLL of

the two slings must be halved.

Common sling arrangements

Single-part, single-leg slings

Double-part, single-leg slings

2-Leg slings

27

3-Leg and 4-Leg slings

When slinging a rigid object with a multiple legged sling it must be assumed that only two of the sling

legs are taking the load. Additional legs do not increase the WLL.

Where an object is flexible and the load is evenly distributed make sure that each leg takes an even share

of the load.

Be careful when lifting irregular shaped objects - it is possible that only one leg of the sling is taking the

whole load.

The larger the angle from the vertical made by slings on a hook the more likely the slings eyes are to slip

to the bill of the hook.

In this case put the eyes into a bow shackle large enough so that they do not jam. Make sure that the

shackle pin is resting on the hook.

28

Direct lifting

It is the duty of a dogger to direct the crane operator to position the head of the jib or the bridge directly

over the load.

Then make sure that the load hook is positioned directly above a load before slinging and lifting.

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soon as it is raised. Dragging a load can put undue strain on the lifting gear and crane boom especially if

the load is dragged from the side.

General handling

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hard materials.

Use packing to prevent the sling from coming into contact with sharp edges. This will lengthen the life of

the sling and prevent breaks.

Make sure that packing or lagging is secure so that it will not fall out when the slings go slack. Before

lifting a load make sure that it is not caught or trapped in some way.

Machinery and plant with lifting lugs should be marked with the mass. Caution: Some lifting lugs are used

GPSUIFBTTFNCMZBOEEJTNBOUMJOHOPUGPSMJGUJOHUIFFOUJSFVOJU

.BDIJOFSZQMBOUBOENBUFSJBMCPYFTXJUIMJGUJOHMVHTNVTUIBWFUIF8--DMFBSMZNBSLFE

"MMMPBETEFMJWFSFEUPBTJUFUIBUDPVMECFIB[BSEPVTTIPVMECFTUSBQQFEPSXSBQQFE'PSFYBNQMFMPBETPG

QJQFNFUBMPSUJNCFSTIPVMECFTUSBQQFECFGPSFMJGUJOH

4QSFBEFSTBSFSFDPNNFOEFEGPSMJGUJOHMFOHUITPGUJNCFSQJQFPSTUFFM*GBTQSFBEFSJTOPUBWBJMBCMFo

double wrap before lifting.

29

Do not bash the eye of a sling down at the nip point. This practice will decrease the WLL and damage

the sling.

Structural steel

-PBETPGTUSVDUVSBMTUFFMVOJWFSTBMCFBNT34+TPOUSVDLTNVTUIBWFSFTUSBJOJOHTQJLFTGJUUFEJOUIFUSVDL

to prevent them from falling out. Removing the chains or straps if there are no restraining spikes in place

is very dangerous.

Structural steel can be very dangerous. When a load arrives on site walk around the truck and check that

the steel has not shifted into a dangerous position for lifting after the load binder chains were secured.

Many serious accidents have occurred as load binding chains were removed from steel beams. Deep

beams can inflict especially severe injuries.

Always lift steel reinforcing level. Do not lift it vertically or at a slope. It is not possible to make the inside

steel in a bundle tight enough to prevent them falling out if the bundle is at an angle. Steel reinforcing can

kill if it falls.

As the load is lifted keep hands well away. Steel beams tend to snap together or roll up as the sling bites

into the nip.

Loose items

Loads of loose items such as scaffold clips must be raised in properly constructed boxes branded with the

WLL or SWL.

Do not lift loads of this kind in 200 litre drums because:

t UIFTFESVNTIBWFOPSBUFEMJGUJOHDBQBDJUZ

t JUJTOPUQPTTJCMFUPLOPXUIFDPOEJUJPOPGUIFCBTFPGUIFESVN5IFZIBWFVTVBMMZCFFOEJTDBSEFE

because they are unfit to hold liquid).

t UIFIPMFTDVUJOUPUIFTJEFTGPSUIFTMJOHPSIPPLTPGUFOQVMMUISPVHIVOEFSUIFXFJHIU

t UIFTIBSQFEHFTPGUIFIPMFTDBODVUUISPVHIBTMJOH

30

Rubbish bins

Rubbish bins should have proper lifting lugs and be branded with the WLL or SWL. Rubbish bins that are

overloaded must not be lifted. Where rubbish can be blown out or spill from a bin secure the load before

MJGUJOHFTQFDJBMMZJOXJOEZDPOEJUJPOT

4MJOHSVCCJTICJOTXJUIBGPVSXBZTMJOH5PUJQUIFCJOSFMFBTFUIFUXPGSPOUTMJOHTBOESBJTFUIFCJOXJUI

the two back slings.

%POPUVTFUIFTQFDJBMMJGUJOHQPJOUTUSVOJPOT

EFTJHOFEUPBUUBDIUPUIFTVQQMJFSTUSVDLGPSMJGUJOHGPS

slinging a bin. These are often unsuitable for use with general purpose slings.

Do not stand behind a bin when tipping rubbish out. It will whip back suddenly as soon as it is clear of

the ground.

Handling steel plate

Steel plate can be lifted with:

t QMBUFDMBNQTUIBUBSFEFTJHOFEUPJODSFBTFUIFQVSDIBTFPOUIFQMBUFBTUIFQMBUFJTMJGUFE

t IPPLTPSTIBDLMFTXIFSFUIFSFBSFMJGUJOHIPMFTJOUIFQMBUF

Do not use home made type plate clamps or plate dogs. Remember that steel plate can injure or kill.

The angle between the legs of a sling must not be more than 60 unless a spreader beam is used.

Steel plate can be lifted vertically or horizontally.

Lifting vertically:

t 6TFBOBQQSPQSJBUFQMBUFDMBNQXIFSFBTMJOHDBOOPUCFBUUBDIFEBOEUIFSFJTOPMJGUJOHIPMF"O

example is the dished and flanged end-plate for a pressure vessel.

t 1MFBTFOPUFUIBUJUDBOCFEJGGJDVMUUPSFNPWFPSBUUBDIBTMJOHXIFSFQMBUFJTTUPSFEWFSUJDBMMZJOB

rack or is to be fed into bending rolls.

t "TBQMBUFUPVDIFTUIFHSPVOEBOEUIFUFOTJPOJTSFMFBTFEGSPNUIFTMJOHTBTJOHMFIPPLDBODPNFPVU

of the hole causing the plate to fall. To prevent this lift with a hook put through a ring attached to a

short length of chain that is shackled to an appropriate plate clamp.

31

t "MXBZTNBLFTVSFUIBUUIFUFOTJPOSFNBJOTJOUIFTMJOHTVOUJMUIFQMBUFJTJOQMBDF

Lifting horizontally:

t 6TFBQQSPWFEHSJQQJOHQMBUFDMBNQT6TFBTQSFBEFSCFBNGPSMPOHUIJOQMBUFTUPQSFWFOUEBOHFSPVT

GMBQQJOHTBHHJOHBOEWJCSBUJPO

Pallets

A wide variety of loads are delivered to worksites on pallets. Before a palleted load is lifted from a truck

check that:

t UIFQBMMFUJTGSFFGSPNEFGFDUT

t UIFMPBEJTTFDVSFETPUIBUOPUIJOHDBOGBMMPGG

t UIFMPBEJTQSPQFSMZTMVOH

The WLL of a standard hardwood pallet is 2000 kg. The WLL can be dramatically reduced if there are

any missing boards or any other defects.

Please note: Some pallets are designed for packaging not lifting.

Do not lift a pallet that has defects. To lift a load on a damaged pallet raise the load just enough to slide

an undamaged pallet underneath. Alternatively place an undamaged pallet beside the damaged one and

then lift and move it onto the new pallet. Then lower the load and sling properly before lifting and moving

the load to the desired place.

If no spare undamaged pallets are available send the load back to the supplier to be re-palleted. Always

raise palleted bricks inside a brick cage to prevent loose bricks falling.

32

Turning over loads

When turning over a load such as a steel beam the sling must be attached to the hook on the side of the

load that is to be lifted. This will ensure that it will be raised on a diagonal through the centre of gravity.

It is then a simple matter to lower the crane or lifting media turning the beam over in a safe and

controlled manner. It is important that the beam is slung so that when the beam is lowered the nip will

pull against the eye.

"TUFFMCFBN34+IBTBIJHIDFOUSFPGHSBWJUZBOEBOBSSPXCBTFXIFOJUJTTUBOEJOHPOJUTGMBOHF*GB

EPHHFSOJQTUIFTMJOHJODPSSFDUMZUPUVSOUIFCFBNJUXJMMGMPQUPQQMFPWFSBOEQPTTJCMZCSFBLUIFTMJOHT

The same principles apply when turning over all loads.

33

Bends and hitches

Doggers must know how to secure loads and tag lines with bends and hitches. Learn those described and

illustrated below.

Snubber turns for holding and lowering heavy loads. Two, three or more turns should be used.

Rolling hitch To secure stopper, or two ropes pulling in opposite directions. Very useful preferable to clove hitch or blackwall hitch, providing rolling turns are put on in proper direction of pull. Safe.

Sheet bend to join two dry ropes of different sizes. Safer when double sheet bend is used. The smaller rope must be bent around the larger rope.

Buntline or becket hitch to secure ends of tackles to beckets. Foolproof; cannot come undone like half hitches.

Double sheet bend.

Fishermans bend and half hitch useful for bending rope onto rings, handles of buckets, etc requires the extra half hitch.

Timber and half hitch useful for hoisting lengths of timber. Only safe when additional half hitch is put on end of hauling part.

Clove hitch used to commence rope lashing. Not safe for other purposes unless ends secured, with additional half-hitch.

Bowline single used for making temporary eye in end of rope.

Bowline running used for making a temporary eye to run along another part of rope.

(i) Bowline on the bight.

(ii) Bowline on the bight.

(iii) Bowline on the bight the bowline on the bight is formed by making the first part of a bowline with the bight of the rope and passing the whole hitch through its bight.

34

Shortener for single-part rope or snotter to join rope to hook of tackle, etc. and does not damage the

rope. At least two full turns of the standing part are to nip the two bights before the bights are placed

on the hook.

N.B. When shortening synthetic rope slings it is usually advisable to twist the bights twice about each

other because of the slippery nature of many synthetic ropes.

Single snotter shortener partly made. Two bights ready to be placed on hook.

Single snotter shortener with both bights fitted on hook.

Round turn and two half hitches widely used for securing running ends of tackles. The more turns made before hitches are made the more control is possible.

Figure of eight knot as for an overhand knot, but easier to untie.

Overhand knot to make a stop on a rope, to prevent ends from fraying or to prevent it slipping through a block.

Double shortener for sling on hook.

Double shortener for sling partly made.

Double shortener each of the two parts of the bale-sling or strop is turned back on itself, so that

two bights are formed at a suitable length. The bights are then turned about each other as in a simple

overhand knot and place on the hook.

Marlin spike hitch should not be used for sending tools or materials aloft. A better method for tools is to open up the rope and push tool through.

Direction of pull on spike

35

12. STACKING

Make sure that on completion of moving a load all materials are securely and safely stacked. Stacks of

materials must be arranged:

t TPUIBUUIFSFJTBEFRVBUFDMFBSBODFGSPNNBDIJOFSZUIBUDPVMEUPQQMFBTUBDL

t TPUIBUUIFSFJTBDDFTTGPSQFPQMFGPSLMJGUTDSBOFTUSBJOTBOETPPO

t TPUIBUUIFTMJOHDBOCFSFNPWFEBTFBDIVOJUJTQMBDFEPOUIFTUBDL"MXBZTQVMMBTMJOHPVUCZIBOE

to prevent the possibility of the crane toppling a stack).

t TPUIBUUIFSFJTBDDFTTUPGJSFFYUJOHVJTIFST

#FGPSFTUBDLJOHNBLFTVSFUIBUUIFHSPVOEJTTUBCMFMFWFMBOEOPUMJLFMZUPGMPPEJOUIFFWFOUPGSBJO*G

there is heavy rain check the ground for signs of it giving way. If the ground is not level make sure that the

stacks are chocked level and secure.

When a stack is removed check the ground for signs of it giving way before placing another stack in the

same position.

Clearance

There must be clearance of:

t OPUMFTTUIBONFUSFTBMPOHTJEFSBJMXBZUSBDLT

t OPUMFTTUIBONFUSFTGPSUSVDLBDDFTT

t OPUMFTTUIBONFUSFGPSXBMLXBZT

t OPUMFTTUIBONFUSFTGPSBDDFTTGPSBCSJEHFBOEHBOUSZDSBOFPQFSBUPS

t OPUMFTTUIBONFUSFTGPSBDDFTTGPSBCSJEHFBOEHBOUSZDSBOFXIFSFUIFTQFFEPGUIFDSBOFJT

greater than 0.8 metres per second

Use your common sense. There must be access to carry out the work normally carried out on site and for

stretcher access in the case of emergency.

Stacking steel plate

Make sure that the stack supports are spaced between 2 and 3 metres apart.

36

Where plate is stored horizontally with no packing and is wider than 0.75 metres stagger into groups of

plates that make up a suitable lift.

When steel plate is stacked upright in racks the plate can easily swing (and could crush someone) when

the crane takes the weight of the plate.

Use adequate packing and the proper plate clamps to avoid having to stand inside a rack. Do not lift a

plate from a rack if someone is inside the rack under any circumstances.

To avoid horizontal stacks becoming dangerously high tie stacks together with packing.

Stacking rolled steel, coils and other round loads

Round loads must be blocked or chocked at the bottom to prevent the whole stack rolling away. Every

round load must be blocked.

Each layer of the stack must be one unit less than the layer below. The stack will then resemble

a pyramid.

Stacking timber

When stacking shorter lengths of timber place the alternate layers at right angles. This is called pigstying.

Bundles of timber must be strapped and have dunnage under and between the bundles. When stacks are

high they must be straight and set on level beds. Check for movement in the ground after rain. Ladders

must be provided for access to the top of high stacks.

37

13. PERSONAL PROTECTIVE EQUIPMENT (PPE)

$SBOFESJWFSTBOEEPHHFSTPGUFOIBWFUPXFBSIFMNFUTHMPWFTFZFQSPUFDUJPOGBDFNBTLTBOESFTQJSBUPST

and steel capped boots to protect themselves from injury.

It is the responsibility of your employer to provide the necessary protective equipment. It is the

responsibility of doggers or crane drivers to wear and use the equipment properly where and when

necessary.

Safety helmets

Safety helmets with chin straps must be worn wherever there is a risk of objects falling from above and on

any work site where the hard hat sign is displayed.

Helmets should comply with AS 1801 Industrial safety helmets.

Gloves

Wear close fitting pigskin gloves to protect hands from:

t )FBUBOEBCSBTJPO

t .PMUFONFUBM

t 4IBSQFEHFT

4QFDJBMQVSQPTFHMPWFTNBZCFSFRVJSFEGPSQSPUFDUJPOBHBJOTUDIFNJDBMTJODMVEJOHBDJETBMLBMJTTPMWFOUT

fats and oils.

Eye protection

Wear eye protection that conforms to AS 1337 Eye protectors for industrial applications if you are likely

to be exposed to:

t 1IZTJDBMEBNBHFDBVTFECZoGMZJOHQBSUJDMFTEVTUNPMUFONFUBM

t $IFNJDBMEBNBHFDBVTFECZoUPYJDMJRVJETHBTFTBOEWBQPVSTEVTUT

t 3BEJBUJPOEBNBHFDBVTFECZoTVOMJHIUWJTJCMFMJHIUJOGSBSFEMBTFS

Respiratory protection

Wear a face mask that conforms to AS 1716 Respiratory protective devices if you are likely to be

exposed to:

t 5PYJDHBTFTBOEWBQPVST

t *SSJUBUJOHEVTUTTVDIBTTJMJDB

Inhalation of some chemical vapours and gases can cause death or a wide range of unpleasant symptoms

including narcosis and headaches.

Common dusts such as silica can cause lung disease later in life and is found wherever there is

FYDBWBUJPOJFCVJMEJOHTJUFTSPBEXPSLTUVOOFMMJOHBOENJOJOH

38

Hearing protection

Hearing damage is likely if you are exposed to long periods of industrial noise above 85 decibels. This is

the noise level of a large truck or loader.

A chainsaw for example has a noise level of about 92 decibels.

If you think it is likely that you are being exposed to dangerous noise levels ask your employer to provide

you with hearing protectors complying with AS 1270 Acoustics Hearing protectors.

Footwear

$IPPTFCPPUTXIJDIBSFDPNGPSUBCMFHJWFNBYJNVNHSJQBOEHJWFQSPUFDUJPOGSPNQJODIJOHKBNNJOH

and crushing.

A range of lightweight flexible boots with steel or plastic caps is available that comply with AS-2210

Safety footwear.

Sun protection

5PQSFWFOUQFSNBOFOUEBNBHFDBVTFECZVMUSBWJPMFUSBZTBMXBZTXFBSBIBUMPOHTMFFWFTMPOHUSPVTFST

and use UV cream when working outside.

Know the location of the first aid room and the nearest first aid kit. There should be a first aid kit on every

floor of a multi-storey building site or within 100 metres of any part of the workplace.

The standard first-aid symbol in Australia is a white cross on a green background.

First-aid kits on construction sites should have a carrying handle. There should be a notice near to

the first-aid room with the name(s) of those in the workplace who hold an approved occupational

first-aid certificate.

It is recommended that riggers take the time to do an approved first-aid certificate course.

First aid

Crane drivers work in a high risk industry. Not only are there many minor injuries but there are also

TFSJPVTJOKVSJFTXIFSFUIFJOKVSFEQFSTPOXJMMOFFEGJSTUBJEUPSFTUPSFCSFBUIJOHIFBSUCFBUPSUPTUFN

blood flow.

39

14. COMMUNICATION

Two-way radios

Crane drivers must communicate by two-way radio when they are out of earshot and line of sight from the

dogger. It is important that the two-way system provides clear and immediate signals without interference.

There are two types of two-way radio: conventional and trunked.

Conventional radio

Great care is taken when allocating frequencies to make sure that there are no other operators using the

same frequency in the area.

Always use a good quality system from a reputable company with a properly allocated frequency for the

area. Interference on your frequency can be a safety hazard. If there is continual interference have the

system checked or a new frequency allocated.

Trunked radio

Trunked radio is a computer controlled two-way system that locks other radio users out of your frequency.

No other operator can cut in and overpower your signal.

With trunked radio it is possible to have several separate groups on one building site communicating by

radio without interfering with each other.

Trunked radio is recommended for large worksites.

Directions for crane drivers

Doggers must give crane drivers clear verbal signals when directing crane movements. The noise of the

crane motor and distortion over the radio can make it difficult for the crane driver to hear directions.

The following are the standard directions for crane drivers from doggers:

Hook movement Hook up & Hook down

Stopping Stop

40

Speak clearly and say the name of the part of the crane to be moved first - then the direction

of movement.

Creep speed: Appropriate hand signal for motion with hand opening and close

41

15. FLEXIBLE STEEL WIRE ROPE

FSWR is constructed of wires and strands laid around a central core. In the illustration below there are

19 wires to the strand and 6 strands around the core making up the rope.

*UJTJNQPSUBOUOPUUPDPOGVTFXJSFTBOETUSBOETMGBTUSBOEJTCSPLFOUIFSPQFJTVOVTBCMF"TJOHMF

broken wire is not as important.

The core can be:

Fibre Core (FC) or Independent Wire Rope Core (IWRC)

The tensile strength of FSWR ranges from 1220 megapascals (MPa) to 2250 MPa. The most commonly

used tensile strengths are 1770 MPa and 1570 MPa.

"TJYTUSBOETPGXJSFTFBDIJTUIFNJOJNVN'483DPOTUSVDUJPOUIBUDBOCFVTFEGPSTMJOHT

Size

The size of a rope is determined by its diameter. The smallest diameter FSWR that can be used for lifting

is 5 mm.

42

Lay

Lay is the direction the wires are formed into strands and the strands are formed into the finished rope.

The strands can be laid either left or right around the core. In left hand lay the strands are laid anti-

clockwise and in right hand lay they are laid clockwise.

Ordinary Lay is where the wires are laid in the opposite direction to the strands.

Langs Lay is where the wires are laid in the same direction as the strands. There is therefore:

Right hand ordinary lay RHOL

Left hand ordinary lay LHOL Right hand

Langs lay RHLL

Left hand Langs lay LHLL

Lay does not affect the working load limit of the rope but it does determine characteristics such as the

spin of the rope. Most rope available in Australia for lifting is right hand lay.

Inspection and discard

It is important to check all rope for wear and tear before use. Rope can deteriorate due to several factors.

5IFTFGBDUPSTJODMVEFBCSBTJPOGBUJHVFDPSSPTJPOTUSFUDIJOHGSPNPWFSMPBEJOHBOETIPDLMPBEJOHBOE

mechanical damage.

When inspecting:

t %FUFSNJOFUIFDPOTUSVDUJPOBOEMBZPGUIFSPQF

t $IFDLGPSTJHOTPGTUSFUDIJOH

t $IFDLUIFXIPMFSPQFGPSCSPLFOXJSFT8IFSFCSPLFOXJSFTBSFQSFTFOUDPVOUUIFOVNCFSPGCSPLFO

wires in a length of rope eight times the rope diameter. The total number of broken wires in a length

PGYEJBNFUFSNVTUOPUFYDFFEPGUIFUPUBMXJSFT

43

For example:

In a 6 x 24 rope (6 strands of 24 wires) the total number of wires is 144. The diameter of the rope

is 12mm.

Length of rope to inspect = 12 (mm) x 8

= 96mm

Number of wires = 6 x 24

= 144

PG XJSFT

Therefore: 14 broken wires in a 96mm length would indicate that the rope is unfit for use.

There are also many new types of rope construction for special purposes. Manufacturers will advise about

the best type of rope for a particular application.

Discard FSWR sling if there is:

t "TJOHMFCSPLFOXJSFCFMPXBUFSNJOBMGJUUJOHPSBNBDIJOFTQMJDF

t "CSBTJPOBOEDPSFDPMMBQTF

t $PSSPTJPO3FEPYJEFQPXEFSBOEMPPTFBOETQSJOHZXJSFTDBOJOEJDBUFTFSJPVTDPSSPTJPO$IFDLUIF

valleys between the wires for corrosion beneath the surface.

t ,JOLTPSGSBDUVSFTGSPNCFOEJOHPSSFFWJOH

t $SVTIFEPSKBNNFETUSBOET

t #JSEDBHJOH5IJTJTXIFSFUIFTUSBOETMPPTFOGSPNUIFJSQSPQFSUJHIUMBZ*UDBOCFDBVTFECZSPUBUJPO

of the end of a rope or a sudden release from high loading. It is often found in Langs Lay.

t )JHITUSBOEJOH5IJTPDDVSTXIFSFUIFSFIBTCFFOGBVMUZXIJQQJOHPGUIFSPQFFOETBOEBTUSBOEIBT

slipped around the lay and projects above the surface.

t "MTPDIFDLTQMJDFTGPSEBNBHFUVDLTDPSSPTJPOBOEESBXJOHPVU/FWFSBMMPXBTQMJDFUPQBTT

BSPVOEBTIBSQPCKFDUSFNBJOJOUIFAOJQPGBSFFWFETMJOHPSCFQVMMFESPVHIMZGSPNVOEFSPS

through an object.

44

t $IFDLUIFUBMVSJUPSTXBHFETQMJDFTGPSGBUJHVFDPSSPTJPOBOECSPLFOTUSBOETXIFSFUIFSPQF

enters a splice. Reject a rope where there is one broken wire immediately above or below a

talurit or swaged splice.

1. Mechanical damage due to rope movement over sharp edge projection whilst under load.

2. Localised wear due to abrasion on supporting structure. Vibration of rope between drum and jib head sheave.

3. Narrow path of wear resulting in fatigue fractures, caused by working in a grossly oversize groove, or over small support rollers.

4. Severe wear in Langs Lay, caused by abrasion at cross-over points on multi-layer coiling application.

5. Severe corrosion caused by immersion of rope in chemically treated water.

6. Typical wire fractures as a result of bend fatigue.

7. Wire fractures at the strand, or core interface, as distinct from crown fractures, caused by failure of core support.

8. Typical example of localised wear and deformation created at a previously kinked portion of rope.

9. Multi-strand rope bird caged due to tortional unbalance. Typical of build-up seen at anchorage end of multi-fall crane application.

10. Protrusion of IWRC resulting from shock loading.

45

Maintenance

The lubrication applied to the rope when it is manufactured does not last the working life of the rope.

Without lubrication a rope will be subject to greater internal friction.

The frequency of lubrication is determined by the operating conditions. High speed heavy duty operation

and wet or corrosive conditions both call for more frequent lubrication.

Scrub or scrape free rust and examine for lack of lubrication. (Do not use a wire brush). Discard the rope

if there is evidence of more than superficial corrosion.

*GBSPQFJTFODSVTUFEXJUIEJSUBOEHSFBTFTDSVCDMFBOBOEBQQMZPJM"NFEJVNWJTDPTJUZCMBDLPJM

is suitable.

A shock load can lessen the WLL without signs of wear being immediately evident. If you are in doubt

have it tested by the manufacturer or a competent testing organisation.

When using FSWR:

t "WPJESFWFSTFCFOET

t 6TFTVJUBCMFQBDLJOHUPQSPUFDUUIFSPQFGSPNTIBSQFEHFT

t %POPUFYQPTFXJSFSPQFUPUFNQFSBUVSFTFYDFFEJOH$

t %POPUMJGUXJUIXJSFSPQFMFTTUIBONNEJBNFUFS

t %POPUVTFBSPQFUIBUTIPVMECFEJTDBSEFE

t %POPUVTF-BOHT-BZVOMFTTUIFFOETBSFGJYFEUPQSFWFOUUIFSPQFVOMBZJOH

t %POPUBMMPXLJOLTPSLOPUTUPEFWFMPQ

Storage

4UPSFXJSFSPQFDMFBSPGUIFHSPVOEJOBDMFBOESZQMBDF

Make sure that wire rope is not in contact with corrosive substances when it is stored. Make sure that

wire rope is properly lubricated before storage to minimise the risk of corrosion.

46

16. SHEAVES AND DRUMS FOR FLEXIBLE STEEL WIRE ROPE

Sheaves

Sheaves are used in pulley systems to gain a mechanical advantage.

Flare angle and groove depth

5IFHSPPWFEFQUIPGBTIFBWFTIPVMEOPUCFMFTTSPQFUIBOUJNFTUIFSPQFEJBNFUFS)PXFWFSJGUIF

rope is positively prevented from leaving the groove the minimum depth of the groove can be equal to the

rope diameter.

The sheave groove sides should have a flare angle of a minimum of 42 and a maximum of 52.

The round grooves should be slightly larger than the nominal diameter of the rope. Grooves which are too

large will flatten the rope. Grooves too small will pinch the rope and the extra friction can cut it to pieces.

Sheaves should have a smooth finish with flared edges which are rounded-off.

Sheave diameters

The table below gives sheave diameters and safety factors for types of work:

47

Caution:.PEFSODSBOFTBOEIPJTUTBSFDPNQMFYFOHJOFFSJOHFRVJQNFOUBOENBOZIBWFTQFDJBM

construction luff and hoist wires. It is essential that the sheaves which were designed for a particular

crane or hoist are used for that purpose.

*UJTBMTPFTTFOUJBMUIBUXIFOBSPQFJTSFQMBDFEUIFSFQMBDFNFOUJTUIFTBNFEJBNFUFSBOEDPOTUSVDUJPO

and that the sheave system is thoroughly checked to ensure that any damaged or worn grooves likely to

ruin the new rope are repaired or replaced.

Inspection

Sheaves should be inspected regularly. Pay particular attention to the sheave groove and flange. Any

cracks or chips on the flange can cut the wire as it lays into the groove.

5IFHSPPWFTIPVMECFDIFDLFEGPSXFBSXIJDIIBTSFEVDFEUIFHSPPWFEJBNFUFSHJWJOHBOVOFWFOCFBSJOH

surface for the wire.

All sheaves should be checked for lubrication. Badly lubricated sheaves cause extra friction in the system

and wear on the sheave pin and bearing.

The pin should be prevented from rotating with the sheave. Some sheave pins only have a small cotter pin

which fits into a recess on the cheek plate. The cotter pin sometimes shears and allows the pin to turn

with the sheave.

Rotating pins are dangerous as they turn and can cut through the cheek plate.

A jockey sheave is sometimes used as the first diverting sheave to reduce the fleet angle. This sheave

fits on an extended pin to allow it to slip from side to side reducing the fleet angle. The jockey sheave pin

should be kept well greased and free from grit and dirt to allow the sheave to slide across the pin.

Drums

%SVNTBSFUIFQVMMJOHNFDIBOJTNXIJDISPUBUFTIBVMTJOBOETUPSFTTVSQMVTSPQF5IFCSBLJOH

mechanism is connected to either the drum or the gearing which is joined to the drive mechanism.

The rope should lay neatly on the drum and not be bunched up. There should be a minimum of two full

turns on the drum at all times.

The rope must be anchored to the drum with a fixed mechanical anchorage.

48

Be aware of the danger of not properly tightening an anchorage. Do not rely on the frictional grip from the

two turns on the drum.

The top layer on a multi-layered drum must not be closer than two rope diameters to the top of the flange

when the drum is full.

Drum capacity

Fleet angles

The maximum fleet angle is measured from the centre of the drum to the centre of the first diverting

sheave then back to the inside flange at the middle of the drum.

The fleet angle for a grooved drum is 5 and for an ungrooved drum is 3. To achieve these angles the

distance from the drum to the first diverting sheave must be a minimum of:

t UJNFTIBMGUIFXJEUIPGUIFESVNGPSBOVOHSPPWFEESVN

t UJNFTIBMGUIFXJEUIPGUIFESVNGPSBHSPPWFEESVN

Example 1:

Width of the grooved drum = 1 metre

12 x 1 x 0.5 = 6

Therefore the sheave must be 6 metres from the drum.

Example 2:

Width of the ungrooved drum = 1 metre

19 x 1 x 0.5 = 9.5

Therefore the sheave must be 9.5 metres from the drum.

49

If the fleet angle is too large or the distance between the drum and the first lead or diverting sheave

JTUPPTIPSUUIFSPQFXJMMOPUMBZOFBUMZPOUIFESVNBOEXJMMDSFBUFTFWFSFXFBSPOUIFSPQFBOEUIF

sheave flange.

Effect of fleet angle on spooling.

50

17. CHAIN

Although chain is from 5 to 6 times heavier than FSWR of the same lifting capacity it is more durable. It

can withstand rough handling and can be stored without deterioration.

Types of lifting chain

t .JMETUFFMTUSFTTSFMJFWFEDIBJOTUBNQFE-

t )JHIUFOTJMFRVFODIFEBOEUFNQFSFEDIBJOoTUBNQFE1

t )JHIFSUFOTJMFRVFODIFEBOEUFNQFSFEDIBJOCSBOEFE518#PS$.BOE

HA800 alternately.

t 7FSZIJHIUFOTJMFRVFODIFEBOEUFNQFSFEDIBJOCSBOEFE7PS

High Tensile and Very High Tensile (Grade T. 80 and 100) are used extensively for lifting. Very little low

HSBEFDIBJOJTVTFEGPSMJGUJOH.PTUJGOPUBMMDIBJODPNQPOFOUTBSFBMTP)JHI5FOTJMFTUSFOHUI(SBEF5

or 800) and are branded to show grade and chain size.

*GEPHHFSTEPOPUVOEFSTUBOEUIFHSBEFNBSLJOHPGBDIBJOUIFZTIPVMEDIFDLXJUIUIFNBOVGBDUVSFSPS

the manufacturers supplier for clarification.

Caution: Industrial lifting chain is not normally sold through general hardware outlets. Chain from general

hardware outlets is usually unsuitable for industrial lifting.

Look for the grade markings

Safe working loads for slings of special alloy chain (Marked C.M., A, T or 8).

51

Safe use and maintenance

Do not use a chain that is 5.5mm diameter or less for lifting.

A chain sling is only as strong as its weakest link

8IFONBLJOHVQBDIBJOTMJOHBMXBZTVTFDIBJOIPPLTMJOLTIBNNFSMPDLTBOEDPVQMFSTPGUIFTBNF

grade and WLL and that are in a good state of repair.

Do not lift a load heavier than the WLL of the chain.

%POPUVTFBDIBJOJOXIJDIUIFMJOLTBSFTUSFUDIFEMPDLFEPSEPOPUNPWFGSFFMZ

%POPUVTFDIBJOUIBUJTHPVHFEPSXPSONPSFUIBOPGUIFEJBNFUFS

%POPUUXJTULJOLPSLOPUDIBJO

Do not drop a chain from a height.

Do not roll loads over a chain.

%POPUVTFBDIBJOXJUIBMJOLUIBUJTDSBDLFEPSUIBUIBTCFFOXFMEFEPUIFSUIBOCZUIFNBOVGBDUVSFS

Use protective padding when using chain around sharp corners.

Do not attempt to use chain when the temperature exceeds 260 unless heat reduction charts are used.

Inspection and discard

lnspect your chain slings regularly.

If necessary clean the chain before inspection.

MOTQFDUFBDIMJOLGPSTJHOTPGXFBSUXJTUJOHTUSFUDIJOHOJDLTPSHPVHJOH

Links that are stuck together show that the chain has been stretched.

Cracks can be found by dusting chain with fine powder. Dust any link that is suspect and then blow the

loose particles away. Dust particles left will be lodged in any cracks making them more visible. Magnetic

particles can also be used.

Any worn links should be measured for degree of wear which must not exceed that allowed for by

the manufacturer.

Measure the links to check for wear

52

5IFNBYJNVNBMMPXBCMFDIBJOXFBSJT

5IFNBYJNVNBMMPXBCMFFMPOHBUJPOPGBDIBJOJT

5IFNBYJNVNJODSFBTFJOIPPLPQFOJOHJTPGUIFPSJHJOBMUISPBUPQFOJOH

5IFNBYJNVNBMMPXBCMFXFBSJOUIFCJUFPGBIPPLJT

Inspect upper and lower terminal links and hooks for signs of wear at their load-bearing points and for any

signs of distortion.

lnspect links and couplings for signs of wear at their load bearing points and for excessive play in the load

pin between the body halves.

Withdraw any chain from service immediately if it has defects. Clearly mark the chain with a tag stating

that it must not be used until it has been inspected by the manufacturer.

Destroy any chain that cannot be repaired.

If the chain is not tagged or properly stamped it must be removed from service.

Enter all inspection details on an inspection record card.

53

18. FLAT WEBBING AND ROUND SYNTHETIC SLINGS

Flat webbing and round synthetic slings are used for lifting where it is necessary to protect the load from

EBNBHFBOEGPSQSPUFDUJPOGSPNFMFDUSJDBMIB[BSET5IFZBSFNBEFGSPNOZMPOQPMZFTUFSQPMZQSPQZMFOFPS

aramid polyamide. Each sling must be labelled with the WLL.

Round synthetic slings

Inspection

Synthetic slings must be inspected before each use. They must also be inspected at least once every three

months. If a sling is subject to severe conditions the inspections should be more frequent. Send each sling

for a proof load test at least every 12 months.

Look for:

t "OZFYUFSOBMXFBSTVDIBTBCSBTJPOPSDVUTBOEDPOUVTJPOT

t *OUFSOBMXFBSXIJDIJTPGUFOJOEJDBUFECZBUIJDLFOJOHPGUIFTMJOHPSUIFQSFTFODFPGHSJUBOEEJSU

t %BNBHFUPBOZQSPUFDUJWFDPBUJOHPGUIFTMJOH

t %BNBHFDBVTFECZIJHIUFNQFSBUVSFTTVOMJHIUPSDIFNJDBMTJOEJDBUFECZEJTDPMPVSBUJPO

t %BNBHFUPUIFMBCFMPSTUJUDIJOH

t %BNBHFUPUIFFZFTPSBOZUFSNJOBMBUUBDINFOUTPSFOEGJUUJOHT

t 8IFSFUIFTMJOHJTDPWFSFECZBTMFFWFUIFTMFFWFNVTUDPWFSUIFTMJOHGPSUIFGVMMMFOHUIGSPN

eye to eye.

Discard a synthetic sling if:

t 5IFMBCFMIBTCFFOSFNPWFEPSEFTUSPZFE

t 5IFSFJTBOZEBNBHFUPUIFTMFFWFPSQSPUFDUJWFDPBUJOH

t "OZMPOTMJOHDPNFTJOUPDPOUBDUXJUIBDJE

t "QPMZFTUFSTMJOHDPNFTJOUPDPOUBDUXJUIBMLBMJOFTVCTUBODFT

t "QPMZQSPQZMFOFTMJOHDPNFTJOUPDPOUBDUXJUIBOPSHBOJDTPMWFOUTVDIBTQBJOUDPBMUBSPS

paint stripper.

t 5IFSFBSFBOZWJTJCMFDVUTPOUIFTMJOH

Types of synthetic slings and fittings

54

Examples of extreme damage to flat synthetic-webbing slings.

/#"OZMPOTMJOHXJMMMPTFNPSFUIBOPGJUTTUSFOHUIXIFOJUJTXFU

After six months continuous exposure to sunlight send a sling in for testing.

Synthetic slings must be stored:

t *OBDMFBOESZXFMMWFOUJMBUFEQMBDF

t "XBZGSPNUIFHSPVOEPSGMPPS

t "XBZGSPNEJSFDUTVOMJHIUVMUSBWJPMFUMJHIUBOEGMVPSFTDFOUMJHIUT

t "XBZGSPNFYUSFNFTPGIFBU

t "XBZGSPNTPVSDFTPGJHOJUJPO

t "XBZGSPNBUNPTQIFSJDPSMJRVJEDIFNJDBMT

t "XBZGSPNUIFQPTTJCJMJUZPGNFDIBOJDBMEBNBHF

The working life of synthetic slings will be shortened if exposed to any of the above.

(a) Damaged sleeve (b) Some damage to load-bearlng fibres

(c) Badly damaged sleeve

(d) Load-bearlng fibres have been cut (e) Cut load-bearlng fibres (f) Broken load-bearing yarn

(g) The use of hooks that are too narrow has damaged the eye of the sling

(h) Burn damage to sleeve and load-bearlng yarn

(i) Surface wear evident by furry surface

55

19. FIBRE ROPE

'JCSFSPQFJTOPUXJEFMZVTFEGPSMJGUJOH*UEPFTOPUIBWFUIFTUSFOHUIPSWFSTBUJMJUZPG'483DIBJOPS

synthetic slings. Do not use a fibre rope that is less than 12mm for lifting.

It is most commonly used as a tagline for guiding or steadying a load because it is flexible and non-

conductive. Fibre rope taglines must be at least 16 mm in diameter.

Maintenance

Keep fibre rope neatly coiled when stored and protected from:

t GBMMJOHPCKFDUT

t GJSFBOEFYDFTTJWFIFBU

t BDJETBOEPUIFSDIFNJDBMT

t TQBSLTBOENPMUFONFUBM

t XBUFSBOESVTU

t TBOEBTIFTBOEEJSU

t SBUTNJDFXIJUFBOUTBOEDPDLSPBDIFT

Inspection

When inspecting fibre rope look for:

t 4JHOTPGCSJUUMFOFTTDIBSSJOHPSCSPXOEJTDPMPVSBUJPOEVFUPFYDFTTJWFIFBU

t "EJSUZHSFZDPMPVSMPTTPGXFJHIUBOECSJUUMFOFTTEVFUPTVOSPU

t 4JHOTPGNJMEFXCZPQFOJOHUIFTUSBOETBOEMPPLJOHBOETNFMMJOHGPSNPVME

t %JTDPMPVSBUJPOBOEQPXEFSZGJCSFTEVFUPUIFFGGFDUTPGBDJEBOEPUIFSDPSSPTJWFBHFOUT

t "EFDSFBTFJOEJBNFUFSBOEBOJODSFBTFJOUIFMFOHUIPGUIFMBZEVFUPPWFSMPBEJOH

t 0OFTUSBOETUBOEJOHPVUIJHIFSUIBOUIFPUIFST$BMMFEIJHITUSBOEJOHJUDBOCFDBVTFECZGBVMUZ

splicing or whipping.

All of the above defects make the rope unfit for lifting purposes.

56

20. ACCESSORIES

From the hook to the load the lifting gear can be made up of many parts.

The WLL of lifting gear is only as great as the part of the sling with the lowest WLL. For example if the

WLL of:

the hook is 2 tonnes

the shackle is 2 tonnes

the ring is 1 tonne

the rope is 2 tonnes

then the WLL for the lift is 1 tonne.

Always use accessories with at least the WLL of the sling to avoid errors.

Hooks

)PPLTNBZCFGJUUFEXJUIBTBGFUZDBUDIQBSUJDVMBSMZXIFSFUIFSFJTBDIBODFPGUIFTMJOHTCFJOHEJTQMBDFE

A wide variety of hooks are available for use with chain slings. Hooks are mostly 80 grade alloy steel and

are stamped with the WLL. Make sure when selecting a hook for a chain sling that the hook has at least

the same WLL as the chain.

.BLFTVSFUIBUUIFPQFOJOHJTXJEFFOPVHIUPBDDFQUUIFMBSHFTUSPQFSJOHMJOLPSTIBDLMFUIBUIBTUPCF

placed over the hook.

.BLFTVSFUIBUUIFJOTJEFPGUIFIPPLPSACJHIUJTSPVOEFETPUIBUJUEPFTOPUDVUJOUPPSEBNBHFTMJOHT

and fittings.

Crane hooks must freely rotate at all times. If the load exceeds two tonnes there must be a roller thrust

bearing or ball between the trunnion and nut.

*GBDIBJOIPPLPQFOJOHJTTUSFUDIFENPSFUIBOJUNVTUCFXJUIESBXOGSPNTFSWJDF%JTDBSECFOUPS

distorted hooks. Do not attempt to weld or repair them. Hooks must not have any fittings welded to them.

57

Rings

"SJOHNVTUIBWFBUMFBTUUIFTBNF8--BTUIFDIBJOIPPLBOEPUIFSQBSUTPGBTMJOH

%JTDBSEBOZSJOHXIJDIIBTCFFOTUSFUDIFECZNPSFUIBO%POPUQMBDFBSJOHPSTIBDLMFPSFZFCPMU

over a crane hook unless it hangs freely.

Shackles

There are two main types of shackle Dee and Bow. All shackles used for lifting must be stamped

with the WLL. Do not use a shackle that does not have the WLL marked. Make sure that the WLL of the

TIBDLMFJTBUMFBTUBTHSFBUBTUIFDIBJOMJOLTBOESJOHTJOUIFTMJOHZPVBSFVTJOH

Do not use a bolt and nut in place of the proper shackle pin. A bolt that does not fit tightly is likely to

bend and break.

%JTDBSEBOZTIBDLMFUIBUJTXPSOJOUIFDSPXOPSQJOCZNPSFUIBO%POPUVTFBTIBDLMFUIBUJT

CFOUEFGPSNFEPSEBNBHFE%FGPSNFETIBDLMFTQSPCBCMZIBWFNJDSPTDPQJDDSBDLTXIJDIDBOMFBEUP

complete failure during lifting.

To prevent jamming tighten shackle pins finger tight and then release a quarter turn. Use washers or

ferrules to centre thimbles and hooks on the shackle pin to prevent unnecessary strain.

Where several sling eyes are to be connected to a lifting hook use a large bow shackle so that all the sling

eyes can be safely accommodated. The pin must rest on the hook and the sling eyes in the bow section.

Do not use a screw shackle where the pin can roll under the load and unscrew.

Eyebolts

There are collared and uncollared eyebolts. Do not use uncollared eyebolts for any lifts other than vertical

lifts because they can break off.

A typical use for an eyebolt is for lifting pre-cast concrete panels which have ferrules cast into them. Make

sure that eyebolts are securely screwed into the ferrule or nut before use.

Do not lift if the ferrule is loose. Do not hammer an eyebolt to tighten. Use a podger bar. Make sure that

the eyebolt and ferrule has a solid feeling.

Do not put a sling through two or more eyebolts. Use two slings attached to the eyebolts with shackles.

Do not attach slings to eyebolts with hooks because the hook is usually too small.

58

Swivels

Swivels both prevent chain or rope from twisting and allow it to untwist.

Swivels can have two eyes (eye and eye swivel) or have an eye attached to a shackle (clevis and

eye swivel).

Use of collared eyebolts

Make sure the eyebolts are screwed down tightly so that the collar is in contact with the load.

Here the strain on the eyebolt is doubled

Turnbuckles

"UVSOCVDLMFPSSJHHJOHTDSFXJTVTFEGPSUFOTJPOJOH'4835IFDPOWFOUJPOBMUVSOCVDLMFIBTUXPUISFBET

POFMFGUIBOEBOEPOFSJHIUIBOEXIJDIXJMMJODSFBTFUIFUFOTJPOPGSPQFBTUIFZBSFTDSFXFEUPXBSET

each other.

They can have either eyes or clevises at each end. Only suspend loads with turnbuckles with eyes or

clevises at each end not hooks.

Turnbuckles must have the WLL marked. Do not lift if it is not marked.

8IFOJOTQFDUJOHDIFDLGPSXFBSBOETMBDLOFTTJOUIFTDSFXUISFBEBOENBLFTVSFUIBUUIFUISFBEJTGVMMZ

engaged. Otherwise inspect in the same way as chain.

59

APPENDIX (i) Areas and volumes

Areas

Area of a square = length x width

For example:

2m x 2m = 4 square metres

Area of a rectangle = length x width

For example:

2m x 5m = 10 square metres

3

3

Area of a circle = diameter2 x .79

For example:

3m x 3m x .79 = 7.1 square metres

60

Area of a triangle = base x height 2

For example:

3m x 3m 2 = 4.5 square metres

Volumes

Volume of a cube = length x height x width

For example:

3m x 3m x 3m = 27 cubic metres

Volume of a rectangular solid = length x height x width

For example:

2m x 4m x 6m = 48 cubic metres

61

Volume of a cone or pyramid = area of base x height 3

For example (pyramid):

2m x 2m x 1.5m 3 = 2 cubic metres

For example (cone):

3m x 3m x .79 x 4m 3 = 9.5 cubic metres

Volume of a sphere = diameter3 x 0.53

For example:

3m x 3m x 3m x 0.53 = 14.3

62

Calculating the weight of a load

5PDBMDVMBUFUIFXFJHIUPGBMPBEJGJUJTVOLOPXOZPVNVTUNVMUJQMZUIFWPMVNFPGUIFMPBECZUIFVOJU

weight of the material.

For example:

A rectangular stack of hardwood 3 metres long 1 metre high 0.5 metre across.

Volume of rectangular solid = length x width x height

3m x 1m x .5m = 1.5 cubic metres

Unit weight of hardwood is 1120 kgs per cubic metre

1.5 x 1120 = 1680

Therefore the total weight of the load is 1680 kgs.

63

APPENDIX (ii) Tables of massesAcid (crated maximum) 200 kg

"MFCFFSMJUSF 250 kg

"MVNJOJVNDVN 2.7 t

Aluminium ingot 5-15 kg

"TCFTUPTDFNFOUTIFFUQMBJONYN 18 kg

"TIFTDPBMDVN 800 kg

"TQIBMUMJUSFESVN 200 kg

#BSCFEXJSFDPJM 50 kg

#MVFNFUBMDVN 2.0 t

Beer (see Ale)

#JUVNFOMJUSFESVN 200 kg

#PMUTWBSJPVTCBH 50 kg

#SBTTDVN 8.5 t

#SJDLTDPNNPO 4 t

#SPO[FDVN 8.5 t

$BTUJSPODVN 7.2 t

$BTUTUFFMDVN 7.9 t

$MBZDVN 1.9 t

$FNFOUCBH 20 or 40 kg

$PBMDVN 864 kg

$PODSFUFDVN 2.4 t

$PQQFSDVN 9.0 t

$PQQFSNNUIJDLTRN 27 kg

%PPST 1 t

%PHTQJLFT 50 kg

%SVNTFNQUZMJUSF 13 kg

&BSUIDVN 1.9 t

'BUUBMMPXFUDHBMCBSSFMTMJUSF 200 kg

'FODJOHXJSFDPJM 50 kg

'JCSPVTQMBTUFSTRN 9 kg

Fibre board. sq m 0.6 kg

Fibro cement sheets

Flat

NNUIJDLTRNFUSF 7 kg

NNUIJDLTRNFUSF 11 kg

Corrugated

TUBOEBSETRNFUSF 11 kg

EFFQDPSSVHBUJPOTTRNFUSF 12 kg

Compressed

NNUIJDLTRNFUSF 26 kg

'JTICPMUTNNEJB 1 kg

'JTIQMBUFTIPMF 13 kg

'JTIQMBUFTIPMF 18 kg

Galvanised flat iron 0.5 mm sheet

1.8 m x 90 mm 7 kg

(MBTT0NNUIJDLTRNFUSF 27 kg

(SBOJUFDVN 2.6 t

Grease (44 gal) 200 litre 200 kg

(ZQTVNDVN 2.3 t

(ZQTVNCBH 50 kg

Hardwood (see Timber)

)FSNBUJDPSFDVN 5.4 t

)FNQCBMF 300 kg

*DFDVN 930 kg

*SPODBTUN 7.25 t

*SPOQJH LH

*SPOPSFDVN 5.4t

+VUFCBMF 150 kg

Kerosene (44 gal) 200 litre 200 kg

-FBEDVN 11.4 t

-FBENNUIJDLTRN 34 kg

-FBEQJHPSJOHPU 36 kg

-JNFTUPOF

CBHT 1 t

-JNFTUPOF

DVN 2.6 t

-JNFIZESBUFECBH 22 kg

-JNFIZESBUFECBHT 1 t

/BJMTDBTF 50 kg

/FUUJOHXJSFNSPMMN 25 kg

0JMTBMMUZQFTHBMESVNMJUSF 200 kg

1BJOUMJUSF 4 kg

1BMJOHT)8NTBXO 1 t

1BMJOHT)8NTBXO 1 t

1BSUJDMFCPBSENNUIJDLTRNFUSF 12 kg

Petrol (44 gal) 200 litre 200 kg

Pig iron 50 kg

Pipes

Stoneware

100 mm 55 m 1 t

150 mm 32 m 1 t

225 mm 20 m 1 t

300 mm 15 m 1 t

$BTUJSPONMPOHMJOFEo

80 mm nominal inside dia LHN

100 mm pipe LHN

150 mm pipe LHN

200 mm pipe LHN

225 mm pipe LHN

300 mm pipe LHN

4UFFMHBMWBOJTFEo

8 N.B.0.D. 13.5 mm LHN

10 N.B.O.D. 17 mm LHN




64




$PQQFSHJOUFSOBMEJBNFUFSoBQQSPY

12.7 mm O.D. LHN

16 mm O.D. LHN

25 mm O.D. LHN

38 mm O.D. LHN

50 mm O.D. LHN

1JUDIBOEUBSHBMMJUSF 200 kg

1MZXPPENNNYN 7 kg

Plasterboard (Gyprock) 13mm thick

sq metre 27 kg

3BJMTTUFFMNBTTFTBSFCSBOEFEPOTJEFo

HEIGHT mm BASE width mm

157 229 LHN

102 165 LHN

157 146 LHN

173 140 LHN

137 127 LHN

94 94 LHN

65 60 LHN

4BOECFBDIESZDVN 2.0 t

4BOECFBDIXFUDVN 2.3 t

4BOESJWFSXFUDVN 1.5 t

4DSFXTDBTF 50 kg

4IBMFDVN 2.6 t

4JTBMCBMF 200 kg

4MFFQFSTNNYNNYN 80 kg

4MFFQFSQMBUFT 1 t

5BMMPXHBM

MJUSF 200 kg

5BSHBM

MJUSF 200 kg

5FSSBDPUUBDVN 1.8 t

5JMFT.BSTFJMMFTUFSSBDPUUB 350 kg

5JMFT.BSTFJMMFTDPODSFUF 375 kg

5JODVN 7.3 t

5JOJOHPU 32 kg

5JNCFSJSPOCBSLDVN 1.4 t

5JNCFSPUIFSIBSEXPPETDVN 1.1 t

5JNCFSTPGUXPPETDVN 640 kg

Tubular scaffolding (1 in bore)

48 mm O.D. 4.8 mm thick LHN

8BUFSGSFTIMJUSF 1.0 kg

8BUFSGSFTIDVN 1.0 t

8FBUIFSCPBSETSVTUJDBUFEo

)BSEXPPENNYNNYN 1 t

8PPMQBDLTQBDLBWFSBHF 150-160 kg

;JODDVN 7.0 t

;JODJOHPU 26 kg

65

APPENDIX (iii) First aid

Crane operators and doggers work in a high risk industry. Not only are there many minor injuries but there

BSFBMTPTFSJPVTJOKVSJFTXIFSFUIFJOKVSFEQFSTPOXJMMOFFEGJSTUBJEUPSFTUPSFCSFBUIJOHIFBSUCFBUPSUP

stem blood flow.

Know the location of the first aid room and the nearest first aid kit. There must be a first aid kit on every

floor of a multi-storey building site or within 100 metres of any part of the workplace.

The standard first aid symbol in Australia is a white cross on a green background.

First aid kits on worksites should have a carrying handle. There must be a notice near to the first aid room

with the name(s) of those in the workplace who hold an approved occupational first aid certificate.

It is recommended that crane operators and doggers take the time to do an approved first aid certificate.

66

APPENDIX (iv) Terms used in this guide

DIAMETER: The length of a straight line drawn from one side to the other through the centre of a circle.

DOGGER: A person qualified to sling and direct loads.

DUNNAGE: Packing under loads.

EYEBOLT: Lifting ring.

GRADE: The tensile strength of chain.

HAMMERLOCK & COUPLERS: Attachable chain links.

LOAD FACTOR: The fraction of the safe working load created by a particular slinging method.

REEVE: A method of slinging where the sling passes back through itself reducing the safe working load.

RING: Chain link.

SAFE WORKING LOAD: The maximum load that can be safely lifted by a particular sling or machine.

SHACKLES: Attachment for joining a sling to a load or a hook.

SHEAVE: A pulley through which steel wire rope moves.

4-*/(-JGUJOHHFBSNBEFGSPNTUFFMXJSFSPQFDIBJOPSTZOUIFUJDT

SNIGGING: Dragging a sling or a load.

SNOTTER: Fibre rope sling.

SPREADER: A beam with a central lifting attachment that reduces the strain on the lifting gear.

48*7&-"SPUBUJOHTMJOHBUUBDINFOUUIBUBMMPXTUXJTUJOHXJUIPVUTQJOOJOHUIFXJSFIPPLPSMPBE

TURNBUCKLE: Attachment to increase and hold tension in FSWR or for fine adjustment of

load height.

67

APPENDIX (v) Sample exam questions

Below are some of the questions you could be asked in the examination for a Bridge and gantry crane

certificate. You can find the answers to the questions in this guide.

1. How much weight can you raise and lower with your crane?

2. The crane hook is branded 20 tonne. The crane bridge is branded 5 tonne. What is the lifting

capacity of the crane?

3. When can a crane be slightly overloaded?

4. Where is the main switch for your crane?

5. Can you remove a danger tag from the main switch and close the switch?

6. Before turning on the main switch what must be checked about the collector wires?

7. How often must you check the limit switches?

8. How does the hoist brake work?

9. Where is the cross travel unit or crab and what is its function?

10 How many turns of wire must be left on the drum when the hook is at its lowest point?

11. The depth of an open sheave must be how many times the diameter of the wire?

12. What defects must be inspected for in a sheave?

13. Under what circumstances can a dogger ride on a load?

14. When can a load be moved down shop over peoples heads?

15. What is the procedure if the crane chaser is receiving an electric shock from the sling or the load?

16. What must you do in the event of an electrical fault in your crane?

17. Why is it important not to snig or drag a load with a crane?

18. How many kilograms are there in one tonne?

19. Show by means of a sketch a circle of 12 mm in diameter.

20. What are the defects that condemn fibre rope?

21. What is the maximum heat that fibre rope can be subject to?

22. What is the formula for working out the WLL of steel wire rope (FSWR)?

6TFUIFGPSNVMBUPXPSLPVUUIF8--PGB'483NNEJBNFUFS

24. What are the defects that condemn FSWR?

25. What is the smallest diameter FSWR for supporting loads?

26. What is the maximum heat that FSWR can be subject to?

27. What is the formula for working out the WLL of chain?

28. Use the formula to work out the WLL of a grade 80 chain 20 mm in diameter.

68

29. What is the maximum allowable wear available in the link of a chain?

30. What is the maximum allowable stretch in the link of chain?

31. List the defects that condemn chain?

32. What is the maximum allowable heat that chain can be subject to?

33. What are the brand markings found on grade 80 chain?

34. How do you find out the capacity of synthetic webbing slings?

35. What are the main defects that affect the capacity of synthetic web slings?

36. What happens to the SWL when you reeve or nip a sling around a square load?

37. What happens to the SWL when you reeve or nip a sling around a round load?

38. What is the SWL of two one tonne slings with an angle between of: 60 90 120?

39. What is the capacity of the slings needed to lift with two slings reeved around a 15 tonne round load

where the angle between the slings is 60?

40. What diameter FSWR sling is needed to lift a seven tonne load shackled into a lug?

41. What is the difference between the lifting capacity of a three legged and a four legged sling of the

same size?

42. What type of shackle would you use for multiple slings?

43. Must the eyes of a sling rest on the pin or on the D of the shackle?

44. What type of eyebolts must be used for attaching multiple slings?

45. Where are uncollared eye bolts used?

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47. What must you do if you are signalling to a driver by radio and someone keeps cutting across

your channel?

Catalogue No. WC00001 WorkCover Publications Hotline 1300 799 003

WorkCover NSW 92-100 Donnison Street Gosford NSW 2250Locked Bag 2906 Lisarow NSW 2252 WorkCover Assistance Service 13 10 50Website www.workcover.nsw.gov.au

ISBN 0 7310 5159 9 Copyright WorkCover NSW 0508

bridge and gantry crane drivers guide 0001

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