Manual for Crane Operator

Chapter 1: Introduction to Overhead Cranes

•    Overhead Crane Overview
•    Overhead Crane Inspection
•    Overhead Crane Operation
•    Rigging
•    Review
Chapter 2: Basic Rigging Concepts
•    Questions to Insure Safe Rigging Operations
•    Duties & Responsibilities
◦    Qualified Inspector
◦    Qualified Rigger
◦    Qualified Operator
•    Static or Dynamic Load Rating
•    Lifting
•    Hand Signals
Chapter 3: Rigging Gear & Inspection Criteria
•    Wire Rope Sling
•    Rigging Components
•    Synthetic Web Slings
•    Inspection
Chapter 4: Putting Slings to Work – Hitch, Capacity, & Hardware Selection
•    Personal Protective Equipment
•    Rigging Fundamentals
•    Hardware
•    Chain Slings
•    Synthetic Web Slings
•    Determining Factors
•    Safe Operating Practices and Procedures
•    Hoist Hooks
•    Safe Rigging Practices
•    Center of Gravity
Chapter 5: Safe Rigging Practices & Procedures for the Offshore Oil & Gas Industry
•    Cargo
•    Securing a Load
•    Dynamic Load
•    Operators and Riggers
•    Hazardous Material
•    Personnel Transfer

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 Chapter 1
Introduction to Overhead Cranes

An overhead crane, commonly called a bridge crane, is a type of crane found in industrial environments.
An overhead crane consists of parallel runways with a traveling bridge spanning the gap. A hoist, the
lifting component of a crane, travels along the bridge. If the bridge is rigidly supported on two or more
legs running on a fixed rail at ground level, the crane is called a gantry crane
Unlike mobile or construction cranes, overhead cranes are typically used for either manufacturing or
maintenance applications, where efficiency or downtime are critical factors.

Over head Cranes Overview

In the simplest of terms, an overhead crane is a machine, or piece of equipment, that allows you to lift
and move heavy materials from one location to another in a precise manner. There is no “one size fits
all” approach to defining an overhead crane, as each overhead crane is carefully designed and
engineered for a specific purpose or application to suit a business’ material handling needs.
Overhead cranes can be designed and built in all kinds of configurations, and different components can
be swapped out or engineered to improve its capacity and performance. Some of the most popular
reasons for using an overhead crane include:
 Loading or unloading materials from a truck
 Moving materials around a facility more efficiently than a tow motor or manpower can
 Flipping or pulling dies in and out of stamping machines at a manufacturing facility
 Feeding raw material into a machine at a manufacturing facility
 Moving pieces or parts down an assembly line in a controlled fashion
 Moving containers around a shipyard or railyard
 In addition to simplifying some of the processes described above, there are two main reasons
why a company would want to install an overhead crane, or a series of overhead cranes, in their
facility:
 Efficiency—Overhead cranes are more efficient than using a group of workers or tow motors to
lift and move material and can work up to 2-3 times faster. Think about how a manufacturer,
mill, or warehouse can streamline their processes and procedures by introducing an overhead
crane to automate the lifting, maneuvering, and unloading of materials at their facility.
 Safety—Another advantage of installing an overhead crane in a manufacturing, assembly, or
warehousing facility. Cranes can be used to lift and move materials in extreme environments
and can handle corrosive or dangerous materials like hot metals, chemicals, and heavy loads. A
workstation or jib crane can be put in place to help workers move heavy objects in a controlled
manner and help cut down on repetitive motion injuries and muscle strains.
 Other benefits to using an overhead crane system include:
 Reduction in workplace accidents
 Reduction of product or material damage
 Improved workflow
 Lowered costs

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  Green solution that reduces environmental impact

Overhead Crane Inspection

Due to the size and weight of the objects often being lifted and transported by overhead cranes, routine
inspections are necessary to ensure continued safe operation. An initial inspection of the crane (new or
altered) prior to initial use is required. Once placed into service, overhead cranes require two different
types of inspections. Frequent inspections are done daily to monthly, while periodic inspections are
completed at monthly to annual intervals. The purpose of the two inspection types is to examine critical
components of the crane and to determine the extent of wear, deterioration or malfunction.

Frequent Inspections
Items to be Inspected Frequency
Functional operating mechanisms for maladjustment Daily
Deterioration or leakage in lines, tanks, valves, drain pumps Daily
and other parts of air or hydraulic systems
Hooks with deformation or cracks (visual) Daily
Hooks with deformation or cracks (written record with Monthly
signature of inspector and date)
Hoist chains and end connections for excessive wear, twist or Daily
distortion interfering with proper function, or stretch beyond
manufacturer's recommendations (visual)
Hoist chains and end connections for excessive wear, twist or Monthly
distortion interfering with proper function, or stretch beyond
manufacturer's recommendations (written record with
signature of inspector and date)
Running Rope and end connections for wear, broken strands, Monthly
etc. (written record with signature of inspector, rope identity
and date)
Functional operating mechanisms for excessive wear Daily to Monthly
Rope reeving according to manufacturers' recommendations As recommended

Periodic Inspections
Items to be inspected:
 Deformed, cracked or corroded members
 Loose bolts or rivets
 Cracked or worn sheaves and drums
 Worn, cracked or distorted parts, such as pins, bearings, shafts, gears, rollers, locking and
clamping devices.
 Excessive wear on brake-system parts, linings, pawls and ratchets
 Inaccuracies in load, wind and other indicators
 Electric , gasoline, diesel, or other types of motors for improper performance
 Excessive wear of chain drive sprockets and excessive chain stretch

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  Deteriorated electrical components, such as pushbuttons, limit switches or contactors
 In addition to the initial inspection, the all new and altered crane-functions are tested for:
 Hoisting and lowering
 Trolley travel
 Bridge travel
 Limit switches, locking and safety devices

Overhead Crane Operation

The manufacturer's instructions must be followed when operating to help ensure overhead crane safety.
 Size of load
 Attaching the load
 Moving the load
 Hoist limit switch
 Standard Hand Signals for Controlling Overhead and Gantry Cranes

Physical Requirements of Crane Operators

Physical qualifications for crane and derrick operators are safety related and required. However, OSHA
requirements for Crawler, Locomotive, Truck and Derrick operators are limited to the following:
 Have vision of at least 20/30 Snellen in one eye, and 20/50 in the other, with or without glasses.
Exception:
 Derrick operators shall have adequate vision with or without glasses for the specific operation.
 Be able to distinguish red, green, and yellow, regardless of position of colors, if color
differentiation is required for operation.
 Hearing, with or without hearing aid, muse be adequate for the specific operation.
 A history of epilepsy or of a disabling heart condition shall be sufficient reason for his
disqualification.

Physical Rigger Requirements and Qualifications

 High school diploma or equivalent
 Must be NCCCO certified Level 1, minimum
 Significant work experience as a rigger, 2+ years minimum
 Must be up to date, and willing to comply with all OSHA safety standards
 Familiar with all necessary safety equipment
 Able to assess each load and select proper equipment for the job
 Solid working knowledge of all rigging equipment
 Able to inspect rigging equipment to ensure it is in good working order
 Experience with crane assembly and disassembly
 Solid math skills for calculating load requirements
 Physically capable of working in demanding conditions
 Able to sit, stand, bend, and lift 50 lbs on a regular basis
 Excellent vision and hearing

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  Not afraid of heights or climbing ladders, scaffolding, etc.
 Fluent in English; bilingual a plus
 Reliable and hardworking with a team-player attitude

Rigging
Rigging, the equipment, the action of designing and installing the
equipment, in the preparation to move objects. A team
of riggers design and install the lifting or rolling equipment needed
to raise, roll, slide or lift objects such as with a crane or block and
tackle.
Rigging, which involves securing materials to be moved by a crane or
another type of lifting equipment, is a common process at
construction sites. But when improper rigging causes a load to fall,
serious injuries or deaths can occur.
Rigging comes from rig, to set up or prepare. Rigging is the equipment
such as wire rope, turnbuckles, clevis, jacks used with cranes and
other lifting equipment in material handling and structure relocation.
Rigging systems commonly include shackles, master links and slings,
and lifting bags in underwater lifting.

What are company policies?

Company policies are guidelines that help employers deal with the
health, safety and accountability of employees, as well as their interactions with customers or clients.
Business policies can also be used as a guideline for federal or state regulatory requirements, legal
issues and other situations that can lead to severe consequences for employees.
 
Here’s a list of company policies you may need:
 Equal opportunity policy
 Workplace health and safety
 Employee code of conduct policy
 Attendance, vacation and time-off policies
 Employee disciplinary action policy
 Employee complaint policies
 Ethics policy
 Work schedule and rest period policies
 Substance abuse policies
 Workplace security policies
 Bring Your Own Device (BYOD) policies
 Compensation and benefits policy
 Travel policies
 Employee fraternization policy

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  Inclement weather policies
 Employee face mask policy (during COVID-19)

Why are company policies important?

Company policies
put in writing what you expect from your employees. These may be related to performance, values or
behavior. Additionally, company policies can serve as pre-warnings for employees, since they outline the
consequences of failing to abide by the rules.
 
Company policies are important for a variety of other reasons, including:
 Setting expectations
 Keeping management accountable
 Ensuring compliance with the law
 Helping defend against legal claims
 Assisting with fair treatment of employees

List of company policies to consider creating

Here are some of the policies that your company should consider putting in place:
 
Equal opportunity policy
Many countries mandate that you must be an equal opportunity employer by law. For example, in the
United States, the U.S. Equal Employment Opportunity Commission enforces a wide range of federal
laws that prohibit workplace discrimination.
 
An equal opportunity policy (EOP) prevents companies from discriminating against job applicants or
employees if they are a member of a protected class (e.g, race, gender, age, religion, familial status,
color). The EOP is essential for any anti-harassment, workplace violence, non-discrimination or diversity
policies your company may consider developing.
 
Workplace health and safety
It’s important to provide your employees with a safe and healthy work environment, especially since
workplace health and safety violations can cause harm to your employees, cost your business money
and damage your reputation.
 
Your business should be proactive and write a health and safety policy that is designed for each
workplace. For example, you might specify what employees should do in case of office emergencies or
how to handle unsafe materials. The Occupational Safety and Health Administration (OSHA) has
guidelines on how to create a safe workplace and protect workers from occupational hazards that you
can base your policy on.
 

Employee code of conduct policy 

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A clear and concise code of conduct can help employees understand your r expectations in terms of
performance and behavior. This policy might include specific rules related to substance abuse, sexual
harassment, giving gifts, dress code, confidentiality, and even the use of cell phones or social media
during work hours.
 
Misunderstandings may still occur, but at least employees have something to refer to if they’re unsure
about what your expectations are.
 
Here’s an example of a policy you could include in your code of conduct regarding employee
discrimination and harassment:
 
WMB Company is committed to eradicating discrimination and unlawful harassment in our workplaces.
Any actions, jokes or comments based on an employee or client’s race, religion ethnicity, sex, age or any
other legally protected class are not tolerated and will be met with significant disciplinary action.
 
Attendance, vacation and time-off policies
Having a standard way to request a day off or take vacation leave will help things run more smoothly in
the office. A PTO policy should outline how much time off employees receive, when and how they can
accrue more time off, who they should contact to request their time off and anything else they may
need to know about taking PTO (e.g., is vacation use-it-or-lose-it?). Other time off policies to consider
creating include parental leave policies and bereavement leave policies.
 
You can also choose to create a separate attendance policy that outlines what is considered tardy, how
far in advance they should request time off and what happens if they don’t show up for work.
 
Here’s an example of a company attendance policy you can use to help write your own:
 
Employees are expected to be on time and regular in attendance. This means being at your workspace
and ready to work at your scheduled time each day. You will be given a 10-minute grace period after the
start of your shift before you will be considered tardy. Employees who are tardy on more than five
occasions will be subject to disciplinary action. Absenteeism and tardiness are burdensome to your co-
workers and leaders, and will not be tolerated without just cause.
 
Employee disciplinary action policy
Some of the most important company policies involve discipline and employee conduct. Before you can
hold your employees accountable for their actions, it’s important to record your expectations in terms
of performance and behavior in your employee handbook or individual employee contracts. With
complete access to the rules and regulations of the workplace, you can then enforce disciplinary action
when appropriate while using the employee handbook as a point of reference.
 
A simple step-by-step list of what happens regarding disciplinary action can make it easy for employees
to know what to expect if they violate a company policy. Describe a specific process you will follow to

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ensure every employee is treated fairly when it comes to discipline. Have a lawyer review this
information before you include it in your employee handbook to make sure all disciplinary action is
legal.
 
Employee complaint policies
Grievances are formal complaints your employees can file to document their concerns with an aspect of
their workplace. These grievances might be filed as a result of an incident or conflict with a fellow
employee. A grievance can be filed for nearly any reason, including physical workplace complaints,
financial issues like payroll and social circumstances like harassment or bullying. It’s important to outline
a formal process for resolving complaints within your company so that employees know how to handle
their concerns in a professional way.
 
It may also be a good idea to develop a non-retaliation policy to protect employees who make good
faith complaints against their manager or co-workers.
 
How to develop company policies as an employer 
If you want to develop business policies to address important workplace issues, consider following the
steps below:
 
Identify the need for the policy
Observe the way your management and employees deal with workplace issues, and identify which areas
could use improvement. For instance, if employees consistently violate unwritten rules, you may
consider adding a new policy that addresses this and other related issues.
 
Determine the content needed for the policy
Write down key areas that need to be addressed within the policy. For instance, you can include
different sections or clauses that prevent you or your employees from finding loopholes. Consider all
aspects of the policy, what you would like your employees to do and what you would like them to avoid
doing. It’s also a good idea to include what form of disciplinary action will be taken if a policy is violated.
 
Consider checking with an attorney before distributing any policies to employees.
 
Communicate the new policy to employees
Current employees need to be notified of new policies when they’re released or added to the employee
handbook. You may even consider adding a signature line to the new policy to make sure employees
know that they must follow the rule from the date they sign it. This prevents conflict later on if an
employee states they were never aware of the policy after receiving disciplinary action for violating it.
 
It’s also important to review and discuss company policies with new employees during onboarding so
they know what to expect. Consider having them sign a form stating that they were given an employee
handbook or a list of your policies, rules and regulations.
 

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Update and revise the policy as necessary
You may consider amending or revising your policies as necessary in accordance with laws and
regulations or according to your company’s objectives and any employee feedback.

Standards Organization
A standards organization, standards body, standards developing organization (SDO), or standards setting
organization (SSO) is an organization whose primary function is developing, coordinating, promulgating,
revising, amending, reissuing, interpreting, or otherwise producing technical standards to address the
needs of a group of affected adopters. Put another way, such an organization works to create uniformity
across producers, consumers, government agencies, and other relevant parties regarding terminology,
product specifications (e.g. size, including units of measure), protocols, and more. Its goals could include
ensuring that Company A's external hard drive works on Company B's computer, your blood pressure
measures the same with Company C's sphygmomanometer as it does with Company D's, or that all
shirts that should not be ironed have the same icon (an iron crossed out with an X) on the label.
Most standards are voluntary in the sense that they are offered for adoption by people or industry
without being mandated in law. Some standards become mandatory when they are adopted by
regulators as legal requirements in particular domains, often for the purpose of safety or for consumer
protection from deceitful practices.
 International standards organizations
 Regional standards organizations
 National standards bodies
 Standards developing organizations (SDOs)

International standards organizations

Broadly, an international standards organization develops international standards. (This does not
necessarily restrict the use of other published standards internationally.)
There are many international standards organizations. The three largest and most well-established such
organizations are the International Organization for Standardization, the International Electrotechnical
Commission, and the International Telecommunication Union (ITU), which have each existed for more
than 50 years (founded in 1947, 1906, and 1865, respectively) and are all based in Geneva, Switzerland.
They have established tens of thousands of standards covering almost every conceivable topic. Many of
these are then adopted worldwide replacing various incompatible "homegrown" standards. Many of
these standards are naturally evolved from those designed in-house within an industry, or by a
particular country, while others have been built from scratch by groups of experts who sit on various
technical committees (TCs). These three organizations together comprise the World Standards
Cooperation (WSC) alliance.
ISO is composed of the national standards bodies (NSBs), one per member economy. The IEC is similarly
composed of national committees, one per member economy. In some cases, the national committee to
the IEC of an economy may also be the ISO member from that country or economy. ISO and IEC are
private international organizations that are not established by any international treaty. Their members

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may be non-governmental organizations or governmental agencies, as selected by ISO and IEC (which
are privately established organizations).

Regional standards organizations

Regional standards bodies also exist, such as the European Committee for Standardization (CEN),
the European Committee for Electrotechnical Standardization (CENELEC), the European
Telecommunications Standards Institute (ETSI), and the Institute for Reference Materials and
Measurements (IRMM) in Europe, the Pacific Area Standards Congress (PASC), the Pan American
Standards Commission (COPANT), the African Organisation for Standardisation (ARSO), the Arabic
industrial development and mining organization (AIDMO), and others.
In the European Union, only standards created by CEN, CENELEC, and ETSI are recognized as European
standards (according to Regulation (EU) No 1025/2012), and member states are required to notify the
European Commission and each other about all the draft technical regulations concerning ICT products
and services before they are adopted in national law. These rules were laid down in Directive 98/34/EC
with the goal of providing transparency and control with regard to technical regulations.
Sub-regional standards organizations also exist such as the MERCOSUR Standardization Association
(AMN), the CARICOM Regional Organisation for Standards and Quality (CROSQ), and the ASEAN
Consultative Committee for Standards and Quality (ACCSQ), EAC East Africa Standards
Committee www.eac-quality.net, and the GCC Standardization Organization (GSO) for Arab States of the
Persian Gulf.

National standards bodies

In general, each country or economy has a single recognized national standards body (NSB). A national
standards body is likely the sole member from that economy in ISO; ISO currently has 161 members.
National standards bodies usually do not prepare the technical content of standards, which instead is
developed by national technical societies.
Example national standards bodies
Organization Initials Country
American National Standards Institute ANSI United States
Asociación Española de Normalización y Certificación, Spanish AENOR Spain
Association for Standardization and Certification
Association Française de Normalisation, French Association for AFNOR France
Standardization
Badan Standardisasi Nasional BSN Indonesia
Bangladesh Standards and Testing Institution BSTI Bangladesh
Brazilian National Standards Organization ABNT Brazil
British Standards Institution BSI United Kingdom
Bulgarian Institute for Standardization BDS Bulgaria
Bureau voor Normalisatie/Bureau de Normalisation NBN Belgium
Bureau of Indian Standards BIS India
Bureau of Standards Jamaica BSJ Jamaica
Dirección General de Normas DGN Mexico
Deutsches Institut für Normung DIN Germany

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 Eesti Standardimis- ja Akrediteerimiskeskus, Estonian Centre for EVS Estonia
Standardisation
Ente Nazionale Italiano di Unificazione UNI Italy
Euro-Asian Council for Standardization, Metrology and Certification GOST Russia (Soviet
Union)
Finnish Standards Association SFS Finland
Institut Luxembourgeois de la normalisation, de l’Accréditation, de la ILNAS Luxembourg
Sécurité et qualité des produits et services,
Luxembourg Institute for Standardization, Accreditation, Security, and
Quality of Products and Services
Instituto Argentino de Normalización y Certificación IRAM Argentina
Instituto Colombiano de Normas Técnicas y Certificación, Colombian ICONTEC Colombia
Institute of Technical Standards and Certification
Japanese Industrial Standards Committee JISC Japan
Koninklijk Nederlands Normalisatie Instituut NEN Netherlands
Korean Agency for Technology and Standards KATS South Korea
Magyar Szabványügyi Testület, Hungarian Standards Institution MSZT Hungary
Organismul Național de Standardizare, Romanian Standards ASRO Romania
Association
South African Bureau of Standards SABS South Africa
Standardization Administration of China SAC China
Standards Council of Canada SCC Canada
Standards New Zealand SNZ New Zealand
Standards Norway SN Norway
Standards Organisation of Nigeria SON Nigeria
Swedish Standards Institute SIS Sweden
Swiss Association for Standardization SNV Switzerland
Turkish Standards Institution TSE Turkey
Standards Australia SAI Australia
Jabatan Standard Malaysia DSM Malaysia
Instituto Português da Qualidade, Portuguese Institute for Quality IPQ Portugal

NSBs may be either public or private sector organizations, or combinations of the two. For example, the
Standards Council of Canada is a Canadian Crown Corporation, Dirección General de Normas is a
governmental agency within the Mexican Ministry of Economy, and ANSI is a 501 non-profit U.S.
organization with members from both the private and public sectors. The National Institute of Standards
and Technology (NIST), the U.S. government's standards agency, cooperates with ANSI under
a memorandum of understanding to collaborate on the United States Standards Strategy. The
determinates of whether an NSB for a particular economy is a public or private sector body may include
the historical and traditional roles that the private sector fills in public affairs in that economy or the
development stage of that economy.

Standards developing organizations (SDOs)

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A national standards body (NSB) generally refers to one standardization organization that is that
country’s member of the ISO. A standards developing organization (SDO) is one of the thousands of
industry- or sector-based standards organizations that develop and publish industry specific standards.
Some economies feature only an NSB with no other SDOs. Large economies like the United States and
Japan have several hundred SDOs, many of which are coordinated by the central NSBs of each country
(ANSI and JISC in this case). In some cases, international industry-based SDOs such as the CIE,
the IEEE and the Audio Engineering Society (AES) may have direct liaisons with international standards
organizations, having input to international standards without going through a national standards body.
SDOs are differentiated from standards setting organizations (SSOs) in that SDOs may be accredited to
develop standards using open and transparent processes.

Terminology
When it comes to standardization, the first thing that comes to mind is ISO (International
Organization for Standardization), but besides ISO there are other two major players in the
standardization field.
But first things first, as you probably know, ISO  standards have to be bought (and they are very
expensive) so you won’t find them on the Internet, but I have found a few resources that explain them,
even if briefly.

 The EuroTerm Bank project has published the very comprehensive terminology document
“Towards Consolidation  of European Terminology Resources: Experience and
Recommendations from EuroTermBank Project“. Chapter 2 “Terminology infrastructure and
standardization” gives a complete overview of important issues related to standards and
standardization. A thorough explanation for each standard is provided. I believe this is one the
best you can find to have a general idea on the standards.
 2. Another great source on ISO standards related to translation and terminology is the webpage
by Uwe Muegge, a corporate terminologist, who lists the standards which are linked to more
detailed information about them.
 3. This is ISO’s page with the standards which you can buy but, if you can’t, then at least you can
take a look at its contents. ISO/TC 037 “Terminology and other language and content
resources”. Also, check this link out.
 4. The Pavel tutorial has a detailed section (5) on standards.
 LISE (Legal Language Interoperability Services) document “Guidelines for collaborative
legal/administrative terminology work” presents on section 8, page 69, the “Relevant
international standards” with a short description of each. Unfortunately it only includes those
standards mentioned in the Guidelines, but still, it is very useful. It also has a good glossary
which I mention in “Resources in English”. By the way, not to be confused with LISA, their name
is similar but their last name is different, and unfortunately LISA “passed away” recently.
 Anja Drame made a presentation for TermNet explaining standardization and ISO standards
called “International Terminology Standardization: reasons, institutions, results,
implementation”. At the end she presents a list of ISO standards.

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  In addition to ISO, we have other two big brothers in terminology standardization:
o The International Electrotechnical Commission (IEC) that deals with terminology in the
electrical, electronic, and related technologies field, and
o The International Telecommunications Union (ITU) that publishes internationally-
recognized terminology recommendations and manages a terminology database on
telecommunications.
 So, yes, LISA. LISA dealt with localization standards but I mention it here just because everybody
in the translation field knows or at least should know what LISA was. When I was studying to
get my master’s in translation, LISA was still up and running, but unfortunately they could not
continue their work due to insolvency and close on February 2011. Pavel’s tutorial provides
supposedly a link to LISA, but I believe the tutorial hasn’t been updated in a while.  LISA was a
big deal at the time and it’s still mentioned in several sources (such as Pavel) which provide a
link to a page that does no longer exist. Anyway, if you haven’t heard of it, check the wiki here. 
It also provides other good sources if you want to learn more.
 LISA Oscar Standards. After LISA (Localization Industry Standards Association) was declared
insolvent, it designated other institutions as its successor organization for its standards portfolio.
Its OSCAR standards documents are available for download, such as Translation Memory
eXchange (TMX), Segmentation Rules eXchange (SRX), and XML Text Memory (xml:tm), among
others. Another source containing this information is GALA (Globalization and Localization
Association) –US and UK
 ISO’s 704 standard “Terminology Work and Principles.
 Try ISO’s online browsing platform (OBP) to look for definitions and terms.
 Streamlining translation – ISO 12616: 2002, Translation-Oriented Terminography by Carol B.
Eckman.
 Translation quality standards in Europe: An overview by Gloria Corpas Pastor
 ISOcat Data Category Registry defines widely accepted linguistic concepts.

Standard, Regulations:
In the rigging industry, there are a variety of relevant associations that set standards, and specific
requirements may vary from region to region. In addition, different types of jobs and rigging equipment
may come with unique safety requirements. If you’re interested in working in the lifting and rigging
industry, or need to complete fall protection or rigging courses, then there are a few standards
organizations you should know about, including OSHA Regulations and ASME Standards.
There are legal requirements in OSHA standards that you must know about and comply with. The most
important standard for you depends on the type of work you are doing. If you are working in general
industry, ensure that your materials handling activities follow 29 CFR 1910.184 for sling use. In addition,
you should consider looking at a related standard for overhead and gantry cranes, 29 CFR 1910.179. If
you are working in shipyard employment, then 29 CFR 1915.112 is the standard to follow. If you are
working in construction, 29 CFR 1926.251 is the standard to follow. Other standards include 29 CFR
1917.13, Slinging, for marine terminals and 29 CFR 1918.81, Slinging, for longshoring.
Consult these standards to ensure full compliance with their provisions.

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OSHA standards and documents are available online at www.osha.gov.
Sling manufacturers often manufacture and mark slings in accordance with the specifications set forth in
the American Society of Mechanical Engineers (ASME) standard B30.9-2018, Slings, rather than with the
specifications found in OSHA’s existing sling standards. As long as there is no indication that the newer
ASME specifications have lessened employee safety, OSHA will continue to accept, under its policy for
de minimis violations, the use of slings
manufactured and marked in compliance with the ASME standard. De minimis violations require no
correction and result in no penalty.
The following Regulations and Standards were used to develop this course.
 General Industry Subpart N Material Handling and Storage 1910.184 Slings
 Construction Industry Subpart CC Cranes and Derricks in Construction and Subpart H Materials
Handling, Storage, Use, and Disposal
 1926.251 Rigging Equipment for Material Handling
 ASME B30.9 Slings
 ASME B30.10 Hooks
 ASME B30.20 Below the Hook Lifting Devices
 ASME B30.21 Lever Hoists
 ASME B30.26 Rigging Hardware

The Occupational Safety and Health Administration (OSHA)

OSHA is perhaps the best-known workplace safety organization in the United States. Officially, it’s part
of the U.S. Department of Labor. OSHA helps set standards to keep a wide variety of workers safe on the
job, from office workers to truck drivers. Each state develops its own health and safety standards, which
are then overseen by OSHA. However, OSHA does set some federal standards. One federal OSHA
standard limits the arrest distance to six feet, with few exceptions.

The American Society of Mechanical Engineers (ASME)

While organizations like OSHA are a part of the federal government, ASME is a professional association
that also helps set standards and codes for certain professions and equipment. In the rigging industry,
ASME B30.26 “applies to the construction, installation, operation, inspection, and maintenance of
detachable rigging hardware, including rigging equipment like “shackles, links, rings, swivels,
turnbuckles, eyebolts, hoist rings, wire rope clips, wedge sockets, rigging blocks and load indication
devices.”
Many workers in the rigging and lifting industries will be required to complete certain certification
courses. Managers may be required to complete Competent Person fall protection courses, while
additional rigging certification may be required for individual workers.
OSHA 29 CFR 1926.1400 Assembly/Disassembly Director
This standard applies to power-operated equipment, when used in construction, that can hoist, lower
and horizontally move a suspended load. Such equipment includes, but is not limited to: Articulating
cranes (such as knuckle-boom cranes); crawler cranes; floating cranes; cranes on barges; locomotive
cranes; mobile cranes (such as wheel-mounted, rough-terrain, all-terrain, commercial truck-mounted,

15
and boom truck cranes); multi-purpose machines when configured to hoist and lower (by means of a
winch or hook) and horizontally move a suspended load; industrial cranes (such as carry-deck cranes);
dedicated pile drivers; service/mechanic trucks with a hoisting device; a crane on a monorail; tower
cranes (such as a fixed jib, i.e., “hammerhead boom”), luffing boom and self-erecting); pedestal cranes;
portal cranes; overhead and gantry cranes; straddle cranes; sideboom cranes; derricks; and variations of
such equipment. However, items listed in paragraph (c) of this section are excluded from the scope of
this standard.

General Requirements
All overhead and gantry cranes installed after August 31, 1971, must meet the specifications of the
American National Standard Institute (ANSI) / American Society of Mechanical Engineers (ASME) Safety
Code for Overhead and Gantry Cranes, ANSI B30.2.0-1967 which is incorporated by reference as
specified in 29 CFR 1910.6(e)(19) and was last updated in 2016
Cranes can be modified and load capacity rerated as long as the modifications and associated structure
is thoroughly checked for the new rated load by a qualified engineer or the equipment manufacturer
The rated load of the crane must be plainly marked on each side of the crane - if more than one hoist is
present, each hoist must have its rating shown
Clearance must be maintained above and to the side of cranes
Walkways cannot be placed in a crane operating zone that would compromise employee safety when
the crane is in operation
Parallel cranes must have adequate clearance between the two bridges if no walls or structures are
between them
Only designated personnel are permitted to operate a crane
Design Requirements
OSHA specifies design requirements on the construction of the cab and its controls as well as the cab’s
lighting; foot-walks, ladders and stairways; bridge and trolley bumpers; hoist, holding, trolley and bridge
brakes; electrical components; hoisting equipment; and warning devices.

Recommended Practices:
Determine Who is Qualified, Competent, Designated, or Certified
Who is responsible (Competent) for the rigging of the load? Who from your team has been authorized
to remove a bad sling or piece of hardware from service? Who can then inspect that piece of rigging
equipment and is Qualified to make the ultimate decision on if it can be put back into service or should
be disposed of to prevent further use? Who is Certified to operate crane equipment on the job site?
Ultimately, the onus is on the employer to determine which of their workers are Qualified, Competent,
Designated, or Certified to perform the task at hand.

Inspect Your Rigging Hardware

Rigging hardware that will be used, must be inspected and free of deformation, cracks, stretch,
excessive nicks or gouges, etc.
If you’re unfamiliar with best practices, inspection, and removal from service criteria for detachable
rigging hardware, then you should purchase ASME B30.26 – Rigging Hardware. This standard covers:

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  Shackles
 Adjustable Hardware (turnbuckles, eye nuts, swivel hoist rings)
 Compression Hardware (wire rope clips, wedge sockets)
 Links, Rings, and Swivels
 Rigging Blocks

Inspect Your Lifting Slings

In the lifting and rigging industries, ASME B30.9 is one of the most commonly-referenced standards that
applies to the fabrication, attachment, use, inspection, testing, and maintenance of slings used for load-
handling purposes. The variety of different lifting slings that this standard applies to are:
 Wire rope slings
 Alloy chain slings
 Synthetic rope slings
 Metal mesh slings
 Synthetic web slings
 Synthetic roundslings
Prior to each use, all types of lifting slings need to be inspected for damage or irregularities to help avoid
costly downtime and help to keep everybody on the job site safe. Routine inspection should be looked
at as an investment that, over time, will help keep valuable equipment running and keep workers safe.

Select Rigging Gear Based on the Rating and Working Load Limit (WLL)
Working Load Limit (WLL) is the maximum mass or force which the product is authorized to support in a
particular service. When determining the WLL needed, all components, including shackles, turnbuckles
and hook must be made from the same strength materials with equal WLL ratings. The WLL is only as
good as its weakest, or lowest WLL components—which is why it’s essential to ensure that all
components in a particular configuration match the duty required for the job.

Determine the Total Load Weight Prior to the Lift

The total weight of the load needs to be known prior to the lift. Make sure to include the known weight
of the load—plus, all slings, hardware, and below-the-hook devices like lifting beams, spreader bars, c-
hooks, magnets, etc.

Determine the Proper Sling Type and Sling Hitch

A rigger must decide the best sling type and best sling hitch type to use for the task at hand. The goal is
to have proper support and connection to the load.
Vertical Hitch – One end of the sling is attached to the hook, while the other end is attached directly to
the load. When a sling is used in a vertical hitch, the full lifting capacity of the sling material can be
utilized.
 In most cases, use more than one sling. A single sling can rotate or introduce twist into the sling
 Do not use for lifting loose materials, long materials, or unbalanced loads that can tip

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Choker Hitch – The sling passes through one end around the load, while the other end is placed on the
hook. Or, you can add a block of wood between the hitch and the load to improve grip and angle of the
choke.
 Do not use on loose bundles
Use slings that are long enough so the choke is effective and on the sling—not on the eye or any fittings
Double-Wrap Choker Hitch – Full 360° contact around the load can be achieved using a double wrap
choker hitch. This hitch compresses the load and can help prevent it from slipping out of the sling.
 Do not overlap slings at the bottom of the load
Basket Hitch – The sling cradles the load while both eyes are attached overhead. More than one sling
may be necessary to help ensure load control.
 Do not use basket hitches with loads that are difficult to balance

Determine that the Load is Structurally Sound and Free of Obstructions

Make sure that the load is secure and properly supported. Check the area surrounding the load to make
sure it won’t get snagged or caught on any nearby obstructions when being lifted, moved, or
lowered. Perform a Job Site Analysis (JSA) to identify any potential hazards. After a hazard is identified, a
determination should be made on how to control or eliminate the hazard altogether.

Determine the Proper Sling Angle

The sling angle must be taken into account when determining the proper sling and angles used to make
an overhead lift (90°, 60°, 45°, 30°). The smaller the angle, the less load a sling can carry. Always check
your rigging chart to understand the capacity of the sling you’re using at any given angle.

Find the Load’s Center of Gravity (COG)

The Center of Gravity (COG) is the point at which the load is balanced—where the horizontal and vertical
balance points intersect. The Center of Gravity should be directly below the load hook and the
connection to the load right above center of gravity.

Know Your Proximity to the Load

Where will you and your co-workers be standing when the load is up in the air? Never stand under a
load or in close proximity to a load when it is being lifted, moved, or lowered.
When moving a suspended load:
 Keep the load as low as possible
 Keep only essential employees near the load
 Ensure everyone is accounted for and in line of sight or radio contact when a lift is made
 Ensure everyone is accounted for after the lift is complete

Use Sling Protection on All Types of Slings

Slings must be protected from cutting or damage. Failure of any sling from cutting or abrasion is
preventable. Use corner pads, guards, and sleeves to protect against cutting and abrasion for all types of

18
lifting slings. ALL slings must be protected from corners, protrusions, rough surfaces, and in some cases
—where used with hardware.
Best practice is to add protection on all edges on the load—including those that are not the primary
load-bearing areas.

Account for Environmental Conditions

Are there any unusual loading or environmental conditions? These conditions should be accounted for
when putting your lift plan together:
 Extreme temperatures
 Wind
 Moisture/snow/ice
 Chemically-active environments
 Changes in elevation

Check All Rigging Gear Has the Proper Identification and/or Markings
Every item used to make a lift must have all of the correct identification (manufacturer’s name, working
load limit, serial number, etc.)
Missing sling tags or missing markings/identification on rigging products is one of the most common
problems our rigging inspection group finds when they’re out in the field.

Potential incidence of non compliance:

Upon detecting a violation, the bureau inspector issues an Incident of Noncompliance (INC) to the
operator and uses one of two main enforcement actions (warning or shut- in), depending on the severity
of the violation. If the violation is not severe or threatening, a Warning INC is issued. The Warning INC
must be corrected within a reasonable amount of time specified on the INC. The Shut-in INC may be for
a single component (a portion of the facility) or the entire facility. The violation must be corrected
before the operator is allowed to continue the activity in question.
In addition to the enforcement actions specified above, the bureau can assess a civil penalty of up to
$44,675 per violation per day if: 1) the operator fails to correct the violation in the reasonable amount
of time specified on the INC; or 2) the violation resulted in a threat of serious harm or damage to human
life or the environment.

Crane Operator Qualifications

To become a crane operator you usually have to obtain a licence to Perform High Risk Work. To gain a
licence, you will need to register with an approved Registered Training Organisation and work under the
supervision of a licensed operator. You will also need to keep an approved logbook to record
competencies achieved during training. Assessment by an independent assessor will then be required.
The Perform High Risk Work Licence is issued under the National Standard for Licensing Persons
Performing High Risk Work. You can also become a crane operator through a traineeship in Building and

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Construction (Specialist Trades), Construction Crane Operations or Mobile Crane Operations. Entry
requirements may vary, but employers generally require Year 10. For more details, see Section 2. Ask
your career adviser about the possibility of starting some of this training in school.

Will all crane operators need to be certified nationwide?

Operators of most cranes above 2,000 lb. capacity when used in construction will need to be either
certified by an accredited crane operator testing organization, such as the National Commission for the
Certification of Crane Operators (NCCCO), or qualified through an audited employer program [§
1926.1427(a)].

Where in the rule can I find this information?

Section 1926.1427 of the new rule describes crane operator certification/qualification requirements.
Option 1, which is anticipated to be the most commonly used, requires operators to be certified by a
nationally accredited crane operator testing organization that tests operators through written and
practical testing and providing levels of certification based on equipment capacity and type.

I am currently a CCO certified crane operator, what do I need to do?

Nothing. CCO certification provided by the National Commission for the Certification of Crane Operators
(NCCCO) fully meets the new OSHA rule. This applies to certifications of operators of all the crane types
NCCCO currently offers (Mobile Cranes, Tower Cranes, Overhead Cranes, Articulating Cranes). 

How does OSHA define a "crane" in the new rule?

The standard defines a crane as "power-operated equipment that, when used in construction, can hoist,
lower, and horizontally move a suspended load" [§ 1926.1400]. updated 10/15/10

Operators of which cranes are included in this rule?

Cranes covered by the rule, when used in construction applications, include: mobile cranes, crawler
cranes, tower cranes, boom trucks, articulating boom (knuckleboom) cranes, floating cranes, cranes on
barges, and locomotive cranes. Also included are industrial cranes (such as carry decks), pile drivers,
service/mechanic trucks with a hoisting device, monorails, pedestal cranes, portal cranes, overhead and
gantry cranes, straddle cranes, and variations of such equipment. It also includes multipurpose machines
when configured to hoist and lower (by means of a winch or hook) and horizontally move a suspended
load [§ 1926.1400].

How about articulating cranes (knucklebooms)?

When used purely to deliver materials, articulating/knuckleboom truck cranes are excluded. However,
when they are used to hold, support, or stabilize material to facilitate a construction activity, or they are
handling prefabricated components (such as roof trusses or wall panels) or structural steel,
they are covered by the new rule [§ 1926.1400(c)(17)]. See the NCCCO Articulating Crane Operator
Certification Requirement flowchart for guidance on whether certification is required for your particular
job.

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How about cranes with attachments?
The rule applies to cranes when used with attachments such as hooks, magnets, grapples, clamshell
buckets, orange peel buckets, concrete buckets, draglines, personnel platforms, augers or drills, and pile
driving equipment, whether attached to the crane or suspended [§ 1926.1400(b)].

Are any lifting devices excluded?

OSHA has excluded many lifting devices, among them: excavators, backhoes (even when used to lift
suspended loads), concrete pumps, aerial lifts, tow trucks, digger derricks, gantry systems, and forklifts.
All tree trimming and tree removal work is also excluded [§ 1926.1400(c)].
However, in some circumstances, many of these normally excluded from the new rules can be included
when used for certain specialized tasks. For more information, please consult OSHA 1926.1400(c)
Exclusions. updated 09/24/10

If I am not yet certified, when is the deadline?

The rule was published in the Federal Register on August 9, 2010, and took effect November 8, 2010.
There is a four-year compliance period for the crane operator certification/qualification requirement,
i.e., employers must be in compliance by November 10, 2017 [§ 1926.1427(k)]. updated 10/31/14

How is my state license affected?

Option 4 of the personnel requirements of the new rule allows states with their own programs to
continue requiring a license as long as their exams are at least as strict as the federal rule. This includes
requirements such as written and practical tests and providing levels of certification based on
equipment and capacity and type. These jurisdictions have six months from the date of publication in
the Federal Register to come into compliance. Most state and city programs recognize CCO certification
[§ 1926.1427(e)]. updated 1/26/11

If I am not certified, can I still operate cranes?

If you are not certified, you may only operate cranes covered under the rule after November 10, 2017, if
you meet OSHA’s definition of an “operator-in-training,” which includes having received sufficient
training from your employer to operate the crane safely and being continuously monitored by an
“operator’s trainer.” There are also restrictions on the types of lifts you can make. [§
1926.1427(f)]. updated 10/31/14

Do I have to be tested in English?

OSHA permits tests to be administered in any language the operator understands, but there are
conditions. The certification card must note the language used on the test, and all the materials that are
required to be on the crane (e.g., operations manual) must be in the same language as the test [§
1926.1427(h)(2)].

Does OSHA specify what the written and practical crane operator tests must include?

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Yes. OSHA lists the information necessary for the safe operation of the type of crane to be operated for
the written test, and it outlines which skills the practical exams must test [§ 1926.1427(j)].

I operate cranes for a crane company contracted to do military work. Am I covered by the military
option for qualifying crane operators?
No. The so-called “Option 3” only covers employees of the United States military (Department of
Defense or Armed Services). All contractor companies with crane operators on site need to meet the
certification, qualification, or state licensing requirements listed [§ 1926.1427(d)(1)].

I work in general industry as a crane operator. Do I need to be certified?

OSHA 1926.1400 covers cranes in construction only. For crane work in general industry, refer to OSHA
1910.180. There are no federal operator certification requirements at this moment in general industry
[§ 1926.1400(a)]. updated 01/26/11

How does this rule affect electric utility personnel that operate digger derricks and small cranes (e.g.,
15 ton) on power line construction?
Digger derricks are specifically excluded from the new rule when used for auguring holes for poles
carrying electric and telecommunication lines [§ 1926.1400(c)(4)]. Note that when used in other
construction lifting duties, digger derricks are not excluded [Preamble p.70]. updated 1/26/11

I operate a crane with a maximum lifting capacity of 10 tons, but I never pick up loads larger than
1,500 lb. Do I need to be certified?
The exclusion for cranes of 2,000 lb. and below refers to the maximum manufacturer-rated capacity.
Even if you lift lighter loads, it is the crane’s maximum-rated capacity that must be 2,000 lb. or less for
you to be exempt from the requirements of 1926.1427. Employers are still responsible for training their
operators on the safe operation of the type of equipment the operator will be using [§ 1926.1441(e)].

Are sideboom cranes and derricks covered by the new standard?

Yes, sideboom cranes and derricks do fall within the scope of 1926 Subpart CC. However, the operator
certification requirements in OSHA 1926.1427 do not apply to these two specific types of cranes [§
1926.1436(q) & 1440(a)]. posted 12/12/11

Do operators of a dedicated drilling rig need to become certified or qualified?

Dedicated drilling rigs are specifically excluded from the requirements in 1926 Subpart CC. This would
exclude them from the operator certification requirement as well [§ 1926.1400(c)(11)]. posted 12/12/11
Operators
Operators
Crane operators control cranes or draglines to lift, move, position or place machinery, equipment and
other large objects at construction or industrial sites, ports, railway yards, surface mines and other
similar locations.
Duties

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Crane operators typically do the following:
- Control equipment with levers, wheels, or foot pedals
- Move material according to a plan or schedule they receive from their superiors
- Set up and inspect material moving equipment
- Make minor repairs to their equipment
- Record material they have moved and where they moved it from and to
In warehouse environments, most crane operators use forklifts and conveyor belts. Automated sensors
and tags are increasingly used to keep track of merchandise, allowing operators to work faster. In
warehouses, operators usually work closely with hand material movers.
Many crane operators work for underground and surface mining companies. They help to dig or expose
the mine, remove the earth and rock, and extract the ore and other mined materials.
In construction, crane operators remove earth to clear space for buildings. Some work on a building site
for the entire length of the construction project. For example, operators often help to construct high-
rise buildings by transporting materials to workers far above ground level. Mobile cranes are used to do
work a boom truck can’t do – higher lifts, heavier loads, and lifts that need a longer reach.

Responsibilities:
Reviewing requirements for the crane with the Lift Director
• Knowing what types of site conditions could adversely affect the operation of the crane and
consulting with the Lift Director
• Crane – Hook to Wheels / Hook to Foundation
• Inspecting the crane
• Reporting needed adjustments or repairs to designated person Calculating or determining net capacity
• Considering all factors known that might effect crane capacity and reviewing with Lift Director
• Knowing standard signals
• Understand basic load rigging

Following is a closer look at some, but not all, of the responsibilities of four key roles identified in
ASME B30.5 and B30.3:

Crane Owner
ASME defines the “crane owner” as the party with custodial control of the crane and provides the
necessary operational and maintenance information to the crane user. Other responsibilities
include, but are not limited to:
 Providing a crane that meets the user’s requested configuration and capacity.
 Providing all applicable load rating charts and diagrams and additional technical information
when requested by crane user; field assembly/disassembly; operation; maintenance info;
and placards and warning decals supplied by the manufacturer.
 Establishing inspection, testing and maintenance procedures, and informing the crane user.
 Designating qualified personnel for maintenance, repair, transport, assembly/disassembly
and inspections.

23
  Maintaining data for the rope currently installed on each drum of the crane.

Crane User
ASME defines the “crane user” as the party that arranges the crane’s presence at the site and
controls the crane while on site, including ensuring only qualified operators who meet ASME’s
standard B30.5 requirements operate the crane. The crane user also ensures all members of the lift
team are aware of their roles and responsibilities. Other responsibilities include:
 Ensuring compliance with requirements of the current ASME volume.
 Ensuring the crane is operating according to manufacturer’s requirements and the worksite
regulations.
 Using only qualified supervisors and operators.
 Ensuring the crane is in proper operating condition by verifying proper documentation has
been received from the crane owner and frequent inspections are performed.
 Verifying the crane has sufficient capacity to perform the work.
 Informing crane owner if any rope has been replaced or shortened.

Site Supervisor
The site supervisor is described by ASME as the party that exercises supervisory control over the
worksite and the work currently being performed. In some cases, the site supervisor and the lift
director may be the same person. Other responsibilities include:
 Ensuring the operator meets requirements of the applicable ASME volume.
 Ensuring the crane meets inspection requirements prior to initial use.
 Determining which regulations are applicable to crane operations.
 Ensuring a qualified lift director is designated, rigging is supervised by a qualified person and
maintenance is performed by a designated person.
 Ensuring crane operations are coordinated with other jobsite activities.
 Ensuring the area for the crane is adequately prepared, including access roads, sufficient
room to assemble/disassemble the crane, ground conditions, proximity to power lines and
other hazards and traffic control.
 Ensuring adverse conditions are addressed, such as poor soil, wind velocity or gusting winds,
fog, heavy rain, cold and artificial lighting.
 Allowing crane operations near power lines only after applicable requirements are met.
 Permitting special lifting operations, such as multiple crane lifts, only after the applicable
procedures are implemented.

Lift Director
The lift director is described by ASME as the party that directly oversees the  work being performed
by the crane and the associated rigging crew. According to ASME B30.5, a lift director must be
onsite for all lifting operations.
Responsibilities include:
 Halting crane operations if alerted to an unsafe condition.

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  Ensuring area preparations are completed before crane operations commence.
 Ensuring necessary traffic controls are in place.
 Ensuring workers understand their responsibilities and the associated hazards.
 Appointing signal people and ensuring they meet the applicable requirements.
 Allowing crane operations near power lines only when applicable requirements are met.
 Ensuring precautions are implemented for special lifting operations, such as multiple crane
lifts.
 Ensuring rigging is performed by competent personnel.
 Ensuring the load is properly rigged and balanced.

Issues Common in working with Third Parties

An "assumption." a thing that is accepted as true or as certain to happen, without proof. Assumptions
are the personal judgments of the individual. Mostly we assume things that are mundane and
inconsequential in ordinary discussion with our family, colleagues or fellow employees. But, when
specific decisions are to be acted on, assumptions must be or should be, verified as accurate. When the
Owner of a crane requests an annual crane inspection, what does he expect or assumes the information
on the report will provide? I think we can agree that at least he thinks he will be informed of defects
that would cause loads to drop or the crane to collapse within a years time, we did say it was an
"annual." Therein Lies the first problem!
Think hard about this; the owner has total control of the moving, loading, maintenance, and repair of
the crane for a year without the Inspector's observation! Should the Inspector then "assume" all of
these various operations are performed properly? After an accident, I have never personally known of
an Owner admitting maintaining or loading their cranes improperly. Therein Lies the second problem.
The basic factors affecting the condition of any component are; quality of design, the environment in
which it has been subject to, operating methods, good or bad, and the amount of maintenance
provided. These fundamental applies to all manufactured products. These various operations performed
unilaterally by the crane Owner are critical to the crane's condition. There are disclaimers on our reports
that will not protect us from litigation. Are we to assumed the crane is "good" for a year, but we have no
control over that year, how dumb is that?
In this paper, I will concentrate on defects in components that have caused accidents that were
"assumed" satisfactory during an annual inspection, yet, not verified for one reason or another by the
"crane surveyor." Therein lies the third problem.
To say it more honestly - we assume the satisfactory condition of components that we can't see for now
and in the future?! Three issues concern me when I certified cranes they are, Fatigue which we can't
see, Hidden which we can't see, and Corrosion inside where we can't see. How then, can we protect our
"good selves?"
What do the OSHA standards actual say? A complete inspection of the crane must be made "at a
minimum, annual." It is to be properly documented and performed by a competent person. OSHA calls
these inspections "periodic" their durations are from one to twelve months in length. Over the years our
industry began naming them "annual" inspection and Crane owners and Litigators got the erroneous
notion that they lasted for a year. Just by a simple change in naming our inspections, periodic not
annuals-would help in communication to Owners.

25
But, to whom is OSHA assigning the responsibility for this inspection? OSHA regulations in Construction
and General Industry are directed toward Employers and Employees relationship, not a third party
Inspection company. Only in Maritime OSHA part 1919 and various State programs do they address the
Surveyor and employer with specific duties. An important one is, reviewed and documented service and
repair records provided by the employer.
The Owner can take days with two or three people to make a complete, Periodic Inspections and
should! The third party inspector is allowed four to eight hours for the total inspection with one
operator. Is this realistic for a year-long feeling of bliss by the crane Owner? Here is a review of this
discoursed.
• Complete wire rope inspection
• Internal Brakes on Hydraulic Hoists
• Corrosion and material loss inside structural members 4. Fatigue in structural assemblies not
disassembled for inspection
• Physical structural connection at A-Frames, Counterweight connections that are not visible
• Documented maintenance and services records.
In my opening statement, I listed three problems the third party crane Surveyor (inspector) needed to
overcome to protect themselves from unwarranted assumptions by Owners and Plaintiffs. First, the idea
(assume) that the inspection is a complete in-depth evaluation of all the crane's components and it will
last for one year. Second, we know very well that the Owner has complete control over the crane's
operation and maintenance which will affect its condition. Lastly, we are dependent on activities over
which we have no control, how dumb is that!

Special Responsibility:
Permitting special lifting operations only when equipment and procedures required by this volume, the
crane manufacturer, or a qualified person are employed.
Ensuring precautions are implemented when hazards associated with special lifting operations are
present. Such operations include but are not limited to:
• Multiple crane lifts;
• Lifting personnel;
• Pick and carry operations;
• Mobile cranes operating on barges.
• Ensuring that the applicable requirements of ASME B30.23 are met when lifting personnel;

Human Factors for Crane Operations

The human factor specifically refers to the "human unsafe behavior" during the operation of the
crane, and is the most direct factor that causes the safety risk accident of the crane, mainly

26
including fatigue work, illegal operation, inadequate supervision and inspection, improper
binding or promotion, wrong command and no personal protection.

Why human reliability analysis?

• Human reliability analysis comprises a group of methods used together to better understand
and control human performance. They are advanced methods and this briefing note only
provides an introduction to them – it does not provide all the skills needed to conduct an
analysis, but will help in understanding them.

• The likelihood of a human error in a task is directly related to the way the task itself is
designed, and the quality of the following key factors:

• • Workplace design (including the working environment, tools, controls, displays etc.).

• • Documentation (written procedures, signs, labels).

• • Operator competence (level of training, qualification, experience, etc., in the task).

• Human reliability analysis is used to gather and present information on these factors in a logical
way. Organisations use human reliability analysis to examine the extent to which they have
those factors under good control. If the level of control (and therefore human reliability) can be
improved, the analysis should point to how this can be achieved. Certain techniques can
generate ‘human error probabilities’ for tasks giving an estimate of the chance of a human error

• There are five basic steps:

• Identify critical tasks Errors happen every day at work and most are harmless, though some can
result in fatalities, injury, plant damage or other losses. These can occur immediately in the case
of operational or emergency response tasks, or some time later if, for example, a maintenance
error renders a vital but infrequently used device inoperable. ‘Critical’ errors such as these can
be identified in several ways: • Through formal hazard and operability studies (HAZOPs) which
inevitably raise human error as a source of risk. • From probabilistic safety assessment (PSA)
which may identify specific errors that need to be controlled. • By examining historical data,
accident and near miss records to find out what happened in the past and establish whether it is
under better control now. • By ‘brainstorming’ – ask experts (designers or users of systems and
equipment) which errors could lead to a major problem. • By behavioural safety observation.
The above may result in a large list of tasks. It may be necessary to further screen this, so as to
examine in detail only a sample of the tasks, whilst ensuring that examples of all types of task
performed in your workplace are chosen.

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• Perform a hierarchical task analysis (HTA) Briefing Note 11 explains HTA in more detail. HTA
consists of describing a task in terms of all the sub-tasks needed to carry it out. Tasks and sub-
tasks can be shown in either a ‘tree’ – similar to an organisation chart – or as a set of headings
and sub-headings in a table (see the example on page 3 of this note – moving a load using a
crane).

• Identify errors, consequences and defences Using the task analysis as a starting point, identify
feasible types of error in the tasks and sub-tasks. This can be done using available human error
identification methods. They provide keywords to prompt ideas – can the task be omitted, can
the action be performed on the wrong object, in the wrong order, etc.? This information is
usually recorded in a table, also recording the possible consequences of the identified errors and
the safeguards and recovery mechanisms in place to prevent errors or to detect and correct
them (an example table is shown in the crane example later).

• Estimate human error probabilities (HEPs) The techniques for generating HEPs are highly
specialised and should be used only by an expert (Reference 2). All are based on two principles:
1) any task, even if it is performed under the best achievable conditions, has a finite probability
of failure and 2) less than ideal conditions will increase that probability of failure. Techniques fall
into two types: data-based and expert-judgement based – although both types require some
level of expert judgement. The data-based techniques provide lists of types of tasks and provide
a HEP associated with it. For example, the human error assessment and reduction technique
(HEART method, Reference 3) describes types of task such as ‘Complex task requiring high level
of comprehension and skill’. Tasks fitting this description have an average failure probability of
0,16 and certain error producing conditions will raise this. If, for example, the operator has to
perform the task under time pressure, the failure probability can increase 11-fold (note that this
can generate probabilities of more than 1, in which case, the probability of failure is taken to be
1 or certain failure). Technique for human error rate prediction (THERP) contains tables of errors
at a more detailed task level, for example: ‘select wrong control on a panel from an array of
similar-appearing controls… identified by labels only’. The HEP for this is 0,003 with an error
factor of 3. Again, the analyst would judge whether certain conditions could affect performance
and can multiply or divide this HEP by a factor of up to 3 depending upon whether conditions
are considered to be worse or better than average. Expert judgement methods involve groups of
task experts in a structured discussion of the tasks and conditions and estimating the probability
of failure from the information considered.

• Develop conclusions and make recommendations for reducing error The information gathered
in steps 1 to 4 should show whether the task is under good control or not. It should also show
what could be done to improve human performance in the task by indicating any factors (task
design, workplace design, competence or procedures) that are particularly poor. Step 4 –
generating HEPs – is optional, but reducing errors is the same whether the errors are quantified
or not, and consists of examining the information to determine which aspects of the tasks and

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 conditions under which the task is performed are less than optimal. For example, if the complex
task could be simplified, this should reduce error probabilities and, similarly, if the task schedule
could be re organized to reduce time pressure on operators, this should also improve
performance in the task.

Language barriers

 Crossing the Language Barrier on Construction Sites The importance of good communication cannot be
stressed enough in the dangerous and hazard fraught environment of a construction site. If workers are
not able to communicate with each and with their employers, there could be serious repercussions.
Other than the obvious, that it may hamper productivity, it can also have a negative effect on site safety.
All workers including those whose first language is not English, need information and training to
understand the risks involved in their work and to enable them to do the job safely, even more so when
the job involves life threatening circumstances such as those presented by construction work. There are
a variety of workplaces and sites across Oz, where workers speak languages other than English as their
first language. Even workers who have a slight knowledge and understanding of English may not have a
level of understanding high enough to understand the safety regulations and procedures of the site. It’s
important for employers to be aware of the language preferences of their workforce so they can make
sure that health and safety is discussed in ways that everyone understands. In workplaces where there
are a variety of languages spoken, language differences can be a noticeable barrier to the successful
communication of important information relating to health and safety information. This includes the
need to discuss issues and ensure that safe work procedures are being practiced. Those workers that
come from culturally diverse backgrounds may also have different attitudes towards health and safety
because of their previous work environments and its impact on their attitudes and beliefs. Employers
should tailor communication to the needs of their employees in order for all workers to understand the
hazards and risks presented on their site. This is vital to protecting their health and safety and ensuring
they behave in a manner that protects the health and safety of their co-workers. Employers should
ensure instruction is given to workers in a language that they fully comprehend especially with regard to
safety procedures. It is the duty of employers to ensure workers are informed about the company’s
health and safety policy and procedures, hazards on the site, safe work processes, procedures safe
operation, use, maintenance or replacement of protective equipment, injury and incident reporting
procedures, consultation structures (such as health and safety representatives, designated work groups,
management contacts and meeting schedules), procedures for resolving health and safety issues,
emergency and first aid procedures as well as warning signs and symbols. One of the best methods to
employ in ensuring good communication is a face-to-face discussion and demonstration. This method is
effective in communicating across different languages and also allows for feedback, interaction and for
misunderstandings to be identified ½ and addressed immediately. Written material in their language of
choice is also effective and should be clear, concise, in simple language and have pictures and visual aids
to accompany written material to make understanding easier. Employers or supervisors also need to

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figure out whether translation or interpreting is needed or whether there are bilingual employees that
may be able to help. Employers also need to ensure consistent safety signs are used and that employees
are taught terms that are common to the workplace, such as the names of equipment and processes,
relevant job titles and key safety instructions. By ensuring that all workers understand what is expected
of them in terms of health and safety compliance, they safer the workplace will be

Cultural barriers

Culture is a phenomenon that has been created by people, represents the way communities live, and
determines how everyone appears at work. Culture is the behavior of people, how to create systems of
work, procedures, and routines to follow, and how can anyone formally or unofficially agree to follow
such processes so that they can become the norm. The United Kingdom executive director of H&S
described safety culture as “the product of individual and collective values, attitudes, competencies and
behavior patterns that define commitment to the organization’s H&S program”. The “set of beliefs,
criteria, attitudes and expectations shared by members of a community, organi-zation or group” was
another definition. For decades, “culture” has been used as a management feature. The safety culture is
the key component of the SM system of an organization. Where the considered the relationship
between safety culture and safety performance is both qualitative and quantitative of theoretical study
and experimental. the strengthening of SM is always the highest priority in construction work.
Promoting a safety culture will be one of the most effective ways. At the same time, safety culture
should be understood as an expression of organizational culture. And establishing a culture of safety is a
priority for senior management, and the safety culture at the project level is also reflected in the
behavior of the project manager. But staff are responsible for following procedures and thinking about
how they work, where additional duty should not be considered SM can reflect and affect the
company’s safety culture. And organizations with a positive safety culture are characterized by trust-
based communication through shared perceptions of the importance of safety and confidence in the
efficiency of preventive measures. Safety culture plays critical role in the safety of employees in the
workplace. Almost every workplace has safety culture problems. For a good reason, cultures in the
workplace grow slowly and can be killed quickly. There are factors that cause a particular problem of
safety cultures and lead to negative attitudes towards safety and increase resistance to safety initiatives.
it has been proven that a strong safety culture has a positive impact on safety performance in many
industrial conditions. The lack of a safety culture may be due to a lack of commitment to safety or
occupational safety and health administration (OSHA) requirements . Showing commitment at all levels
of the organization is an important cultural factor. The commitment is a personal responsibility where
employees are committed to applying the safety culture at work. Thus, they will work to safely
communicate, learn, adapt, and modify behavior based on committed mistakes. According to Reference,
safety culture refers not only to the level of compliance with HSE but also refer to the obligation of
senior management, which plays main role in its implementation. Whereas senior management should
formulate a policy that indicates compliance with safety, management’s commitment was the most

30
important measure for determining the impact of unsafe site performance. the main contractors reduce
prices or cost by considering the cost of safety first and then paying responsibility to their
subcontractors to afford the extra costs when it comes to bidding projects. This behavior, whether they
realize it or not, is a guarantee of a culture of safety. One of the factors impacting safety performance in
the AEC industry is the absence of superintendence by the responsible supervisor. There is no regular
supervision or project manager staying on site for a few hours at least once a week. The supervisor was
found as an intermediary broker to make sure safety practice in the construction project. The conduct of
the safety supervisor can affect safety measures that prevent an unexpected accident . In addition, the
worker may not report any accident or say anything to the responsible person in site. Reference said, in
general, the injury is not documented. Whereas many incidents occur because of careless attitudes of
workers regardless of their neglect, from direct monitoring, that indifference should be noted.
Reference clarifies lack of a suitable H&S culture in the AEC industry in developing countries, and
workers are less responsive to H&S issues. Safety rules and procedures can reduce accidents caused by
unsafe conditions because they give a clear picture and limits to the implementation of the safety
program of the construction project. The problems that are often identified are that the rules and
procedures are difficult to understand and implement and are not appropriate for the current situation
and the specifications.It indicate that exploitation and corruption is another example of the factors that
affect safety performance; for example, with exploitation in developing countries, the exploitation of
labor to work for a long time and cheap salaries is a result of absence or inadequacy of OHS systems or
little enforcement. This happens not only for legislative lands but also because of social standards paid
for poverty. Corruption plays a negative role in developing safety culture by reducing levels of
occupational safety measures. Sometimes legislation exists, but those responsible for enforcing the law
do not perform their duties honestly. Unscrupulous organizations exploit this to distance themselves
from spending money on safety measures by spending some money as bribes. The management also
blames individuals for being responsible for accidents, where the responsibility for the incidents is
considered to belong to certain persons. This approach is prominent in organizations based on penal
culture, and this approach corresponds to the community’s desire to identify a clear cause of the
incident . it is explained that another reason affecting the safety culture is the feedback loop not being
closed after an accident; after an accident, the focus is on the employee, often being committed. The
priority is to reduce damage and return to production. Do not provide resources for success that are also
factors that affect safety culture. Staff need some basic resources, such as knowledge and skills, whereas
you cannot expect people to follow safety procedures if they do not know the right way to do it or lack
the skills to actually implement it . The knowledge, skills, and ability of workers to work, particularly with
regard to hazards and risks in their work, may reduce accidents. These competencies can be enhanced
through training and chosen suitable workers. Time is also another resource, where work injuries cannot
be avoided when production is more important than security and the time of purchase or production
approaches faster. These factors can weaken the safety culture, when it may sound like the only safety
resources that the company needs to provide to employees are personal protective equipment.

Crane Types

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Mobile
There are four principal types of mobile cranes: truck mounted, rough-terrain, crawler, and floating

Truck-mounted
The most basic truck-mounted crane configuration is a "boom truck" or "lorry loader", which features a
rear-mounted rotating telescopic-boom crane mounted on a commercial truck chassis.
Larger, heavier duty, purpose-built "truck-mounted" cranes are constructed in two parts: the carrier,
often called the lower, and the lifting component, which includes the boom, called the upper. These are
mated together through a turntable, allowing the upper to swing from side to side. These modern
hydraulic truck cranes are usually single-engine machines, with the same engine powering the
undercarriage and the crane. The upper is usually powered via hydraulics run through the turntable
from the pump mounted on the lower. In older model designs of hydraulic truck cranes, there were two
engines. One in the lower pulled the crane down the road and ran a hydraulic pump for the outriggers
and jacks. The one in the upper ran the upper through a hydraulic pump of its own. Many older
operators favor the two-engine system due to leaking seals in the turntable of aging newer design
cranes. Hiab invented the world's first hydraulic truck mounted crane in 1947. The name, Hiab, comes
from the commonly used abbreviation of Hydrauliska Industri AB, a company founded in Hudiksvall,
Sweden 1944 by Eric Sundin, a ski manufacturer who saw a way to utilize a truck's engine to power
loader cranes through the use of hydraulics. Generally, these cranes are able to travel on highways,
eliminating the need for special equipment to transport the crane unless weight or other size
constrictions are in place such as local laws. If this is the case, most larger cranes are equipped with
either special trailers to help spread the load over more axles or are able to disassemble to meet
requirements. An example is counterweights. Often a crane will be followed by another truck hauling
the counterweights that are removed for travel. In addition some cranes are able to remove the entire
upper. However, this is usually only an issue in a large crane and mostly done with a conventional crane
such as a Link-Belt HC-238. When working on the job site, outriggers are extended horizontally from the
chassis then vertically to level and stabilize the crane while stationary and hoisting. Many truck cranes
have slow-travelling capability (a few miles per hour) while suspending a load. Great care must be taken
not to swing the load sideways from the direction of travel, as most anti-tipping stability then lies in the
stiffness of the chassis suspension. Most cranes of this type also have moving counterweights for
stabilization beyond that provided by the outriggers. Loads suspended directly aft are the most stable,
since most of the weight of the crane acts as a counterweight. Factory-calculated charts (or electronic
safeguards) are used by crane operators to determine the maximum safe loads for stationary
(outriggered) work as well as (on-rubber) loads and travelling speeds.
Truck cranes range in lifting capacity from about 14.5 short tons (12.9 long tons; 13.2 t) to about 2,240
short tons (2,000 long tons; 2,032 t). Although most only rotate about 180 degrees, the more expensive
truck mounted cranes can turn a full 360 degrees.

Rough terrain
A rough terrain crane has a boom mounted on an undercarriage atop four rubber tires that is designed
for off-road pick-and-carry operations. Outriggers are used to level and stabilize the crane for hoisting.

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These telescopic cranes are single-engine machines, with the same engine powering the undercarriage
and the crane, similar to a crawler crane. The engine is usually mounted in the undercarriage rather than
in the upper, as with crawler crane. Most have 4 wheel drive and 4 wheel steering for traversing tighter
and slicker terrain than a standard truck crane, with less site prep.

Crawler
A crawler crane has its boom mounted on an undercarriage fitted with a set of crawler tracks that
provide both stability and mobility. Crawler cranes range in lifting capacity from about 40 to 4,000 long
tons (44.8 to 4,480.0 short tons; 40.6 to 4,064.2 t).
The main advantage of a crawler crane is its ready mobility and use, since the crane is able to operate on
sites with minimal improvement and stable on its tracks without outriggers. Wide tracks spread the
weight out over a great area and are far better than wheels at traversing soft ground without sinking in.
A crawler crane is also capable of traveling with a load. Its main disadvantage is its weight, making it
difficult and expensive to transport. Typically a large crawler must be disassembled at least into boom
and cab and moved by trucks, rail cars or ships to its next location.

Floating
Floating cranes are used mainly in bridge building and port construction, but they are also used for
occasional loading and unloading of especially heavy or awkward loads on and off ships. Some floating
cranes are mounted on pontoons, others are specialized crane barges with a lifting capacity exceeding
10,000 short tons (8,929 long tons; 9,072 t) and have been used to transport entire bridge sections.
Floating cranes have also been used to salvage sunken ships.
Crane vessels are often used in offshore construction. The largest revolving cranes can be found
on SSCV Thialf, which has two cranes with a capacity of 7,100 tonnes (7,826 short tons; 6,988 long tons)
each. For 50 years, the largest such crane was "Herman the German" at the Long Beach Naval Shipyard,
one of three constructed by Nazi Germany and captured in the war. The crane was sold to the Panama
Canal in 1996 where it is now known as Titan.

Other types
All terrain
An all-terrain crane is a hybrid combining the roadability of a truck-mounted and on-site
maneuverability of a rough-terrain crane. It can both travel at speed on public roads and maneuver on
rough terrain at the job site using all-wheel and crab steering.
AT's have 2–12 axles and are designed for lifting loads up to 2,000 tonnes (2,205 short tons; 1,968 long
tons).

Pick and carry

A pick and carry crane is similar to a mobile crane in that is designed to travel on public roads; however,
pick and carry cranes have no stabiliser legs or outriggers and are designed to lift the load and carry it to
its destination, within a small radius, then be able to drive to the next job. Pick and carry cranes are
popular in Australia, where large distances are encountered between job sites. One popular
manufacturer in Australia was Franna, who have since been bought by Terex, and now all pick and carry

33
cranes are commonly called "Frannas", even though they may be made by other manufacturers. Nearly
every medium- and large-sized crane company in Australia has at least one and many companies have
fleets of these cranes. The capacity range is between ten and forty tonnes as a maximum lift, although
this is much less as the load gets further from the front of the crane. Pick and carry cranes have
displaced the work usually completed by smaller truck cranes, as the set-up time is much quicker. Many
steel fabrication yards also use pick and carry cranes, as they can "walk" with fabricated steel sections
and place these where required with relative ease.

Sidelifter
A side lifter crane is a road-going truck or semi-trailer, able to hoist and transport ISO
standard containers. Container lift is done with parallel crane-like hoists, which can lift a container from
the ground or from a railway vehicle.

Carry deck
A carry deck crane is a small 4 wheel crane with a 360-degree rotating boom placed right in the centre
and an operators cab located at one end under this boom. The rear section houses the engine and the
area above the wheels is a flat deck. Very much an American invention the Carry deck can hoist a load in
a confined space and then load it on the deck space around the cab or engine and subsequently move to
another site. The Carry Deck principle is the American version of the pick and carry crane and both allow
the load to be moved by the crane over short distances.

Telescopic handler
Telescopic handlers are forklift-like trucks that have set of forks mounted on a telescopingextendable
boom like a crane. Early telescopic handlers only lifted in one direction and did not rotate.  however,
several of the manufacturers have designed telescopic handlers that rotate 360 degrees through a
turntable and these machines look almost identical to the Rough Terrain Crane. These new 360-degree
telescopic handler/crane models have outriggers or stabiliser legs that must be lowered before lifting;
however, their design has been simplified so that they can be more quickly deployed. These machines
are often used to handle pallets of bricks and install frame trusses on many new building sites and they
have eroded much of the work for small telescopic truck cranes. Many of the world's armed forces have
purchased telescopic handlers and some of these are the much more expensive fully rotating types.
Their off-road capability and their on site versatility to unload pallets using forks, or lift like a crane make
them a valuable piece of machinery.

Harbour
Dry bulk or container cranes usually in the bay areas or inland water ways.

Travel lift
A travel lift (also called a boat gantry crane, or boat crane) is a crane with two rectangular side panels
joined by a single spanning beam at the top of one end. The crane is mobile with four groups of wheels
steerable wheels, one on each corner. These cranes allow boats with masts or tall super structures to be

34
removed from the water and transported around docks or marinas. Not to be confused mechanical
device used for transferring a vessel between two levels of water, which is also called a boat lift.

Railroad
A railroad crane has flanged wheels for use on railroads. The simplest form is a crane mounted on
a flatcar. More capable devices are purpose-built. Different types of crane are used for maintenance
work, recovery operations and freight loading in goods yards and scrap handling facilities.

Aerial
Aerial cranes or "sky cranes" usually are helicopters designed to lift large loads. Helicopters are able to
travel to and lift in areas that are difficult to reach by conventional cranes. Helicopter cranes are most
commonly used to lift loads onto shopping centers and high-rise buildings. They can lift anything within
their lifting capacity, such as air conditioning units, cars, boats, swimming pools, etc. They also perform
disaster relief after natural disasters for clean-up, and during wild-fires they are able to carry huge
buckets of water to extinguish fires.
Some aerial cranes, mostly concepts, have also used lighter-than air aircraft, such as airships.

Fixed
Exchanging mobility for the ability to carry greater loads and reach greater heights due to increased
stability, these types of cranes are characterised by the fact that their main structure does not move
during the period of use. However, many can still be assembled and disassembled. The structures
basically are fixed in one place.

Ring
Ring cranes are some of the largest and heaviest land-based cranes ever designed. A ring shaped track
support the main superstructure allowing for extremely heavy loads (up to thousands of tonnes).

Tower
Tower cranes are a modern form of balance crane that consist of the same basic parts. Fixed to the
ground on a concrete slab (and sometimes attached to the sides of structures), tower cranes often give
the best combination of height and lifting capacity and are used in the construction of tall buildings. The
base is then attached to the mast which gives the crane its height. Further, the mast is attached to the
slewing unit (gear and motor) that allows the crane to rotate. On top of the slewing unit there are three
main parts which are: the long horizontal jib (working arm), shorter counter-jib, and the operator's cab.
Optimization of tower crane location in the construction sites has an important effect on material
transportation costs of a project.
The long horizontal jib is the part of the crane that carries the load. The counter-jib carries a
counterweight, usually of concrete blocks, while the jib suspends the load to and from the center of the
crane. The crane operator either sits in a cab at the top of the tower or controls the crane by radio
remote control from the ground. In the first case the operator's cab is most usually located at the top of
the tower attached to the turntable, but can be mounted on the jib, or partway down the tower. The

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lifting hook is operated by the crane operator using electric motors to manipulate wire rope cables
through a system of sheaves. The hook is located on the long horizontal arm to lift the load which also
contains its motor.
In order to hook and unhook the loads, the operator usually works in conjunction with a signaller
(known as a "dogger", "rigger" or "swamper"). They are most often in radio contact, and always use
hand signals. The rigger or dogger directs the schedule of lifts for the crane, and is responsible for the
safety of the rigging and loads.
Tower cranes can achieve a height under hook of over 100 metres

Types of cranes by function

Cranes are used for
 Construction materials
 Railroad tracks
 Shipping Materials
 Bridges
 Mobile homes
 Cars
 Scrap Metal

Mobile Cranes
Mobile cranes are mounted on a mobile platform like rail or a wheeled truck. Mobile cranes are
designed for easy transporting of loads to a site.
These cranes generally operate a boom from the end of which a hook is suspended by sheaves and wire
rope.
The wire ropes are operated by prime movers, operating through several transmissions. Mobile cranes
are used to lift heavy objects.
Mobile crane services provide the flexibility to access those sites that are difficult for other types of
cranes to access.

Telescopic Cranes
Telescopic cranes one of the forms of heavy cranes employed to transport and move objects from one
place to another. Telescopic cranes are often used in routine hauling operations at ports.
Telescopic cranes are equipped with height adjustments because of which the problems related to
height are solved while transferring goods from one place to another.

Cantilever Cranes
Cantilever Cranes run on an aerial runway. These cranes are also known as ‘hammerhead’. This German-
designed crane consists of a strong, steel-braced central tower on which a mighty double cantilever
beam is fitted.
The forward section of this arm contains the lifting machinery, while rear section contains a
counterbalancing weight.

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The primary function of cantilever cranes is to lift and transfer loads via a rotational movement of the
cantilevered cross beam.

Gantry Cranes
Gantry crane is a crane on the top of the gantry. Gantry is a structure used to straddle an object. They
use a hoist installed in fixed machinery consisting of a rail framework.
These cranes employ a strong overhead gantry to lift heavy industrial loads. Gantry cranes are widely
used in factories, shipyards, and similar commercial places.

Crawler Cranes
Crawler cranes are the special types of cranes fitted with caterpillar tracks are used on soft and boggy
ground where wheeled are unable to operate.
This crane is very stable as it has a very broad base and tracking spreads over a large area.

Aerial Cranes
An aerial crane also known as a flying crane is a helicopter used for lifting heavy loads like containers
and other awkward loads.
Aerial cranes are mostly used in remote or inaccessible areas such as a building or mountain tops. Lifting
operation using aerial cranes is often called a long line because a single sling line is used to carry the
load.

Critical crane components

Predictive maintenance utilizes condition monitoring, advanced inspections, and data analytics to
predict component or equipment failure. Incorporating predictive maintenance elements as part of a
Konecranes CARE Preventive Maintenance program can further optimize maintenance activities, reduce
unplanned downtime and improve equipment safety, productivity and lifecycle value. Analyzing and
identifying anomalies, patterns and trends in crane usage and operating data helps us make informed,
component-specific predictions, and prioritize recommendations and actions. Recommendations to
repair or replace components are driven by a combination of preventive and predictive maintenance
activities.

Crane/Crane Structure
Equipment usage data from TRUCONNECT Remote Monitoring, as well as maintenance and
performance histories, will be the foundation of any Crane Reliability Study and/ or End of Life Study.
Due to the availability of data, the time to perform the analysis is shortened, and the results will be
inherently more accurate. This enables true fact-based decision making as it comes to modernization or
replacement decisions.

Gear Case
Inspection of the internal gear case components is required at intervals recommended by the
manufacturer. In addition, oil analysis combined with operational data can be a good predictor of gear
case failure and can be easily performed during any scheduled preventive maintenance visit. Equipment

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usage data from TRUCONNECT Remote Monitoring may be used in the evaluation of these intervals and
shortened intervals may be recommended when warranted by heavy usage and/or other events.

Hoist And Trolley

The remaining theoretical design life is continuously calculated based on equipment usage data from
TRUCONNECT Remote Monitoring. This measure can indicate when a tear-down inspection, General
Overhaul or replacement is required.

Hoist Motor and Contactors

By analyzing the number of running hours, starts and stops, and over-temperature events that are
collected through TRUCONNECT Remote Monitoring, as well as maintenance and failure data, we can
provide replacement recommendations. Similar data is used in estimating the remaining theoretical life
of the hoist motor contactors.

Hook/Hook Block
Visual inspection and non-destructive testing (NDT) of the hook and internal hook block components are
required at intervals recommended by the manufacturer. In addition, equipment usage data from
TRUCONNECT Remote Monitoring may be used in the evaluation of these intervals and shortened
intervals may be recommended when warranted by heavy usage and/or other events.

Wire Rope
Regular magnetic rope inspections can be a predictor of wire rope fatigue failure. This is highly
recommended in critical and process duty applications. In addition, equipment usage data from
TRUCONNECT Remote Monitoring can be used as part of an overall rope life study, analyzing usage,
designed duty class and rope reeving/sheave configuration.

Hoist Brake
The remaining theoretical life of the hoist brake is evaluated in two ways. First, it is estimated based on
the number of hoist motor starts and number of emergency stops using data from TRUCONNECT
Remote Monitoring. Second, and more accurately, using TRUCONNECT Brake Monitoring; the brake
opening current provides an indirect measurement of the brake air gap / pad wear.

Advanced Controls
Advanced digital controls, variable frequency drives and Smart Features provide additional data through
TRUCONNECT Remote Monitoring that can be used for diagnostics and analytics.

Electrics And Mechanical

Through our extensive equipment maintenance base, we possess a vast statistical knowledge of
component lifetimes. This data is used to develop repair and replacement guide

Categories of crane operations

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 Tower cranes
Seen at most major construction sites, these giants often are hundreds of feet tall and can reach out to
equally large distances. Used to lift large tools (generators, acetylene torches, etc.), concrete and steel,
tower cranes grow taller as the job progresses and appear to be impossibly balanced as their projecting
booms lift enormous weights.

Tower crane operator duties

Essentially, tower crane operators operate the levers on the control console and control crane
movements. They control the crane by responding to hand or radio signals by a supervisor or qualified
signaler. On some jobs they use remote control consoles either from the top of a building or by radio
controls.

Overhead cranes
Sometimes called a bridge crane and found in industry, the overhead crane is essentially a hoist
supported by a rigid overhead girder attached to a roof or a supporting steel structure. Steel production
companies, paper mills and the auto industry use overhead cranes in the day-to-day production work

Overhead crane operators duties

Overhead crane operators control the lifting, moving and positioning of loads on the crane. They
observe and make sure that the load is safely attached and within the lifting limits. They keep the crane
clean and well maintained. If designated as a Crane Operator-Hooker or Hooktender, they can also
physically attach the load.

Mobile cranes
As the title implies, these are cranes that move. They might be mounted on crawlers or rubber-tired
carriers or can be self-propelled. Requiring minimal setup and assembly, mobile cranes are designed to
get to the work site quickly and lift a variety of loads.  Mobile cranes typically have a telescoping boom
with a hook suspended by a wire rope.

Mobile crane operator duties

Mobile crane operators move the control levels, foot pedals and manipulate the dials to operate the
equipment. They are responsible for keeping their equipment maintained and safe. They do the
cleaning, lubrication and do necessary repairs to their rigs. They must constantly inspect the crane
cables and hooks for wear and make sure worn parts are replaced. The mobile crane operator ensures
that weight loads and lifting capacities are not exceeded.

Knowledge of the correct type and capacity of lifting equipment and rigging hardware when lifting
specific items/loads
No machine should be selected to do any lifting on a specific job until its size and characteristics are
considered against:
• the weights, dimensions, and lift radii of the heaviest and largest loads

39
• the maximum lift height, the maximum lift radius, and the weight of the loads that must be handled
at each
• the number and frequency of lifts to be made
• how long the crane will be required on site
• the type of lifting to be done (for example, is precision placement of loads important?)
• the type of carrier required (this depends on ground conditions and machine capacity in its various
operating quadrants: capacity is normally greatest over the rear, less over the side, and non-existent
over the front)
• whether loads will have to be walked or carried
• whether loads will have to be suspended for lengthy periods
• the site conditions, including the ground where the machine will be set up, access roads and ramps it
must travel, space for erection, and any obstacles that might impede access or operation service
availability and unit cost
• the cost of operations such as erection, dismantling, on- and off-site transport, and altering boom
length
The selected machine should:
• be able to make all of its lifts in its standard configuration (that means having the capacity and boom
length to do all known tasks, with jib, extra counterweight, and special reeving held in reserve for any
unexpected problems)
• have at least a 5% working margin with respect to the load capacity of every lift
• be highly mobile and capable of being routed with a minimum amount of tearing down
• have enough clearance between load and boom and adequate head room between the load and
whatever rigging is required to make the lift.

Principles of Crane Operation

Accuracy of Centre of Gravity Measurement

Depending on what you are trying to do, your requirement for accuracy will vary. For example, if you
want to stack books on a table, you only need to know the center of gravity within a few inches. But if
you want your model airplane to fly straight, you need to know its center of gravity within a fraction of
an inch. Below is a list of examples with typical accuracy requirements:

 Human: 2 inches (5 cm)

 Golf ball: 0.05 inch (1.25 mm)
 Rocket: 0.01 inch (0.25 mm)
 Spacecraft: 0.04 inch (1 mm)

How do you Measure Center of Gravity?

Several concepts have been used to measure the center of gravity of a real object.
The simplest concept is to use a load cell system. This is the technique used in the WCG Series and
SE90168 Series of center of gravity measurement instruments. The object is placed on a fixed platform

40
connected to three load cells. The weighted average of each load cell reading gives the location of the
center of gravity of the object.
A different concept is used where high accuracy is required. The object is placed on top of a table that is
pivoted about a defined axis. The moment due to center of gravity offset of the object from the center
axis is measured using a force transducer. The location of center of gravity is derived from the moment
measurement by applying the following formula:
M = W x d: Where M is the moment applied, W is the weight of the object, d is the distance from the
pivot point to the center of gravity of the object This moment measurement method is used in the KSR
and SE8913 series of center of gravity measurement instruments.
Review of advanced rigging guidelines

ADVANCED RIGGING SAFETY COURSE OUTLINE

1. Crane and Rigging Accidents A review of serious crane accidents that addresses their causes and
methods of prevention including a detailed exploration of Responsibilities and Due Diligence.

2. Wire Rope A technical chapter on the construction, application and proper use of wire rope products.
Safety Factors and the effect of Shock Load and other forms of abuse are studied.

3. Hardware Contains a review and explanation of all of the Hardware commonly used in crane and
hoisting situations. Emphasis is on the structural loading of components such as spreader bars, slings
and shackles. Instruction in proper rigging techniques and correct application of rigging hardware.

4. Overhead Cranes Introduction to all of the various types of Overhead Cranes with descriptive
illustrations to aid in identification and learning components. Brief explanation of engineering criteria to
which Overhead Cranes must be designed with emphasis on potential failure points. Knowledge of
Overhead Crane capacity calculations and scenarios where capacity must be restricted are explored.
©2000

5. Rigging Mechanics
Instruction in the calculation of sling loadings due to sling angle and the effect of sling angle on lift lugs
and the load. Method to design proper lift lugs and the ability to recognize lift lugs that are not up to
standard. Procedure to calculate the Composite Center of Gravity of various objects. Proper signals for
mobile and overhead cranes.

6. Safe Operating Practices

Instruction in proper set up of cranes as well as many operating techniques with emphasis on the effect
of off level operation on crane structural strength. Full description of all legal requirements for the
hoisting of personnel and for working around power lines. Excerpts from Alberta regulations such as the
Electric Utility Regulations and from CSA – Z150.

7. Load Charts

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Full description of proper load chart calculations for Mobile Cranes with practice problems for the
student to solve. Sixty percent of the final mark is based on proper load chart calculations. Manufacturer
Recommendations to calculate safe loads for their cranes are followed explicitly with attention paid to
Cold Weather Restrictions. ©2000

8. Management of Serious Lifts

Instruction on the most common sources of error on the part of the Lift Manager that may prevent a
successful lift. The student will learn a proven, logical step by step method of planning critical lifts and
be made aware of many of the outside pressures that can affect the safe outcome of the lift if not
controlled by the lift manager. Instruction of what technical areas of lift planning demand the full
attention of the lift manager.

9. Dynamics of Lifts
An introduction to the changing loads that are induced when handling loads with more than one crane.
Awareness of when weight is transferred from one crane to another during the tailing process so that
adequate surplus capacities can be assured. Little known examples of extreme loadings that can be
placed on tail cranes are explained. Procedures to transfer loads safely from one crane hook to another
and the dynamics of long loads are discussed. The effect of one crane lifting above the other on a two
crane lift is explained, as well as the severe effect that can result from load lines being out of plumb
during lifts. Over-end block lifts are introduced, as well as recognition of the unique tipping properties of
crawler cranes. ©2000
This chapter allows the student to demonstrate their natural ability to solve complex rigging problems.
At the completion of the student effort, the problems are discussed with all proper techniques
described.

Each crane has a load chart that, in short, specifies the crane’s capabilities — detailing its features and
how its lift capacity varies when considering distance and angle. Just like the old saying ‘if you fail to
plan, you plan to fail,’ failing to consult a crane load chart before renting or employing a crane for
a specific job could leave you with too much or too little capacity for your job.
Before a crane is rented, transported, employed or purchased, the crane chart must be consulted.
Everyone, from the crane operator, to the job supervisors, to even the sales guys have to know how to
read a crane chart. Here’s how.
To illustrate how to read a crane chart, we’ve chosen the chart for the Terex RT345XL, a rough terrain
crane with a maximum lift capacity of 45 tons.
1. DIMENSIONS and WEIGHT — The chart shows the crane dimensions. It includes data for operation
with the outriggers extended, transport weight, and steering dimensions. Knowledge of this information
is especially critical if the crane will be working in a confined space, as the lifting capacity varies
depending on whether the outriggers are extended. The transport weight (below) determines the trailer
to be used, how to load the crane on the trailer, the route to take, and what permits are required to get
it to the jobsite.
Along the top axis, the first number is the gross vehicle weight. In the other two columns, the arrows
indicate the weight load for each axle depending on what additional accessories are loaded.

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2. LIFT CAPACITY — This is where the magic happens. In the legend at the top of the chart, you can see
these ratings apply when using 6.5 tons of counterweight, with the outriggers extended to 22
x 22.3 feet. Here, you’d graph out the specific lift the crane is needed for. The ‘ft.’ indicator on the left
axis represents the radius, the distance from the center pin to the center of the load.
EXAMPLE: You need to lift a load of 15 tons (30,000 pounds) a distance of 25 feet. The distance is
measured from the center pin of the crane to the center of the load. Once you determine the distance,
look on that line for the largest capacity; that will indicate how many feet of boom must be extended. In
this case, it is 45 feet.
It’s important to note that the maximum capacity is always measured by the shortest lift, usually over
the rear of the crane, and with the outriggers fully extended. While the Terex RT345 has a maximum
capacity of 45 tons, lifts at any distance or height drops the maximum capacity dramatically.

3. LIFT RANGE — Just as important as lift capacity is lift range. For that, a range diagram is usually
included in every chart which illustrates how much boom length is needed to pick up and lift a load both
at a distance and at height.
EXAMPLE: You need to pick up a load at 25 feet and lift it to the top of a five-story, 65-foot building.
Consulting the range diagram, 69 feet of boom is required to make the lift.

4. LIFT ANGLE — This chart illustrates the maximum lift if a luffing or fixed jib is used. Lifts with jib
lengths of 32 and 49 feet (in addition to boom extension of 105 feet) are illustrated. With higher angles
of lift, the maximum load capacity decreases. With a luffing jib, the angle can be automatically adjusted
from the operators cab. With a fixed jib, of course, the angle is fixed.

5. CRANE IN MOTION — This illustrates the lift capacity for a pick and carry. Here, the chart illustrates
the total weight able to be picked up at a 360-degree angle while stationary on wheels, the total weight
being able to be supported both while slowly rolling with the load at a zero degree angle (creep), and
the total weight able to be supported while moving at 2.5 miles per hour. The column to the left again
indicates the radius of the lift, the one to the far right, the maximum boom length each weight can be
carried at.

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 Preventive Maintenance
Considerations
Beyond the requirement
for safety inspections and repairs, OSHA 1910.179 also mandates that a maintenance program be
implemented per the manufacturer’s recommendations. Not only is this a requirement, it makes
economic sense as well. A properly maintained crane or hoist will last twice as long as one that is
neglected. If you analyze the cost of proper maintenance and the resultant decrease in unplanned
repairs with the extension of useful life, preventive maintenance is one of the best investments you can
make. The great thing is that the preventive maintenance can easily be done in conjunction with the
periodic inspections. So you get safety, reliability and equipment longevity with the same minor
expense.

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Maintenance Considerations
Maintenance Activities Before adjustments or repairs are made on a crane, all of the following
precautions must be taken: - The crane will be moved to a location where it will cause the least
interference with other rolling stock and operations in the area. - control levers will be placed in the
“off” position, all power circuit breakers and isolators will be placed in the “off” or “open” position,

45
except where power is necessary to adjust or service the crane. - a warning sign or “out of order” sign
will be placed at the operator control station. - a crane that has been adjusted or repaired must not be
returned to normal operation until all guards have been replaced, any locks removed by those who
installed them, safety devices reactivated, and the maintenance equipment removed. - all maintenance
activities may only be carried by competent persons, as recorded in the company database of
competent persons. - access behind the jib is not permitted unless the diesel generator is shut down.

LUBRICATION:
Wire rope forms an important part of many machines and structures. It is comprised of continuous wire
strands wound around a central core. There are many kinds of wire rope designed for different
applications. Most of them are steel wires made into strands wound with each other. The core can be
made of steel, rope or even plastics.
Wire ropes (cables) are identified by several parameters including size, grade of steel used, whether or
not it is preformed, by its lay, the number of strands and the number of wires in each strand.
A typical strand and wire designation is 6x19. This denotes a rope made up of six strands with 19 wires
in each strand. Different strand sizes and arrangements allow for varying degrees of rope flexibility and
resistance to crushing and abrasion. Small wires are better suited to being bent sharply over small
sheaves (pulleys). Large outer wires are preferred when the cable will be rubbed or dragged through
abrasives.
There are three types of cores. An independent wire rope core (IWRC) is normally a 6x7 wire rope with a
1x7 wire strand core resulting in a 7x7 wire rope. IWRCs have a higher tensile and bending breaking
strength than a fiber core rope and a high resistance to crushing and deformation.
A wire strand core (WSC) rope has a single wire strand as its core instead of a multistrand wire rope
core. WSC ropes are high strength and are mostly used as static or standing ropes.
Wire ropes also have fiber cores. Fiber core ropes were traditionally made with sisal rope, but may also
use plastic materials. The fiber core ropes have less strength than steel core ropes. Fiber core ropes are
quite flexible and are used in many overhead crane applications.
The lay of a wire rope is the direction that the wire strands and the strands in the cable twist. There are
four common lays: right lay, left lay, regular lay and lang lay. In a right lay rope the strands twist to the
right as it winds away from the observer. A left lay twists to the left. A regular lay rope has the wires in
the strands twisted in the opposite direction from the strands of the cable. In a lang lay rope, the twist
of the strands and the wires in the strands are both twisted the same way. Lang lay ropes are said to
have better fatigue resistance due to the flatter exposure of the wires.
Wire ropes are made mostly from high carbon steel for strength, versatility, resilience and availability
and for cost consideration. Wire ropes can be uncoated or galvanized. Several grades of steel are used
and are described 
Steel cable wire is stiff and springy. In nonpreformed rope construction, broken or cut wires will
straighten and stick out of the rope as a burr, posing a safety hazard. A preformed cable is made of wires
that are shaped so that they lie naturally in their position in the strand, preventing the wires from
protruding and potentially causing injury. Preformed wire ropes also have better fatigue resistance than
nonpreformed ropes and are ideal for working over small sheaves and around sharp angles.

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Wire Rope Lubrication
Lubricating wire ropes is a difficult proposition, regardless of the construction and composition. Ropes
with fiber cores are somewhat easier to lubricate than those made exclusively from steel materials. For
this reason, it is important to carefully consider the issue of field relubrication when selecting rope for
an application.
Wire rope lubricants have two principal functions:
• To reduce friction as the individual wires move over each other.
• To provide corrosion protection and lubrication in the core and inside wires and on the exterior
surfaces.
There are two types of wire rope lubricants, penetrating and coating. Penetrating lubricants contain a
petroleum solvent that carries the lubricant into the core of the wire rope then evaporates, leaving
behind a heavy lubricating film to protect and lubricate each strand (Figure 2). Coating lubricants
penetrate slightly, sealing the outside of the cable from moisture and reducing wear
and fretting corrosion from contact with external bodies.
Both types of wire rope lubricants are used. But because most wire ropes fail from the inside, it is
important to make sure that the center core receives sufficient lubricant. A combination approach in
which a penetrating lubricant is used to saturate the core, followed with a coating to seal and protect
the outer surface, is recommended. Wire rope lubricants can be petrolatum, asphaltic, grease,
petroleum oils or vegetable oil-based
Petrolatum compounds, with the proper additives, provide excellent corrosion and water resistance. In
addition, petrolatum compounds are translucent, allowing the technician to perform visible inspection.
Petrolatum lubricants can drip off at higher temperatures but maintain their consistency well under cold
temperature conditions.
Asphaltic compounds generally dry to a very dark hardened surface, which makes inspection difficult.
They adhere well for extended long-term storage but will crack and become brittle in cold climates.
Asphaltics are the coating type.
Various types of greases are used for wire rope lubrication. These are the coating types that penetrate
partially but usually do not saturate the rope core. Common grease thickeners include sodium, lithium,
lithium complex and aluminum complex soaps. Greases used for this application generally have a soft
semifluid consistency. They coat and achieve partial penetration if applied with pressure lubricators.
Petroleum and vegetable oils penetrate best and are the easiest to apply because proper additive design
of these penetrating types gives them excellent wear and corrosion resistance. The fluid property of oil
type lubricants helps to wash the rope to remove abrasive external contaminants.
Wire ropes are lubricated during the manufacturing process. If the rope has a fiber core center, the fiber
will be lubricated with a mineral oil or petrolatum type lubricant. The core will absorb the lubricant and
function as a reservoir for prolonged lubrication while in service.
If the rope has a steel core, the lubricant (both oil and grease type) is pumped in a stream just ahead of
the die that twists the wires into a strand. This allows complete coverage of all wires.
After the cable is put into service, relubrication is required due to loss of the original lubricant from
loading, bending and stretching of the cable. The fiber core cables dry out over time due to heat from
evaporation, and often absorb moisture. Field relubrication is necessary to minimize corrosion, protect
and preserve the rope core and wires, and thus extend the service life of the wire rope.

47
If a cable is dirty or has accumulated layers of hardened lubricant or other contaminants, it must be
cleaned with a wire brush and petroleum solvent, compressed air or steam cleaner before relubrication.
The wire rope must then be dried and lubricated immediately to prevent rusting. Field lubricants can be
applied by spray, brush, dip, drip or pressure boot. Lubricants are best applied at a drum or sheave
where the rope strands have a tendency to separate slightly due to bending to facilitate maximum
penetration to the core. If a pressure boot application is used, the lubricant is applied to the rope under
slight tension in a straight condition. Excessive lubricant application should be avoided to prevent safety
hazards.

TEMPORARY CRANES
Some lifting companies, has developed a flexible and modular temporary crane system. Our system can
be used to build a crane at any location, simply by assembling the modular components. This enables
our customers to install or replace almost any structure or equipment at any location without the
worries of getting it into position. Often, Conbit’s temporary cranes are used where normal cranes
cannot gain access or are very expensive to mobilise. This is often the case in an offshore environment
or on a very high tower or stack.
Depending on the type of lifting that needs to take place, Conbit advises either a single-boom crane, a
gantry crane or an even more specialised crane solution. All Conbit cranes can be manually installed.
Each modular assembly is completed with structural calculations and load tests, as well as installation
and work procedures. Load plans and load-carrying capacity checks of the installation location are
standard aspects of Conbit’s scope of work.

SINGLE-BOOM CRANES
One of many temporary crane types is the single-boom (or derrick) crane. We supply single-boom cranes
with lifting capacities ranging from 1 to 30 tonnes. Single-boom cranes can also be used in a duo-lift
setup to double the total lifting capacity. For each required capacity, a different configuration is
assembled. This is the main advantage modular design of crane components.

GANTRY CRANES
If space is limited or crane stability is essential, we advise the use of a gantry crane. The advantage of a
gantry crane is that it can lift objects between the gantry legs. This allows a limited lifting distance with a
low-weight structure. Due to its shape, it is a highly stable lifting solution. Off-lead and side-lead forces
of the load can easily be absorbed by this type of crane. Also, lifting operations on moving objects such
as vessels or FPSO’s are preferably executed using gantry-crane solutions.

SPECIAL CRANES
Conbit has designed many special cranes using its modular parts. In many cases, each lifting job requires
a customised crane assembly. This is the case, for example, when lifting below a deck or inside a
structure.

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Inspection Records
Crane owners are required by law to undertake a preventative maintenance program, which includes
regular major inspections of their crane (refer to AS2550) to prevent breakdowns and failures before
they occur.
Recently WorkSafe has become aware of concerns with the authenticity of some records of major
inspections and is investigating these allegations

Recommendations
Crane owners should ensure they:
1. Only engage suitably qualified persons to undertake a major inspection of their crane.
2. Keep a record of all details of the persons engaged to undertake the work, including the
engineer supervising the assessment for continued safe operation, and any persons or
contractors undertaking parts of the work.
3. Review any reports provided in regard to the inspection activity and ensure, that so far as is
possible, records are signed and authorized appropriately.

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50
Inventory records

51
PROPER INSPECTION OF WIRE ROPES
The wire rope on your hoist, just like the tires on your car incur the brunt of the wear and tear of daily
use.  Wire ropes have a finite life that is much shorter than the expected life of the hoist.  Improperly
installed, poorly lubricated, worn and damaged hoisting ropes routinely fail, causing the potential for a
catastrophic accident.  In fact a hoisting rope that was in perfect condition the day before can be ruined
by a single damaging lift that causes a kink or bird cage.
Properly trained and experienced personnel must inspect the wire rope on hoists on a regular basis in
accordance with ANSI and OSHA standards and regulations as well as the manufacturer’s
recommendation. In addition, the operator is responsible to complete visual inspections before each
shift and before lifting a load. 
This fact sheet provides information to determine if a wire rope is damaged and should be replaced. The
use of worn or damaged wire rope can lead to a rapid failure and a drop of a load, which could result in
serious injury or death. 

HOW DO YOU VISUALLY INSPECT WIRE ROPES?

Use the "rag-and-visual" method to check for external damage. Grab the rope lightly and with a rag or
cotton cloth, move the rag slowly along the wire. Broken wires will often "porcupine" (stick out) and
these broken wires will snag on the rag. If the cloth catches, stop and visually assess the rope. It is also
important to visually inspect the wire (without a rag). Some wire breaks will not porcupine.
Measure the rope diameter. Compare the rope diameter measurements with the original diameter. If
the measurements are different, this change indicates external and/or internal rope damage. 
Visually check for abrasions, corrosion, pitting, and lubrication inside the rope. Insert a marlin spike
beneath two strands and rotate to lift strands and open rope.

WIRE ROPE VISUAL INSPECTION  - REPLACE WIRE ROPE IF ONE OF THE FOLLOWING CONDITIONS
EXISTS. 
 Broken wires or excessive wear
 12 randomly broken wires in one lay of rope
 4 broken wires in one strand in one lay
 1 outer wire is broken at the contact point with the core, which has worked its way out
 Wear on individual wires to of ⅓ of original diameter Kinks • 
 Tight kinks – Shortens lay 
 Open kinks – Opens the lay – Caused by sudden release of the load – Hoist operating in
restricted area
 Wear beyond the nominal diameter- The rope diameter for a given rope size, measured across
the high points of the rope. Replace wire rope if the diameter reduction is greater than the
allowable reduction listed below 

WHAT CAN CAUSE A WIRE ROPE TO BREAK?

 Wear on areas that are in contact with hoist sheaves and drums.

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  Corrosion from lack of lubrication and exposure to heat or moisture (e.g., wire rope shows signs
of pitting). A fibre core rope will dry out and break at temperatures above 120°C (250°F).
 Fatigue from repeated bending even under normal operating conditions.
 Overloading the safe working load limit. Follow manufacturers' charts. 
 Mechanical abuse - crushing, cutting or dragging of rope.
 Being used when frozen - if work is performed at lower than 15.5°C, the use of the sling should
follow the manufacturer's recommendations.
Kinks from the improper installation of new rope, the sudden release of a load or knots made to shorten
a rope. A kink cannot be removed without creating a weak section. Discarding kinked rope is best.

Preventive maintenance
A preventive maintenance program based on the crane manufacturer's recommendations shall be
established. 

Maintenance procedure
 Before adjustments and repairs are started on a crane the following precautions shall be taken: 
 The crane to be repaired shall be run to a location where it will cause the least interference with
other cranes and operations in the area. 
 All controllers shall be at the off position. 
 The main or emergency switch shall be open and locked in the open position. 
 Warning or "out of order" signs shall be placed on the crane, also on the floor beneath or on the
hook where visible from the floor.
 Where other cranes are in operation on the same runway, rail stops or other suitable means
shall be provided to prevent interference with the idle crane. 
 After adjustments and repairs have been made the crane shall not be operated until all guards
have been reinstalled, safety devices reactivated and maintenance equipment removed.

Adjustments and repairs

 Any unsafe conditions disclosed by the inspection requirements of paragraph (j) of this section
shall be corrected before operation of the crane is resumed. Adjustments and repairs shall be
done only by designated personnel. 
 Adjustments shall be maintained to assure correct functioning of components. The following are
examples: 
 All functional operating mechanisms. 
 Limit switches. 
 Control systems. 
 Brakes. 
 Power plants. 
 Repairs or replacements shall be provided promptly as needed for safe operation. The following
are examples: 

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  Crane hooks showing defects described in paragraph (j)(2)(iii) of this section shall be discarded.
Repairs by welding or reshaping are not generally recommended. If such repairs are attempted
they shall only be done under competent supervision and the hook shall be tested to the load
requirements of paragraph (k)(2) of this section before further use. 
 Load attachment chains and rope slings showing defects described in paragraph (j)(2) (iv) and (v)
of this section respectively. 
 All critical parts which are cracked, broken, bent, or excessively worn. 
 Pendant control stations shall be kept clean and function labels kept legible.

Pre-Use Inspection of Crane Components

Crane pre-use inspections are required to ensure that the crane is in its perfect condition and operating
optimally. Operators or site managers need to complete this checklist before each crane shift to ensure
the safety of the crane operator, other workers on the site, and the public.

This page will discuss:

 Crane pre-use inspection checklist requirements
 The purpose of the crane pre-use inspection checklist

What are the requirements of a crane pre-use inspection checklist?

According to federal and state regulatory authorities, crane pre-use inspections should follow the ISO
standards, particularly ISO 9927-1 and ISO 4309. This checklist covers all the crucial aspects of
maintenance, enabling the operators to determine the crane's condition before use. It covers the critical
components related to user and workplace safety, as the crane manufacturers and/or professional
engineers or company provides.
‍
Who conducts crane pre-use inspections?
Crane operators, workplace managers, and companies can use a crane pre-use inspection checklist
before every crane operation to ensure all its components are correctly working. The checklist
comprehensively outlines the crane components before starting the crane operation. It helps identify
any defects, damage, wear and tear, and any other problems in the crane to ensure user and workplace
environment safety.

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Testing
  Crack testing of booms and counterweight sheave bracket welds
Booms on non-self-erecting tower cranes are connected by pins passing through male and
female clevises on the ends of each boom section. Every weld on male and female clevises
on the ends of every boom section should undergo NDT before each crane erection for
non-self-erecting cranes. Magnetic particle testing is the usual method
used for performing these tests.

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Counterweight sheave bracket welds, butt heal bosses and welds in cruciform area on
luffing crane booms are known to crack and should also be crack tested by NDT before
each crane erection.

Crack testing of band brakes

Older designs of luffing tower cranes use band brakes. On some of these cranes the steel
band is welded to an end fitting that has a pin passing through it. These welds have been
known to crack.
You should crack test the weld between the band and the end fitting by NDT before each
time a luffing tower crane fitted with band brakes is erected, keeping in mind there may
not be a weld on some brake bands.

Crack testing of slew ring bolts

The integrity of slew ring bolts is critical for making sure both the machine deck and boom
remain attached to the tower. Once removed, slew ring bolts should be replaced unless the
manufacturer’s instructions state they can be reused. If bolts can be reused they should be
tested.
For tower cranes where the slew ring needs to be split each time the crane is moved,
NDT 10 per cent of slew ring bolts is suggested. Bolts to be tested should be selected from the slew
ring by a competent person. Complete removal of the bolts from the slew ring and use
of magnetic particle testing is recommended. If cracks are detected, bolts should be
discarded and replaced with new bolts.

Crack testing of tower bolts or pins

Tower bolts or pins are a critical part of the crane and permit the effective transfer of load
from the crane boom to the crane base. Tower bolts or pins can become damaged and
their effective life can be reduced if the bolts are either under or over-torqued. Some tower
bolts are made from extremely high grade steel and can be more susceptible to cracking.
Unless the manufacturer’s instructions state tower bolts can be reused, they should be
replaced. If bolts can be reused, crack test a minimum of 10 per cent of tower bolts by
NDT before each crane erection. If cracks are found, tower bolts should be discarded and
replaced with new bolts.
A system that makes sure tower bolts or pins are tested over time is preferred. However
a random system of testing can also be used. The tested bolts should be identified by
a method that does not damage the bolt.

Chord thickness testing

Steel lattice-type tower crane booms can be prone to internal and external corrosion
affecting the thickness of the boom. The thickness of the chord wall can be reduced
through abrasive blasting of the boom.

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Main chord sections on tower crane booms should undergo thickness testing at intervals
not exceeding 10 years. Ultrasonic thickness testing is one method of verifying the strength
in the chords of the boom.
Review chord sections for structural adequacy when the thickness is shown by testing
to be 90 per cent or less than 90 per cent of the original thickness.
Further information
The following technical standards provide further information on inspecting and
maintaining cranes:

 AS 2550.1-2011: Cranes, hoists and winches—Safe use Part 1: General requirements

 AS 2550.3-2002: Cranes, hoists and winches—Safe use Part 3: Bridge, gantry,
portal(including container cranes) jib and monorail cranes
 AS 2550.4-2004: Cranes, hoists and winches—Safe use Part 4: Tower cranes
 AS 2550.5-2002: Cranes, hoists and winches—Safe use Part 5: Mobile cranes
 AS 2550.11-2004: Cranes, hoists and winches—Safe use Part 11: Vehicle-loading cranes,
 AS 2550.20-2005: Cranes, hoists and winches—Safe use Part 20: Self-erecting tower
cranes.

Component tested NDT description NDT frequency

Boom clevises Crack test Pre-erection
Counterweight sheave bracket welds – Crack test Pre-erection
moving
counterweights only
Cruciform welds – luffing cranes onl Crack test Pre-erection
Butt heal bosses – luffing cranes onl Crack test Pre-erection
Band brake welds Crack test Pre-erection
Slew ring bolts – where slew ring has to be Crack test minimum 10% Pre-erection
split at disassembly bolts
Tower bolts (where applicable Crack test minimum 10% Pre-erection
Boom lacing welds Crack test minimum 10% Pre-erection
Tower sections Crack test minimum 10% Pre-erection
Aluminium sheaves Crack test Pre-erection
Slew ring bolts – slew ring Crack test bolts 5 years
Boom chord thickness Material thickness testing 10 years
Slew ring Crack test 10 years
Hydraulic luffing cylinder gland nut Crack test 10 years
Hydraulic luffing cylinder and ram-rod ends Crack test 10 years
and caps
A-frame – connector welds on primary chords Crack test 10 years
A-frame lacing welds Crack test 10 years
Hook Crack test 10 years
Welds on hook trolley Crack test 10 years

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testing for tower cranes
Pre-erection inspections / tests
 NDT of welds on vital
components
including boom clevises,
butt heel
bosses and counterweight
rope sheave
brackets
 NDT of tower crane bolts
 NDT of slew ring bolts
 NDT of aluminium
sheave
 The condition of the
power supply
cable—where used
 The condition of motor
brake
 The condition of the
slew ring gear and
pinions
 Air controls and
associated valve
 The condition of ropes
and sheaves e.g.
erecting, hoisting,
counterweight and
trolley, correct rope
tracking and no
signs of damage or excess
wea
 The condition of limit
switches and
limiting devices
 The condition of
counterweights
 The condition and
fitment of machinery
guarding
 Brake systems can be
dismantled and
Commissioning inspections / Major inspection
tests
 Crane electricity supply  Slew Ring
—where used  Hydraulic motors
 Crane base weights or  Hydraulic pumps
ballast—where  Valve blocks
used (bodies)
 Tower section  Hoist and luff drums
identification and  Braking systems
entry  Rope sheaves
 Tower bolts to correct  Hydraulic luffing
tension cylinder
 Pins and fastenings  Gear boxes and
 Climbing frame and drive shafts
connection  Boom
 Jib connection pins and  A-frame
retainers  Pins with moving
 A-frame connections parts for example,
and retainers— boom heel pins and
where applicable ram pins
 Jib and deck pendant  Static pins
pins and  Steel wire ropes
retainers—where used
 Machinery guarding
 Leakage in lines, tanks,
valves, pumps
and other parts of air or
hydraulic
systems
 The condition of the
ropes and
sheaves e.g. erecting,
hoisting, trolley
and counterweight, and
correct rope
tracking
 Isolating switches
 The condition and
phase of the
power supply cable
 Verification the crane
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 inspected for wear and wiring
damage complies with AS/NZS
 dry brakes— 3000:2007:
before each erection Electrical installations
or  Effective operation of
more frequently if controls
directed by the including interlocks
manufacturer  Effective operation of
 wet brakes— indicating
before each erection devices
or  Effective operation of
after 5 000 hours of travel
crane operation deceleration switches
or as directed by the  Effective operation of
manufacturer hoist upper
 Normal service items and lower—where needed
including items —working
supplied by the crane limit switches
manufacturer e.g.  Effective operation of
temperature control units warning
and seating devices
being maintained in a  Effective operation of
serviceable weather-
condition according to the vaning
crane  Effective operation of
manufacturer’s the hoist and
instructions, and travel brakes when the
 Other tests as specified crane is laden
by the to the maximum rated
manufacturer. capacity
 Once the tower crane  Effective operation of
components have the rescue
been delivered to the controlled descent device
workplace they  Other tests specified by
should be inspected by a the crane
competent manufacturer.
person for possible damage
and
wear that may have
occurred during
transport. Inspections
should include:

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  The crane base design
and engineer’s
repor
 Crane ties and structure
to support
them where used
 The power supply and
earthing
testing for mobile cranes
Major inspection
 Chassis including outriggers and boxe
 Drive train and suspension component
 Slew ring
 Slew ring bolts
 Hook rollers
 Drive systems including winches, hydraulic motors, gearboxes and drive-shaft
 Control systems
 Braking systems
 Electrical systems
 Hydraulic systems—cylinders including outrigger cylinders
 Booms
 Safety devices including rated capacity limiters and load indicator
 Outriggers
 Steel wire ropes, and
 Rope sheaves
 Electrical systems—hazardous voltage
 Control systems—non-hazardous voltage
 Electric motors
 Hook assembly

Component Storage and Handling

In order to reduce to a minimum the risk of damage or deterioration which may affect the safety of
equipment, it is essential to provide suitable storage for equipment not in use and in many cases to
prepare it for storage first
The ideal storage requirements vary according to the nature of equipment and reference shall be made
to manufacturers literature. However, in general the storage area should be dry, free from injurious
pollution and not subject to extreme temperatures. Equipment embodying exposed threads or
machined bearing surfaces (e.g. eyebolts, shackles) should be protected and handled with care.
Equipment which is returned to stores wet or has been subject to other substances liable to cause
deterioration should be treated with special care. In particular, it should be remembered that solutions
of chemicals will become more concentrated as the solvent evaporates, e.g. weak acids will become
strong acids. In these circumstances the general advice is to clean and dry the equipment into storage

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The area should be designated for the purpose and preferably controlled to restrict access of
unauthorised persons.
Bins, racks, etc. should be provided and only the heavier, more robust, items allowed to lie on the floor.
Requirements for storing individual items are given in the appropriate sections of the code
When not in use, lifting appliances should be returned to storage or parked in a safe position such as at
the end of a runway. When parked, the hook should be raised so as not to be a danger to persons who
may be walking by or working in the area and to ensure it cannot become accidentally engaged with
anything in the vicinity. In the case of chain, the slack chain should be housed in the slack chain
collecting box if fitted. If a slack chain collecting box is not fitted, ensure the hanging loop of chain does
not present a danger. When lifting appliances are returned to storage, the conditions should meet the
requirements recommended above

Operating Practices
General practices
Operating Rules for Crane Operators
 1. The crane should be centered over the load before starting the hoist to avoid swinging of the
load as lifting starts. Load should not be swung by cranes to reach areas not under or within
reach of crane.
 Crane should be operated smoothly to avoid jerk & abrupt movements of the load. Slack must
be taken from the sling & hoisting ropes before the load is lifted.
 The crane hoisting ropes should be kept vertical. Crane must not be used for side pulls
 The area should be clear and all persons in the area aware when load is lifted. This is to be
ensured by a warning signal while lifting, lowering & while moving. Additional warning signal to
be used in high traffic density area.
 The load should be checked to be certain that it is lifted high enough to clear all obstructions
and personnel when moving.
 Loads must not be carried over people, especially loads carried by magnets. Load or part of
loads, held magnetically may drop. Failure in power to magnets will result in dropping of the
load unless back up power supply is furnished.
 Lifts should not be attempted beyond the rated load capacity of the crane, sling ropes chains
etc.
 On all capacity or near capacity loads, the hoist brakes should be tested by returning the motor
switch or push button to the OFF position after raising the load a few inches off the floor. If the
hoist brakes do not hold the load should be set on the floor and the crane not further operated.
The defect should be reported immediately to the supervisor.
 Before moving a load, load slings, load chains or other load lifting devices must be fully seated
on the saddle of the hook.
 The block should never be lowered below the point where less than two full wraps of the rope
remain on the drum. Should all the rope get unwrapped from the drum, it should be rewound in
the drum groove in the correct direction and seated properly in the groove otherwise the rope

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 may get damaged and the hoist limit switch will not operate to stop the hoist in the high
position
 At no time a load should be held suspended from the crane with the power "ON" unless the
operator is at the operators switch. Under this condition the load should be kept as close as
possible to the floor to minimize the possibility of an injury if the load should drop.
 When a hitcher is used, it is the joint responsibility of the crane operator and the hitcher to see
that hitches are secure and that all loose materials has been removed from the load before
starting a lift.
 Sling hooks hanging loose should not be used to lift loads (if slings hooks are not needed, they
should be properly stored).
 All slings or ropes should be removed from the crane hooks when not in use (Dangling slings or
hooks hung in sling rings can inadvertently snag other objects when moving the crane).
 The crane should not be operated if limit switches are out of order or if ropes show defects or
wear.16. Crane operators should not use limit switches to stop the hoist under normal operating
conditions. (These are emergency device and should not be used as operating controls).
 Limit switch should not be blocked adjusted or disconnected in order to go higher than what
switch will allow.
 Electrical limit switches or warning devices should never be by passed.
 Upper limit switches and lower limit switches should be tested in stopping the hoist at the
beginning of each shift or as frequently as may be directed.
 Load limit switch or overload devices must not be used to measure loads being lifted. This is an
emergency switching device and is not to be used as a production operating control.
 A crane should never move or bump another crane that has a warning signal displayed.
 Contact with runway stops or other cranes shall be made with extreme caution. The operator
must take particular care for the safety of persons on or below the crane and only after making
certain that persons on the other cranes are aware of what is being done.
 If plugging protector is not provided, the controller must always be stopped momentarily in OFF
position before reversing (A slight pause is necessary to give the braking mechanism time to
operate).
 In case of an emergency or swing inspection, repairing, cleaning or lubricating a warning sign or
signal should be displayed and the main switch should be locked in OFF position.
 An attempt should never be made to close a switch that has an OUT OF ORDER or DO NOT
OPERATE card on it. It is necessary to make a careful check to determine that no one else is
working on crane, before removing the card.
 If the electrical power is disrupted, the controllers must be placed in OFF position and kept there
until power is again available.
 Before closing main or emergency switches, all controllers must be in OFF position before
reversing except to avoid accidents (a slight pause is necessary to give the braking mechanism
time to operate)
 Before leaving the crane the operator should perform the following:a. Raise all hooks to an
intermediate position. B. Spot the crane at an approved designated locationc. Place all controls

62
 in OFF position.d. Open the main switch to the OFF position,.e. Make visual check before leaving
the crane.

Crane operator aids

Safety devices and operational aids must not be used as a substitute for the exercise of professional
judgment by the operator.

Safety Devices
The following safety devices are required on all equipment unless otherwise specified:
 Crane level indicator (except on portal cranes, derricks, floating cranes/derricks and land
cranes/ derricks on barges, pontoons, vessels or other means of flotation)
 Boom stops (except for derricks and hydraulic booms)
 Jib stops (if a jib is attached), except for derricks
 Locks on foot pedal brakes
 Integral holding device/check valve on hydraulic outrigger jacks and hydraulic stabilizer jacks
 Rail clamps and rail stops for equipment on rails (except portal cranes)
 Horn (either built into the equipment or on the equipment and immediately available to the
operator)

Operational Aids
These are divided into two categories that differ in the amount of time the equipment may operate
before they are repaired. While an operational aid is not working properly, the temporary alternative
measures specified in the standard must be taken. Category I aids must be repaired within seven
calendar days after a deficiency occurs, while equipment may operate for 30 calendar days before a
Category II aid is repaired. In both cases, additional time is permitted if a necessary part is ordered in a
timely manner but is not received within the seven- or 30-day period.
Certain operational aids are only required on equipment manufactured after a specified date. In some
cases, these are past dates that reflect when these devices began to be installed on equipment. In other
cases, they are future dates that are intended to give manufacturers time to install the devices on new
equipment.

Category I Operational Aids

 Boom hoist limiting device (required on equipment manufactured after December 16, 1969).
 Luffing jib limiting device.
 Automatic anti two-blocking device (required on telescopic boom cranes manufactured after
February 28, 1992; lattice boom cranes manufactured after November 8, 2011; derricks
manufactured after November 8, 2011; articulating cranes equipped with a load hoist
manufactured after December 31, 1999; digger derricks manufactured after November 8, 2011).
 Automatic or warning-type anti two-blocking device (required on lattice boom cranes
manufactured after February 28, 1992 and before November 8, 2011).

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Note: Two-block protection is not required for lattice boom equipment used for dragline, clamshell
(grapple), magnet, drop ball, container handling, concrete bucket, marine operations that do not involve
hoisting personnel, and pile driving work.

Category II Operational Aids

 Boom angle or radius indicator (required on all equipment, except digger derricks
manufactured before November 9, 2010)
 Jib angle indicator if the equipment has a luffing jib
 Boom length indicator if the equipment has a telescopic boom (unless the rated capacity is
independent of the boom length)
 Load weighing and similar devices (required on equipment (other than derricks, articulating
cranes, and digger derricks manufactured before November 8, 2011) manufactured after March 29,
2003 with a rated capacity over 6,000 pounds)
 Automatic overload prevention device, load weighing device, load moment (or rated capacity)
indicator, or load moment (rated capacity) limiter (required on articulating cranes manufactured
after November 8, 2011)
 Outrigger/stabilizer position (horizontal beam extension) sensor/monitor if the equipment
has outriggers or stabilizers (required on equipment manufactured after November 8, 2011)
 Hoist drum rotation indicator if the equipment has a hoist drum not visible from the
operator’s station (required on equipment manufactured after November 8, 2011)
NOTE: Articulating cranes need not be equipped with boom angle or radius indicators, jib angle
indicators, or boom length indicators.

Safety systems and procedures

Whether you’re considering upgrading or modernizing your older crane system, or you’re designing the
specifications for a new overhead crane system, your number one goal should be to improve the safety
of the overhead crane equipment and production processes at your facility.
With modern technologies becoming more readily available and more affordable, the safety features
available for overhead crane systems have never been better. Newer technologies now allow for:
 Remote monitoring and diagnostic information for individual components
 Automated drives to control the speed and motion of the crane
 Radio controls
 Collision avoidance systems
 Overload sensors and read-outs

What Type of Equipment or Systems are Available for Overhead Crane Safety?
OSHA states that Fall Protection is the #1 most frequently cited violation and they’ve established
industry specific requirements (OSHA 1926.501 – Duty to Have Fall Protection) to reduce the risk that
comes with working at height.
You may be surprised to learn that you can be cited for failing to use fall protection equipment at
working heights of as little as 4-8 feet. See below for industry-specific guidelines:

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  Four feet – General industry
 Five feet – Shipyards
 Six feet – Construction
 Eight feet – Longshore operations
Fortunately, compliance in fall protection is increasing and reaching the board rooms of many corporate
executives—in part, because enforcement of mandatory training in fall protection started in May of
2017. If employers are not providing training on fall protection to their employees that are working at
height, they can be cited for it.
Many business owners are looking to add fall restraints and engineered lifeline systems to existing
overhead crane equipment, and are having it included in the specifications for new crane equipment
being installed in their facility. Any operator or maintenance personnel working at heights, or
performing service or inspections from a lift, should have some form of fall protection—whether it’s a
lifeline system engineered into the design of the crane itself, or lanyards or harnesses available for their
employees.
Crane walkways can also be designed for higher capacity cranes to provide maintenance personnel with
a place to safely tie-off and service or inspect their crane. Walkways can also be designed with kick
plates to avoid items falling off the edge onto workers below.

Buzzers, Horns, and Sirens

Per OSHA 1910.179, cranes equipped with radio controls or cab controls are required to have buzzers,
horns, or sirens to provide an audible warning to other personnel while the crane or loads are in motion.
These can also be added in addition to using a warning light for personnel on the ground who may not
be able to see the crane’s warning lights.
In addition to the OSHA requirements, you should familiarize yourself with your state and local codes for
audible warning device requirements. Some states like Michigan and California require the use of
audible warning devices for any crane in motion—regardless of what control method the crane is using.

Warning Lights and Indicator Lights

Warning lights and indicator lights can be built into the design of an overhead crane to provide
personnel on the ground with an idea of where the crane bridge is overhead and where the hook will be.
These lights are automatically on when the crane equipment is turned on and running—helping to
reduce accidents and operator error.
These bright red, blue, or white lights are mounted on the bridge or hoist of the crane and project
directly onto the ground using lasers, LED lights, or a combination of both. The warning lights don’t take
place of audible alarms, but provide an additional visual warning to pedestrian and motorized traffic in
the immediate vicinity of the crane. These lights can illuminate an area up to 15 to 20 feet from
approaching hooks and crane equipment in operation.
Operators can also use these lights as a point of reference tool to help them position the hoist and hook
to make their picks or position a load.
OSHA 29 CFR 1910.179 requires the use of warning lights for any cab-operated overhead crane.

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Variable Frequency Drives and Anti-Sway Technologies
With the introduction of variable frequency drives, microprocessors now control all the components of
the drive system, and provide smoother acceleration and deceleration curves. This allows for smooth
starts, smooth transitions, and smooth stopping which greatly reduces the strain on the gear boxes,
couplers, girders, and other essential crane components. This also greatly prolongs the life of the brake
system as the microprocessor controls and slows down the motor, while the brakes mostly act as a
control to keep the crane from moving.
Also, by eliminating the abrupt starting and stopping of the crane, you get far less load swing because
the crane moves in a controlled manner—making it safer for everyone on the floor.
On the Columbus McKinnon Blog, they highlight some of the inherent safety features built into most
VFD systems:
 Safe Torque Off – A redundant hardware safety circuit that guarantees motor and brake power
are removed when an E-STOP switch or safety controller opens the drive input, eliminating the
need for external disconnects.
 Torque Proving – On some older systems, the motor is pre-torqued to guarantee that the load
can be held before opening the brake.
 Load Check – Continuously checks for hoist overloads and prevents the hoist from lifting when
an overload condition is detected.
 Brake Checks – Monitors the opening and closing of a brake to ensure that it is safe and healthy.
 Micro-Speed – Allows the operator to make slow, precise movements.
 Electronic Programmable Limit Switches– Allows slow down and stop limits without physically
geared limit switches.

Collision Avoidance Systems

As the demand for workplace safety grows, collision avoidance systems have become popular as an
automated way to control the motion of the crane to avoid accidents and collisions. Anti-collision
technologies are becoming more common in facilities that are operating multiple cranes on one runway,
have multiple runway systems in place, or have cranes operating in areas where there may be other
obstacles or obstructions that can block the movement of the crane.
Collision avoidance systems use wired or wireless transmitters that emit radio waves, lasers, LED, or
infrared light signals to transmit information to stationary receivers. These receivers process the signal
from the transmitting device and use that information to determine the location of the trolley and
bridge anywhere in the facility and what obstacles it may encounter. It can then slow or stop the motion
of the crane or trolley if it determines there is the possibility for a collision. This helps prevent
unintentional contact of the crane or trolley with mechanical end stops and other crane or monorail
equipment in operation.
Another benefit of collision avoidance systems is they can be used to help prevent overloading of a
runway system that multiple cranes are operating on. Keeping cranes far enough apart, whether they’re
carrying a load or not, will help prevent undue stress and overloading on certain parts of the runway
beams and supports.

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Slow Down and Stop Limit Switches
Limit switches can be used for a variety of motion controls on an overhead crane. There can be multiple
limit switches used in sequence to slow down and stop the travel of an overhead crane’s bridge, hoist,
or hook block before it makes hard contact with something that could cause load swing.
As the crane approaches the end of its safe travel limit, an electrical or mechanical switch will trigger
and begin to slow down the hoist motion or travel of the bridge. If the hoist or bridge continue to travel,
they will activate a stop switch which will immediately stop the motion altogether before it hits an end
stop.
There can also be multiple limits set for the lifting and lowering motions of the hoist. When triggered,
limit switches on a hoist can manage all of the following:
Provide slowing and stopping motions to reduce mechanical wear on the hoist
Control the speed and the height of the lifting or lowering motion to prevent load swing
Provide a final safeguard to prevent the hoist block from making contact with the floor or the drum,
which can cause the load to swing violently and even break the wire rope

Remote Radio Controls

A wireless remote transmitter with a series of buttons or levers is either held by the operator or is
clipped onto a harness or belt worn by the operator. The remote transmitter sends a radio signal to a
receiver unit mounted on the crane. This unit transforms the signal into electrical energy and passes it
on to the intermediate relay unit on the crane, and the appropriate contact is activated to then move
the crane up and down the runway, move the hoist or trolley side to side, and raise or lower the hook.
The main advantage of using radio controls for an overhead crane is that it eliminates the dependence
on being tethered to the crane itself—either via cab controls or pendant controls. Because the operator
doesn’t have to be near the load to lift, position, or lower it, radio controls can help protect them from
hazards like:
 Vapor, smoke, or chemical exposure
 Radiation
 High heat or hot metals
 High voltage or electric shock
 High humidity
Not only can the operator work on the floor safely away from hazards, but they’ll also get a better
vantage point to perform the lifts effectively. The operator doesn’t necessarily have to walk with the
load as it moves down the crane bay, so radio controls help keep the operator away from trip or fall
hazards like obstacles on the floor, workers, and other machinery or equipment in operation. They’re
also ideal for higher duty classes like D, E, or F where the crane runs up and down the runways more
often, and at a faster rate.
Productivity can also be improved with better visibility—helping with faster load positioning and damage
control as the operator can better judge load and clearance obstacles from the ground.

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Brake-Slip Detection
If you choose to upgrade your crane’s brake system at the same time that you add variable frequency
drive controls, you can greatly reduce the wear and tear and maintenance on your brake system. Having
a microprocessor control the motor and slow the crane’s motion versus using the brakes to slow down
the crane, can prolong the life of the brake system.
Overhead cranes with older brake systems can benefit from newer technologies like wear sensors and
auto-adjust features. Auto-adjust features make sure the brake is always in proper adjustment, and
doesn’t require maintenance or service personnel to manually and repeatedly adjust the brakes. This
results in equal wear on the brake pads and less wear and tear on the moving components. When the
sensors detect anything out of the predetermined variance, they can inform maintenance personnel
when brake adjustment is needed.

Monitoring and Diagnostics

Cranes equipped with variable frequency drives or modern-style radio controls have the ability to
provide diagnostics and monitoring of overhead crane equipment either on the equipment itself or to
users in a remote location.
Operators, and production or maintenance personnel can use a radio or belly box, mobile device, tablet,
or workstation computer to view real-time diagnostic data, including:
 Number of lifts and cycles that the drives have made
 Fault codes
 Capacity of lifts
 Maintenance requirements and intervals for individual components
 System amp draw and voltage
Maintenance personnel can monitor the time between recommended maintenance intervals for
individual components and also use it as a tool to schedule preventative maintenance to help reduce
equipment downtime. For example, by monitoring the predictable preventative maintenance schedule
of a crane’s hoist, they can help improve the crane’s safety by knowing when the hoist has reached the
end of its useful life so that they can either rebuild the internal components or replace it with an entirely
new unit.
This diagnostic information also helps maintenance personnel troubleshoot problems with overhead
crane equipment, and gives others the ability to remotely access the data and troubleshoot for more
complex issues or specialized problems.
Another advantage to having a monitoring and diagnostics system is that the crane can alert the
operator, safety managers, or other designated personnel if it has been overloaded. An overload occurs
when a lift exceeds the crane’s rated capacity. Overloads are prohibited according to OSHA and ASME
B30 standards, and can stress and damage the crane equipment—putting nearby employees in danger if
the crane were to fail.
If the crane is making a lift near, at, or in excess of a calibrated capacity, the drive system can send a
read-out to end-users through a variety of methods, including:
 Displaying on the operator’s radio control or belly box
 Displaying on pendant stations equipped with an LED read-out

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  Displaying on the crane itself, so the operator can read the load the crane is lifting
 Sending it to a remote laptop or workstation
There are also more basic ways to determine if you’re overloading a crane’s capacity, including installing
a load cell sensor that measures the tension force on the hoist’s wire rope. When the load exceeds a
pre-determined percentage of the rated capacity (usually 100-125%), the overload device temporarily
stops the hoist so that the only further action the crane can perform is to lower the load.

Wrapping it Up
Ultimately, providing training for your overhead crane operators is the most important thing you can do
to make your overhead lifting program safer. A 30-year old crane with single or dual speed drives can be
operated just as safely as a brand new crane with variable frequency drives and a collision avoidance
system. It doesn’t matter how many bells and whistles you add to an overhead crane system if the
operators haven’t been trained on how to run it safely.
As the owner of the crane equipment, it’s up to you to arrange for the following:
 Have your operators trained by a Qualified Person (per ASME and CMAA)
 Determine the frequency of training your operators receive
 Have your overhead crane inspected to OSHA, ASME, and CMAA standards

Handling the Load

OSHA 1910.179 Overhead & Gantry Cranes Regulations
The following excerpt is taken directly from OSHA 1910.179*
Size of load
 The crane shall not be loaded beyond its rated load except for test purposes as provided in
paragraph (k) of this section.

Attaching the load

 The hoist chain or hoist rope shall be free from kinks or twists and shall not be wrapped around
the load.
 The load shall be attached to the load block hook by means of slings or other approved devices.
 Care shall be taken to make certain that the sling clears all obstacles.

Moving the load

 The load shall be well secured and properly balanced in the sling or lifting device before it is
lifted more than a few inches.
 Before starting to hoist the following conditions shall be noted:
o Hoist rope shall not be kinked.
o Multiple part lines shall not be twisted around each other.
o The hook shall be brought over the load in such a manner as to prevent swinging.
 During hoisting care shall be taken that:
o There is no sudden acceleration or deceleration of the moving load.
o The load does not contact any obstructions.

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  Cranes shall not be used for side pulls except when specifically authorized by a responsible
person who has determined that the stability of the crane is not thereby endangered and that
various parts of the crane will not be overstressed.
 While any employee is on the load or hook, there shall be no hoisting, lowering, or traveling.
 The employer shall require that the operator avoid carrying loads over people.
 The operator shall test the brakes each time a load approaching the rated load is handled. The
brakes shall be tested by raising the load a few inches and applying the brakes.
 The load shall not be lowered below the point where less than two full wraps of rope remain on
the hoisting drum.
 When two or more cranes are used to lift a load one qualified responsible person shall be in
charge of the operation. He shall analyze the operation and instruct all personnel involved in the
proper positioning, rigging of the load, and the movements to be made.
 The employer shall insure that the operator does not leave his position at the controls while the
load is suspended.
 When starting the bridge and when the load or hook approaches near or over personnel, the
warning signal shall be sounded.

Hoist limit switch

 At the beginning of each operator's shift, the upper limit switch of each hoist, shall be tried out
under no load. Extreme care shall be exercised; the block shall be "inched" into the limit or run
in at slow speed. If the switch does not operate properly, the appointed person shall be
immediately notified.
 The hoist limit switch which controls the upper limit of travel of the load block shall never be
used as an operating control.

Personnel Transfer
General requirements for personnel transfer

Generally the crane shall apply to DIN EN 13852-1 for loading and discharging goods in the applied range
of service and applicable environmental conditions. Due to higher safety aspects for personnel transfers
additional requirements shall apply:
 separate mode for personnel transfer started by a key-operated switch - this specific mode shall
be able to guarantee both soft acceleration and retardation
 normal lifting and lowering speed during personnel transfers shall be reduced to 0.5 m/s
maximum
 secondary break circuit with an independent and separate control
 design of cylinders (Approval of Certifying Body and test certificate acc. to DIN EN 10204 type
3.2 required)
 manual release system for both lowering of the boom and load for leaving the carrier in a safe
way

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  range of service shall be limited for: wind maximum 10 m/s sea state maximum significant wave
height of 2 m
 connection to emergency power system in case of blackout or other defects
 the activation switches or levers shall be of hold-to-run type and shall be marked clearly and
permanently
 the control station for emergency lowering shall be positioned in a place that gives the operator
a clear view of the load and the lifting zone
 communication system for the crane driver with the responsible person
 specific transport appliance for personnel transfer
 the automatic overload protection system (AOPS) is out of order
 a direct drive from the lifting equipment is not allowed

Emergency Response and Rescue Plan

Plan that defines the potential worst-case consequences in the event of a dropped object or
catastrophic failure of the Lifting Equipment, documenting the control measures to be taken prior to the
operation and the emergency response actions required in such an event.
The Site Lifting Component Person (SLCP) shall write a rescue plan for Lifting of Personnel operations
approved by the SLC. A reliable means of personnel rescue shall be available prior to any Lifting of
Personnel operation taking place. All relevant rescue equipment shall be readily available at the lifting
site before the Lifting of Personnel operation commences. Personnel who are required to carry out
rescue shall be suitably trained. A rescue plan is communicated before lifting personnel and details a
method of retrieving personnel safely and efficiently in the event of an accident, incident or equipment
malfunction.
The following equipment can be considered as an integral part of a rescue plan:
• alternative power supply to hoist
• emergency manual lowering device on hoist
• secondary hoist
• rescue basket (for use with alternative hoist)
• full body type harness fitted with a ‘D’ ring/lanyard suitable for rescue purposes
• MEWP • emergency descent/ascent device.

Review
Material handling is a vital component of any manufacturing system and the material handling industry
is consequently active, dynamic, and competitive. A crane is a mechanical lifting device equipped with a
rope drum, wire rope and sheaves that are used both to lift and lower materials and to move them
horizontally. It uses simple machines to create mechanical advantage which helps to move loads beyond
the normal capability of a human. Cranes are commonly used in the transport industry, in the
construction industry and in the manufacturing industry. The overhead cranes handle and transfer
heavy loads from one position to another. Electric overhead travelling cranes are widely used in many
industries for lifting the safe working load. The escalating price of structural material is a global problem.

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Many small scale industries purchase the existing electric overhead cranes from bigger industries and
make the required modification to suit their requirement.
Types of Overhead Cranes
Various types of overhead cranes are used in industries with many being highly specialized. Various
types of overhead cranes are single girder cranes, double girder cranes, gantry cranes and monorails.

Single Girder Cranes

The crane consists of a single bridge girder supported on two end trucks. It has a trolley hoist
mechanism that runs on the bottom flange of the bridge girder.

Double Girder Cranes

The crane consists of two bridge girders supported on two end trucks (end carriages). The trolley runs
on rails on the top of the bridge girders. Double girder electric overhead cranes are widely used in the
industries because they can carry more loads with more span than any other type of crane. In this
project we are concentrating mainly on double girder electric overhead cranes.

Gantry Cranes
These cranes are essentially the same as the regular overhead cranes except that the bridge for carrying
the trolley or trolleys is rigidly supported on two or more legs running on fixed rails or other runway.
These “legs” eliminate the supporting runway and column system and connect to end trucks which run
on a rail either embedded in, or laid on top of, the floor

Monorail
For some applications such as production assembly line or service line, only a trolley hoist is required.
The hoisting mechanism is similar to a single girder crane with a difference that the crane doesn’t have a
movable bridge and the hoisting trolley runs on a fixed girder. Monorail beams are usually I-beams
(tapered beam flanges). Monorail or repair trolley cranes are used for maintenance purpose. For
maintenance of any single or double girder crane, the crane which is to be taken for maintenance is
brought under the repair trolley (monorail) crane so that it can lift the components of the crane for
repair or replacement.

BASIC COMPONENTS OF OVERHEAD CRANE

Girders
Besides the obvious variation of span and capacity, crane girders of various designs are in common use.
The most frequently used designs are wide flange beams, capped structural beams, box girders and
lattice girders. Box girder is the most popular girder design used in overhead travelling crane because of
its design efficiency. Box type girders constructed from structural steel plate. Full depth stiffeners and
additional partial depth stiffeners welded to webs and bearing on cover plates contribute to the internal
strength of the girders. The trolley travels on the cross travel rails mounted on the girders. These girders
are designed so that they will take the vertical load and the deflection of these girders is within the
permissible limit. These girders provide assess for mounting electric panels and platforms are welded to

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them. The girders are designed with positive pre-camber and the vertical deflection due to the working
load and the trolley weight in the central position shall not exceed 1/900 of the span.

End Carriage
End carriages are located on both sides of the girder. They house the wheels on which the entire crane
travels. It consists of structural members, wheels, bearings, axles, etc., which supports the bridge. Wheel
base of the end carriage assembly shall be not less than 1/7 of the bridge span. 4.3 Hoist Machinery The
Hoist Mechanism is an assembly of motor, gearbox, brake, coupling, drum, wire rope and bottom block.
The bottom block consists of sheave assembly which supports a swiveling hook. The hook block is
suspended from drum through wire rope. Selection of wire rope size depends on load to be lifted and
the number of rope falls. Depending upon rope reeving arrangement either rope balancer or equalizer
sheave may be provided on the trolley frame.

Long Travel Machinery

The long travel mechanism is a unit consisting of a motor drive, coupling, brakes, gearing & wheels
designed to travel the whole crane in either direction. Crane wheels are generally double flanged.
However Flange-less wheels with guide rollers are also used. Long travel mechanism is mounted to the
bridge assembly

ELECTRIC OVERHEAD CRANE COMPARISON

Based on Safe Working Load

Double girder cranes can lift the loads up to 500T capacity. Single girder cranes are suitable for low safe
working load. Because of extra girder in double girder cranes load distributed in two girders and hence
double girder cranes can carry safer working load than single girder cranes.

Based on Span
For longer span the double girder cranes are used whereas single girder cranes are useful for smaller
span.

Based on Application
Double girder cranes are efficient for the intensive use. Because of the rigidity of the structure, they are
used in extreme conditions like lifting the molten metals. Single girder cranes are used for irregular and
light use. They are used in small workshops, storage area, etc. 5.4 Based on Cost In general the single
girder cranes are less costly than the double girder cranes. Double girder cranes consist of more
walkways, other accessories which add the cost. Single girder cranes cost less in many ways, only one
cross girder is required, trolley is simpler and installation is quicker.

Based on Long Travel Speed

The single girder cranes are suitable for lower long travel speed whereas the double girder cranes can
run with higher long travel speed.

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 Chapter 2
Basic Rigging Concepts

Questions to Insure Safe Rigging Operations

Who are the competent persons responsible for rigging the load and establishing lines of
communication?
* Are the rigging gear and crane components in acceptable condition, suitable for lifting and properly
identified?
* Are the working load limits adequate, taking into account the following conditions:
• weight of the load?
• sling angle?
• capacity of the gear?
• need for padding slings against sharp corners?
* Will the load be under control?
• Is the hitch appropriate?
• Is the load rigged to the center of gravity?
• Is a tag line available?
• Is there any possibility of fouling or snag- ging of the load on nearby obstructions?
• Will the suspended load be clear of all personnel?
* Do any unusual side loading or environmental conditions such as excessive wind, waves or
temperature exist?
* And are there special requirements imposed by the customer or local regulations?
Before Starting A Lift
Before starting a lift the following conditions must be verified so that the load is free to be lifted from
the deck or ground.
* If a slack rope condition exists, check that the wire rope is properly seated on the drum and in the
sheaves. No fewer than 5 full wraps of rope should remain on the drum in any operating condition.
* Position the hook directly over the load in such a manner as to minimize swinging upon lifting. No
external forces should be applied to loads which will create side loading of the boom. Cranes are not to
be used for dragging loads!
* Care should be taken when swinging the crane in order to minimize the pendulum action of the hook
and suspended load.
* Select appropriate slings and hardware checking their rated capacity and making sure they are
sufficient for the weight of the load to be lifted.
* The hoist rope is never to be wrapped around the load. The load must always be attached to the hook
by means of slings or other suitable devices.
* Be sure to untangle any multiple part lines that would not separate upon application of the load.
* Attach a tag line to control the swing of the load.
* Make certain that the load is secured and properly balanced in the sling or lifting device before it is
lifted. If the load shifts, set it back down and adjust the rigging.
* Always check that the lift and swing paths are clear of obstructions and personnel. The Operator
should avoid moving loads over personnel.

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 * The operator will not hoist, lower or swing while any personnel are on the load or hook. A certified
Personnel Basket or carrier is required for transporting personnel.
* The hook latch must be closed to secure loose slings. All hooks used for support of personnel must be
of the type that can be closed and locked including a safety latch with a redundant locking method.
* When making personnel lifts, the load must be under control in both the up and down directions. No
Free Fall. All personnel to be lifted will use approved personal flotation devices and should stand on the
outer rim facing inward.
* Loads which are suspended by use of slings or hoists should be blocked or cribbed before personnel
are permitted to work beneath or between them.
Hand Signals
When signals are required to control operations, a designated signal person will be assigned to work
with the crane operator. Reliable radio communication protocols and the use of standard hand signals
are encouraged.
Shown here is a hand signal chart published within the API offshore standard RP2D. These standardized
signals are recommended for all crane operations regardless of location.

Riggers
A rigger is a skilled tradesperson who specializes in the assistance of manual mechanical advantage
device comprising pulley, block and tackle or motorised such as a crane or derrick or chain hoists (chain
fall) or capstan winch.

Duties
Riggers attach loads of equipment to cranes or structures using shackles, cables, chains, clamps or
straps, employing pulleys, winches, lifts or chain hoists (aka chain motors). Quick load calculations are
necessary for each load and engineering principles are always in play. Riggers use various suspension
techniques to get their load around obstacles on a construction site or loading dock or event site to the
desired location and height.

Responsibilities
 ASME – Supervised by a qualified Person – 2021 Revision targeted area.
• ASME – Revised 2018 – Ensuring the weight of the load and its approximate center of gravity have been
obtained.
• Selecting the proper rigging equipment, inspecting it, and complying with applicable ASME volumes.
• Ensuring the rated load of the rigging equipment as configured is sufficient for the load based on
number of legs, hitch and effects of angles.
• Properly attaching the rigging equipment
• Ensuring that rigging equipment is adequately protected from abrasion, cutting or other damage during
load handling activities.
• Rigging the load in a manner to ensure balance and stability
• Knowing and understanding the applicable signals for equipment in use.
 Inspecting and preparing loads that need to be moved.
 Setting, aligning, and leveling heavy equipment machinery.

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 Selecting the appropriate rigging gear.
 Preparing rigging equipment including beams, pulleys, clamps, and bolts.
 Inspecting rigging before final use.
 Monitoring and maintaining rigging equipment.
 Maneuvering loads using heavy equipment machinery and by hand.
 Ensuring compliance with state and company safety procedures.
 Communicating with the rigging and construction team.
 Breaking down rigging equipment and conducting post-rigging inspections.

Rigging principles
Rigging Guidelines
The following basic guidelines must be followed for all types of rigging:
 It is essential to determine the proper style, size, length, diameter and thickness of sling needed for the
application prior to use. Select the sling best suited for the job.
 Never tie knots in slings.
 Rigging equipment must not be loaded in excess of its safe working load.
 Hooks must be provided with safety latches.
 Know the limitations of the lifting device
 Determine the center of gravity of the load.
 Protect sling from sharp surfaces.
 Protect load from rigging, if necessary.
 Allow for increased tension caused by sling angles.
 Equalize load on multiple leg slings.
 Maintain load control. If required, attach tag lines prior to lift.
 Keep personnel clear of lift area.
 Lift load a few inches and check rigging.
 Start and stop the lift slowly.
 Watch for obstructions and power lines. Maintain at least 10 feet from energized power lines at all
times.
 Use proper hand signals when communicating with crane operators.

Terminology Related to rigging

Arbor Pit: Opening in the stage floor under the arbors that allows counterweight arbors to travel below
stage level Synonym: Arbor Well, Counterweight Pit, Well Arbor Rod: Vertical, round metal members of
a Counterweight arbor Balance: When counterweight arbor load equally compensates the suspended
load Synonym: In Balance Batten: Horizontal pipe, tube, or other structural shape 1) for hanging scenery,
lighting, curtains, etc.; 2) in a pocket of or attached to a fire safety curtain Synonym: Pipe Batten Heavy:
See also: Out of Balance Block: An assembly of one or more sheaves in a housing designed to support
one or more lines Body Harness Component of a personal fall arrest system consisting of straps that
adjust to fasten around the body; use requires training Synonym: Harness, Safety Harness Bowline:
Popular knot that is used extensively because it is secure and easy to undo Box Truss: Truss consisting of

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4 linear members Breaking Strength: The load at which failure will occur in a component Breasting:
Laterally moving a suspended object Bridle: Two or more support lines running from multiple points to a
single point Bull Line: Line used to lift or control an out of balance line set Carabiner: Hardware clip used
for quick connections; may be load rated Synonym: Biner, Crab, Krab Chain Hoist: Manual or electric
geared mechanical device that uses chain for lifting Synonym: Chain Motor, Chain Fall, Hoist
Compression Fitting: Swage fitting used to terminate wire rope by means of crimping the fitting onto the
rope Synonym: Crimp, Nicopress ® Sleeve, Oval Sleeve, Swage, Wire Rope Sleeve Counterweight: A
weight used to balance the load on a line that is being raised, lowered, or held in position Synonym:
Brick, Pig, Stage Weight, Weight Counterweight arbor: A guided, movable rigid carriage assembly used
to hold counterweights and to counterbalance a load. Synonym: Counterweight Carriage Counterweight
Loader: Person who loads and unloads counterweight arbors Synonym: Loader Dead End: End of a rope
or part of a device that is not active or load carrying Synonym: Bitter End Dead Hung: Suspension of an
object in a fixed, nonadjustable position Design Factor: A ratio of the design load to the breaking
strength of a material or component. End Stop: 1) Position at the end of a traveling device; 2)
Mechanical device that physically limits travel Fire Safety Curtain: Fire resistant barrier which closes off
the proscenium opening in case of fire Synonym: Asbestos (obsolete term), Fire Curtain, Proscenium Fire
Safety Curtain, Safety Curtain Fly Loft: The space between the roof and the performance area that is not
visible to the audience Synonym: Flies, Fly House, Fly Tower Fly Rail: Operating position for a theatrical
counterweight fly system Synonym: Rail Go No-go Gauge: Piece of metal with slots that measures the
accuracy of: 1) a crimp; 2) the spacing of chain links Gridiron: Over stage support structure consisting of
regularly spaced members permanently affixed to the venue to support equipment Synonym: Grid
Guide Shoe: A component of a counterweight arbor assembly that engages the guide rails in order to
maintain vertical alignment over the length of the arbor travel Head Block: The stationary block
assembly above and closest to the counterweight arbor or pin rail. The head block permits lift lines to
change direction. In some counterweight systems, the head block is also grooved to allow the operating
line to change direction by 180 degrees. Hemp House: Venue that uses ropes and sandbags primary
rigging components Lanyard: Component of a personal fall arrest system that connects the safety
harness to the anchorage point; use requires training Lift Line: Any fiber or wire rope reeved through
block(s) and attached to a load. Lift lines operate singly, as spot lines, or in "sets" of several lift lines
working together to support a load. Line Set: A system of multiple lift lines, operated together to raise,
lower, or suspend a load; all of the mechanical, component subsystems required for supporting,
positioning, and operating those lift lines as a system. Loading Bridge: A load-bearing, elevated
personnel access and work area, located to permit counterweight loading and unloading at the arbor.
Synonym: Loading Gallery Locking Collar: A device placed on a counterweight arbor rod to reduce
unintended vertical movement of counterweights on the arbor. Locking Rail: A structural railing that
supports the rope locks. Loft Block: An overhead block through which one or more lift lines pass before
being attached to the batten. A loft block typically permits the change of lift line direction in the vertical
plane. Operating Line: The line that an operator pulls to move, position or hold a counterbalanced load
Synonym: Hand Line, Purchase Line Personal Fall Arrest System: System used to prevent an individual
from falling from a working level; use requires training Rigging: General term for arrangements of
hardware and systems for the raising, lowering, and suspending of scenery, properties, lighting, and
similar loads Rope Lock: A positioning device, located on the locking rail that holds an operating line of a

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balanced counterweight set and prevents unintended movement. Shackle: U shaped fastening device
secured by a bolt or a pin through holes in the ends of the two arms Synonym: Round Pin Shackle, Screw
Pin Anchor Shackle; Pin Anchor Shackle Single Purchase: A system of rigging employing weights, blocks
and lines to hold or move a load of similar weight, using a 1:1 mechanical advantage for counterweight
and batten load. Synonym: Single Reeve Spreader Plate: Plate that is installed between counterweight
arbor rods to keep the rods from spreading during rapid travel or impact, preventing counterweights
from falling out of the arbor. Spike: Act of inserting a spike ribbon through an operating line See also:
Spike Ribbon Synonym: Stab Swaging Tool: Manual or hydraulic tool for crimping compression fittings
Synonym: Nicopress ® Tool Tension Wire Grid: System of interwoven wire rope that serves as a working
platform Synonym: Cable Grid, Izenour Grid, Sky Deck®, Tension Grid, Wire Grid Thimble: A grooved
fitting around which a rope is bent to form an eye. It supports and protects the rope to prevent kinking
and wear Toe Rail: Metal plate at the bottom edge that prevents objects from sliding through the
opening Trim Chain: A length of chain and fittings used to connect a lift line to a batten (or other load)
and adjust its level relative to the other lift lines along the batten Trim: To bring a rigging element to a
defined height Synonym: Trim Height Wire Rope Clip: Mechanical device used for terminating wire rope
by means of a saddle, a U bolt and two nuts Synonym: Crosby Working load limit (WLL): The maximum
rated capacity of a component or system during normal operating conditions, as determined by the
component manufacturer, or as determined by a qualified person for a specific application

 Follow the manufacturers' charts and tables on sling types, angles, and rope diameters and select
a proper sling which suits the load and the slinging method that you are going to use. Sling types
can be endless, single, two, three or four leg.

Types of Lifts:
 Ordinary Lifts
 Pre-Engineered Lifts
 Critical Lifts

Ordinary Lifts 
Ordinary lifts are the easiest ones to handle. They will normally require a verbal planning process and
preliminary lifting and rigging meetings. Only a minimal documentation and evaluation process is
needed, but always being sure that all safety precautions are been taken.

Critical Lifts
Critical lifts need a more detailed plan before execution. This process will normally require a written
procedure and approval process.

Pre-Engineering Lifts

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These are the most challenging ones to deal with. They will require specific rigging points, lifting
procedure and identification of components that will probably need to be managed separately, to avoid
problems, and minimize potential issues.

Major Types of Construction Lifts In Use Today?

Cherry Pickers
Originally named for lift equipment used in orchards to harvest fruit too high on the tree to pick from
the ground, cherry pickers are the type of aerial lift most commonly found in general use today. They’re
mounted on vehicles and have an aerial platform supported by a boom, from which workers complete
their tasks. Cherry pickers are still used today for picking hard to reach fruit, as well as accessing
overhead utility lines, trimming trees, and a wide range of construction and maintenance work.

Personnel Lifts
Sometimes called people lifts, these mechanical ladders are among the most popular yet somewhat
different types of man lifts in use today. Personnel lifts offer greater stability than regular ladders, are
easy to set up and store and can reach heights approaching 50 ft. Although personnel lifts may seem like
simple pieces of equipment, aerial lift training is still required for them to be used properly.

Articulating Boom Lifts

An articulating boom lift, or ABL, is a type of crane that can be repositioned while keeping the basket at
a steady height. Designed for working above ground, articulating boom lifts have two hinged joints,
which give them greater flexibility than other aerial lifts and cranes. With full 360-degree rotation
capabilities, ABLs are ideal for maintenance work, construction, landscaping, and other jobs that require
accessing hard to reach areas. There are, however, certain risks inherent in operating or working from
articulating boom Because they’re often used to access tough-to-reach reach work areas up against the
sides of buildings and other fixed objects, the risk of being crushed or struck by falling objects increases
dramatically. ALC’s aerial lift training will prepare your employees to safely handle ABLs and other types
of construction lifts to help prevent these types of accidents.

Telescopic Boom Lift

As the name implies, a telescopic boom lift is a work platform that can be extended and retracted with
tubular sections that slide in and out much like hand-held telescopic boom lifts. A telescopic boom lift is
usually more expensive than other types of aerial lifts and capable of reaching heights of up to 100 ft. It
is used for trimming trees, HVAC system installation and maintenance, working on bridges, accessing
multi-story buildings from outside, painting, fire rescues, and even helping stranded riders on a stalled
roller coaster. To avoid serious damage to a telescopic boom lift, the workplace and the operators
themselves, thorough operator training is needed before workers can operate them safely.
AerialLiftCertification.com training will ensure your employees know how to properly operate a
telescopic boom.

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Scissor Lifts
Reaching heights up to 60 ft., scissor lifts have an accordion-style mechanism to elevate workers for
construction work, painting, window washing, HVAC system installation and maintenance, and other
overhead Rather than being true aerial lifts, they’re considered to be a form of scaffolding. Regulated by
OSHA, scissor lifts come with their own unique set of safety requirements. Typically used for indoor
construction and maintenance tasks, scissor lifts are just one of the many types of construction lifts
covered in our OSHA-compliant training and certification programs.

Towable Boom Lifts

Lightweight and portable, towable boom lifts are great for working in yards, gyms, and light industrial
jobs. As the name suggests, they can be towed just about anywhere. Being one of the most convenient
types of lift, safety protocols for towable boom lifts are often skipped over. As such, workers can be
more prone to operate towable boom lifts with a casual attitude, which can lead to accidents, injuries
and property damage. But, towable boom lifts need to be operated just as carefully as other types of
construction and man lifts.

Telescopic Forklifts
Commonly referred to as telehandlers, telescopic forklifts combine a telescopic boom lift with a
traditional forklift. A typical telehandler has a reach up to 21 ft. Telehandlers enable operators to
transport items over rough terrain and long distances. They often have oversized tires and a reinforced
cage cab.

Rough Terrain Forklifts

Rough terrain forklifts are similar to telehandlers. But, they tend to offer greater reach than telescopic
boom lifts. Rough terrain forklifts deliver immense strength, too. They are usually capable of carrying
loads up to 8,000 lbs., making these forklifts terrific options for lifting or transporting heavy loads.

Equipmental hazard that affects lift plan

Loading and unloading at ports and docks involves the use of a wide range of lifting equipment. This may
include gantry cranes, slewing cranes, forklift trucks or other similar machinery. Poorly planned lifting
operations can lead to significant risks to people working in the area.

Typical hazards from lifting equipment

Accidents have occurred due to:
 failure of lifting equipment;
 falling loads; and
 workers being crushed by a moving load or lifting equipment.

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Cranes used in port and dock operations
Following a number of failures of lifting equipment at ports, you should ensure that there are robust,
proactive planned maintenance regimes in place for cranes, including an assessment of design life, post-
supply structural modifications and actual use patterns.
Safety critical parts of the crane should be identified and have maintenance and testing regimes in place
to monitor such parts, in line with suggested testing and maintenance intervals.
Dutyholders should consider 'foreseeable misuse', such as overloading or use in high winds. This should
include consideration of dynamic and static overloading that may occur.from the following and how to
Reduce and mitigate its effects:
snagging where a container gets caught up during movement and creates significant momentary forces
in ropes and parts of structure
trying to lift the ship where a container has not been released from those beneath it but the crane driver
believes that it has and the crane attempts to lift, creating significant forces for a short time
jammed containers or twistlocks where a container is still partially connected to those beneath it but the
crane driver believes that it has been freed and the crane attempts to lift, creating significant forces for a
short time
twin lifting situations where the originally specified safe working load (SWL) is exceeded, reducing the
factor of safety
You should also consider the role, scope, time and access afforded to companies carrying out thorough
examinations of cranes, particularly with regard to how schemes are determined and how it can be
ensured that necessary safety critical parts are included in such schemes. You should consider how to
proceed where conflicting expert advice is received and keep records of such conflicts.

Physical barriers
If you’re picturing closed doors, high cubicle walls, and blocked off areas, then you’re on the right track.
Physical barriers are the oftentimes tangible obstacles or boundaries that keep team members apart. 
It’s important to note that, while it’s not exactly tangible, distance can be counted as a barrier in this
category as well. 
When team members are geographically distributed and unable to physically work side-by-side, that
adds another layer of complexity to communication (which is why Buffer’s 2020 State of Remote Work
Report found that communication and collaboration is the biggest struggle when working remotely, tied
only with loneliness). 

How to knock them down:

Nobody is saying you need to immediately convert to an open office floor plan (those have received
criticisms of their own), but there are a few things you can do to help steer your team around physical
barriers, including:
 Provide plenty of space for collaboration, so employees have the option to stay heads down in
their work in their own workspace or head to a spot where more discussion is encouraged.

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  Set ground rules for the different communication mediums on your team (for example, instant
messages are for urgent requests and emails are for status updates and summaries).

 Keep your own office door open to remain approachable, or set regular office hours where team
members can stop by with questions and feedback.

Cultural barriers
Diverse teams are more productive, more creative, and more profitable. But, having employees of all
different backgrounds also presents some challenges in terms of communication. There are different
generations, cultures, races, and more. That means they also have different values, work ethics, norms,
and preferences. 
Sometimes cultural barriers are even more broad, and an employee feels as if they don’t mesh with the
existing culture of an organization. 
Those examples are all at the heart of cultural barriers. It’s tough to communicate effectively with
someone when you can’t understand or relate to them. 

How to knock them down:

If cultural barriers exist, it can be tempting to think that you’re better off building a homogeneous team.
That’s not true. You need to find ways to navigate these cultural barriers so you can reap the benefits of
a diverse team while still communicating well. Here are a few ideas: 
 Have your employees create guides or “user manuals” that share important information about
how to work with them effectively as well as their communication preferences, like how they
prefer to receive praise and feedback.
 Celebrate the differences on your team with various events and educational opportunities
(they’re fun, and they boost understanding!).
 Use a people analytics tool like F4S to measure each team member’s work style and preferred
communication style, and use the culture tool to toggle between different cultures to spot
potential friction points. For example, a slightly low motivation for “reflection and patience” in
Culture A might translate to an extremely low motivation in Culture B, where the average
worker scores higher on “reflection and patience”. This tells you that the Culture A team
member might come across as hasty and impatient when working with a team member from
Culture B, and awareness of this can mitigate tensions before they start.

Communication barrier #3: Language barriers

If you’ve ever tried to converse with someone who doesn’t speak your same language, you know that
reaching a shared understanding is nearly impossible. That’s why language can be a major barrier to
communication.
It’s important to remember that this isn’t just about different dialects, but about jargon too. If a
marketing team member is talking to someone from the finance team using industry lingo like “PPC” and
“top of the funnel,” confusion is inevitable.

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How to knock them down:
Of course, if there’s a major language difference in your workplace, you’ll likely need to look into
translation services to bridge that divide. But, here are some other important things to keep in mind:
 Be mindful of jargon and encourage your team members to state things as simply as possible.
You can even turn it into a fun “jargon alert” type of game to build awareness of when you’re
slipping into the habit of using complex acronyms or lingo.

 Remember body language too. Various gestures and postures are viewed differently by different
people, so don’t neglect your nonverbal communication.

 Use visuals, demonstrations, and examples where possible. Those can help provide a lot more
clarity than written or verbal communication. 

Perceptual barriers
Imagine that you went into a meeting with the assumption that it was going to be a major waste of your
time. How inclined are you to listen closely? To engage in the discussion? To actively participate?
Your motivation is probably running pretty low, isn’t it? That’s a perceptual barrier.
The assumptions we carry with us into exchanges influence our communication style and can actually
hinder our ability to get our point across or receive messages from others. 

How to knock them down: 

It’d be nice if your own perceptions, biases, and assumptions had a simple “off” switch. While navigating
around this barrier isn’t quite that easy, these tips can help: 
 Support your points with facts and evidence. That type of proof helps to back up your claims,
regardless of someone’s perceptions.

 View situations from a different perspective, and encourage team members to do the same. It’s
easy for us to get stuck in our own way of thinking. Putting yourself in someone else’s shoes can
help you understand other intentions, opinions, and approaches.

 Ask clarifying questions. These require that you operate based on the information in front of
you, rather than your assumptions. 

Interpersonal barriers
Let’s clarify this one with another example. Think of a time when you had to converse with someone
who was undeniably stubborn. They insisted that their view was correct, and they refused to listen to
any other points of view.
I’m willing to bet that discussion was difficult, because you couldn’t truly connect with that other
person. That’s an interpersonal barrier in action.

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How to knock them down: 
I won’t sugarcoat it: interpersonal barriers are difficult to overcome, especially if someone is withdrawn
and isn’t willing to engage. But, here are a few tips that can start to get things back on track: 
 Take a deep breath. These situations can be disheartening and frustrating, but escalating
emotions won’t help.

 Remember to listen. So often when we think about “communication,” we think about the words
we’re speaking. But, listening is just as (if not more) important. Give others a chance to speak
their minds. You might learn a lot about where that interpersonal barrier is coming from. 

Gender barriers
There’s no shortage of stereotypes and generalizations about how men and women communicate
differently. 
And while some of those might hold true while others have been debunked, it’s worth paying attention
to any discrepancies between how different genders in your office communicate so you can facilitate
improved collaboration and working relationships. 

How to knock them down:

Your best bet here is to stay away from generalizations and instead learn more about each of your
individual team members—regardless of gender or gender identity. You can do this using the following
strategies:
 This is another area where personal user guides can be helpful. These empower you and your
team members to learn more about each other’s unique preferences and styles, rather than
operating on stereotypes.

 Encourage team members to provide feedback to one another. This is helpful for addressing all
of the communication barriers and enabling people to understand how their messages are being
received by their team members.

 Have open conversations about gender bias on your team. Being candid and transparent about
those issues is far better than turning a blind eye and pretending they don’t exist. 

Emotional barriers
Emotions and communication are closely related. For example, if you feel uneasy or anxious, you might
resist the urge to speak up. If you’re angry and heated, you’ll have a hard time receiving information
that’s being given to you.
Those are just a couple of scenarios where our emotions can act as a barrier to effective
communication. 

How to knock them down: 

Emotions are natural, and they shouldn’t be discouraged or reprimanded. Instead, you and your team
need to understand how to deal with them. Try some of these strategies: 

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  Know when it’s time to walk away. Whether your emotions are escalating or you notice an
exchange is getting heated between team members, normalize “taking a break” and returning to
that conversation when everyone has had a breather.
Practice naming your emotions. As strange as it can feel to say, “I feel angry” in front of your team, it’s
actually helpful in diffusing that emotion. It’s a concept called “name it to tame it.”

Safety and Environmental Management System (SEMS)

A Safety and Environmental Management System (SEMS) is a performance-based approach to
integrating and managing offshore operations. The purpose of a SEMS is to enhance the safety and
environmental performance of operations by reducing the frequency and severity of incidents.

There are four principal SEMS objectives, as highlighted in the Federal Register preamble to the current
SEMS rule:
 focus attention on the influences that human error and poor organization have on incidents;
 continuous improvement in the offshore industry's safety and environmental records;
 encourage the use of performance-based operating practices; and
 collaborate with industry in efforts that promote the public interests of offshore worker safety
and environmental protection.

1990 to 2009
A SEMS framework was proposed in response to the 1990 National Research Council's Marine Board
finding that the bureau's prescriptive approach to regulating offshore operations had forced industry
into a "compliance mentality." The Marine Board found further that this compliance mentality was not
conducive to effectively identifying all the potential operational risks or developing comprehensive
incident mitigation. As a result, the Marine Board recommended, and the bureau concurred that a more
systematic approach to managing offshore operations was needed.
In response to the Marine Board findings, the American Petroleum Institute (API), in cooperation with
the bureau, developed Recommended Practice 75 -  Development  of a Safety and Environmental
Management Program for  Outer Continental Shelf (OCS)  Operations and Facilities.  The API also
produced a companion document, RP-14J, for identifying safety hazards on
offshore production facilities. The API RP-75 was published in May 1993. In 1994, the bureau published a
notice in the Federal Register that recognized implementation of API RP-75 as meeting the spirit and
intent of SEMS. The API RP-75 was updated in July 1998 to focus more on contract operations, including
operations on mobile offshore drilling units.
Since API RP-75 was first published, the bureau has used public meetings, seminars, letters, research,
and Federal Register notices to promote and encourage SEMS implementation. To date, four OCS-wide,
SEMS implementation surveys have been conducted by the API. The bureau has co-sponsored many
widely attended SEMS performance measures workshops and meets regularly with industry trade
associations to promote SEMS.
The SEMS approach for coordinating OCS oil and gas operations recognizes worker safety and pollution
control are largely dependent on proper human behavior. The bureau has asked OCS operators to make
SEMS an essential business practice component.

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On May 22, 2006, the bureau published an Advance Notice of Proposed Rulemaking (ANPR) in the
Federal Register (71 FR 29277), to seek comments and information on ways to improve the regulatory
approach to safety and environmental management for OCS operations.  The purpose of this ANPR was
to acquire information necessary to improve the regulatory system and industry safety and
environmental performance through a requirement for an integrated management system.  Based on
incident investigation findings and performance reviews with operators, the bureau and industry
identified a need for performance improvement in the following four areas: (1) hazards analysis,
(2) operating procedures, (3) mechanical integrity, and (4) management of change. The ANPR then
discussed several options for implementing a SEMS; one option was to require that only the four
elements listed above be adopted and implemented; a second was for operators adopt a
comprehensive safety and environmental management approach comprised of all elements of API RP-
75. 
On June 17, 2009, the bureau published a Notice of Proposed Rule (NPR) in the Federal Register (74 FR
28639) based on industry and public feedback from the 2006 ANPR.  The bureau proposed to publish a
rule with a requirement for operators to adopt only  the four essential elements: hazards analysis,
operating procedures, mechanical integrity, and management of change.  Based on the analysis of
incident panel investigation reports, incident reports, and incidents of noncompliance, bureau subject
matter experts determined that the root cause of most OCS incidents was failure of one or more of
these four elements. The bureau believed that requiring operators to implement a SEMS would result in
reducing the risk and number of accidents, injuries, and spills during OCS activities.  In response to this
proposed rule, the bureau received 61 sets of comments, of which 57 were from individual entities
(companies, industry organizations, or private citizens). Some of the 61 comments were duplicates, not
related to the proposed rule, or the same company submitting multiple comments. 
In response to several requests, the bureau issued a National Notice to Lessees and Operators (NTL No.
2009-N05) on August 12, 2009, announcing a public meeting on September 2, 2009, in New Orleans,
Louisiana, to discuss the proposed rule. 

2010 to 2019
On October 15, 2010, the bureau published the Final Rule for 30 CFR Part 250 Subpart S - Safety and
Environmental Management Systems, in the Federal Register (75 FR 63610). This Final Rule incorporated
by reference, and made mandatory, all elements in the API RP-75, Third Edition, May 2004, reaffirmed
May 2008. This recommended practice, including its appendices, constituted a complete Safety and
Environmental Management System.  API RP-75 (third edition) consisted of 13 sections, one of which
was a ''General'' section. This related to the 12 elements identified in the 2006 ANPR as part of a
comprehensive SEMS, adding the overall principles for a SEMS, and establishing management's general
responsibilities for SEMS success. 
On September 14, 2011, the bureau published a Notice of Proposed Rulemaking in the Federal Register
entitled, ‘‘Oil and Gas and  Sulphur  Operations in the Outer Continental Shelf—Revisions to Safety and
Environmental Management Systems’’ (76 FR 56683). These proposed revisions to 30 CFR 250, subpart
S, grew out of and strengthened the original SEMS framework by supplementing the requirements in
API-RP 75 to ensure that all companies are implementing current best practices and establishing well-
functioning SEMS programs. The final rule known as SEMS II was published on April 5, 2013 (78 FR

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20423). Specifically, it required operators to integrate six additional requirements over and above the
requirements in API RP-75 Third Edition, to enhance the program and facilitate oversight:
1. Job Safety Analysis (JSA) signature and approval requirements;
2. Auditing by an audit service providers (ASPs), accredited by a BSEE-approved accreditation body
(AB);
3. Stop Work Authority (SWA);
4. Ultimate Work Authority (UWA);
5. Employee Participation Plan (EPP); and
6. Reporting Unsafe Working Conditions.
At the time of the SEMS II promulgation, BSEE issued a Fact Sheet to summarize how it modified the
original SEMS requirements.
In December 2019, the API released the fourth edition of Recommended Practice 75, re-titling it
as “Safety and Environmental Management System for Offshore Operations and Assets.” This fourth
edition reorganizes the recommended SEMS framework into 14 elements. BSEE has yet to begin a
formal evaluation of whether or how to adopt the fourth edition changes into its regulatory structure. In
the meantime, BSEE is willing to entertain proposals from operators to adjust their individual
approaches to SEMS based on fourth edition recommendations which appear to have an added benefit
of ensuring that each of the redefined 14 SEMS elements embed four main principles: (1) Commitment,
(2) Risk Management, (3) Human Performance, and (4) Continual Improvement.

SEMS and a Culture of Safety

On May 9, 2013, one month after issuing the SEMS II Final Rule, BSEE issued a Safety Culture Policy
Statement recognizing that a SEMS promotes a culture of safety within operating companies, and that
sustainable improvements in safety performance are only possible when leadership and operating
culture support and promote its maturation. While BSEE does not regulate safety culture, SEMS
requirements should lead to a culture that embraces communication, risk awareness, team
management of the risk, and a learning environment to foster continual improvement.
Additional guidance on enhancing the safety culture of offshore operations is available in the following
publications:
 National Academies of Sciences, Engineering, and Medicine, “Strengthening the Safety Culture
of the Offshore Oil and Gas Industry” Transportation Research Board | Special Report 321,
issued 2016.
 Center for Offshore Safety Publication COS-3-04, “Guidelines for a Robust Safety Culture”, First
Edition, April 2018

Analysis of SEMS Performance based on Audit Results and OCS Performance Measures
SEMS audits conducted to comply with BSEE regulations provide insights into the successes and
challenges of the SEMS regulation. Every three years, BSEE conducts a detailed analysis of the audit
results to determine if BSEE’s regulatory requirements and operator culture, are meeting stated SEMS
program objectives, namely better awareness and control of risks.
As of June 2020, three cycles of SEMS audits had been completed. An analysis of results from all three
audit cycles indicates that offshore operators have mostly established the foundations of a conforming,

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SEMS but are experiencing challenges in operational consistency. Following each audit, operators are
expected to develop and implement a Corrective Action Plan (CAP) that will define the steps, timeline,
and responsible parties for addressing gaps and concerns identified during the SEMS audits. 
Strengthening the CAP process is considered the key to unlocking further improvements in SEMS
effectiveness. BSEE’s oversight of this process is designed to ensure operators address system root
causes rather than simply treating observable symptoms.
Additional guidance on determining SEMS effectiveness, and on improving SEMS auditing and corrective
action processes, are available in the following publications:
 National Academies of Sciences, Engineering, and Medicine, “Evaluating the Effectiveness of
Offshore Safety and Environmental Management Systems” Transportation Research Board
| Special Report 309, issued 2012.
 
 Center for Offshore Safety "Good Practice" documents
 COS-3-01, “Guidelines for Leadership Site Engagement”, First Edition, May 2013
 COS-3-02, “Skills and Knowledge Management System Guideline”, First Edition, December 2013
 COS-3-03, “Guidelines for SEMS Maturity Self-Assessment”, First Edition, October 2017
 COS-3-04, "Guidelines for Robust Safety Culture", First Edition, April 2018
 COS-3-06, “Guidance for Developing and Managing Procedures”, First Edition, January 2020
 
 Center for Offshore Safety Auditing Documents
 COS-1-06, “Guidance for Developing a SEMS Audit Plan”, First Edition, March 2020
 COS-1-07, “Guidance for Developing a SEMS Corrective Action Plan”, First Edition, March 2020
 COS-1-08, “SEMS Audit Report Format and Guidance”, First Edition, March 2020

OCS Performance Measures

BSEE's SEMS regulation requires all operators submit performance measure data to BSEE.
During the first quarter of each year, BSEE's SEMS rule (30 CFR 250.1929) requires all active operators to
submit performance measures data outlined on Form BSEE-0131 (Form-0131 instructions). Information
about the data survey and how to submit performance data is provided in Notice to Lessees 2018-
N05 (issued September 10, 2018), supplemented by Notice to Lessees 2020-N01 (issued December 23,
2019). This latter NTL describes minor modifications to the form, effective January 1, 2020, to eliminate
duplicate data requests. The data helps BSEE gauge aspects of the offshore oil and
gas development & production industry's safety and environmental performance on the OCS. The
bureau uses these formulas to calculate a variety of annual, OCS-wide, performance indices. These
indices allow operators to benchmark their performance against aggregate industry data, as well as
provide the public with OCS performance trends information.
To make the BSEE OCS Performances Measures data collection program more efficient, BSEE developed
a software application that accepts electronic versions of Form BSEE-0131. This application, called
Performance Measures Data, resides in BSEE’s Technical Information Management System (TIMS)
Web database. TIMS is the bureau’s core mission application for planning, permitting, and reporting
functions; it provides the tools to manage the wide array of data and information needed to accomplish

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the bureau’s day-to-day mission requirements effectively. TIMS is the industry’s portal for electronic
submission of documents and data to BSEE.
The Performance Measures Data application enables the user to enter data into an online Form BSEE-
0131, save and submit the data, and keep track of previous submissions. The data collected online is the
same as that collected with the PDF and paper versions of the form. BSEE continues to accept PDF and
paper versions of Form BSEE-0131. 
The continued success of the OCS Performance Measures Program depends on participation by
OCS lease operators. Completed forms may be sent by any of the following ways, with the new online
Performance Measures Data application being the preferred method:

Management of Change (MOC)

Management of Change (MOC) is a best practice that controls safety, health, and environmental risks
and hazards as they pertain to an organization’s changes to its facilities, operations, or personnel. A
properly implemented MOC policy prevents increased risks for current hazards and guards against the
introduction of new hazards. Inadequate MOC can increase risks to the health and safety of employees
and the environment.
Effective MOC involves review of all significant changes to ensure that an acceptable level of safety will
be maintained after the change has been implemented. From this evaluation, the proposed change can
either be set for implementation, amended to make it more safe, or rejected entirely. Should the change
be implemented, personnel should be informed about the change and how to maintain a safe
workspace in this new environment.
Under the Occupational Safety and Health Administration’s (OSHA's) Process Safety Management (PSM)
standard, performing MOC is required when making changes that could affect the safety of a facility.
This can include changes in process chemicals, technology, equipment, procedures, and the number of
employees involved in a process.
While MOC is generally used to examine the effects of a proposed permanent change to a facility,
temporary changes should not be overlooked. A number of catastrophic events have occurred over the
years due to temporary changes in operating conditions, staffing, etc. For this reason, an effective MOC
program should address all changes that could affect the safety of a facility or personnel, regardless of
whether or not it is permanent.

Authorization process for JSEAs and lifting plans

JSEA: Operations Authorization An effective safety management system requires that the conditions and
requirements that must be satisfied for operations to begin and continue be clearly established and
agreed on. An ISMS is a process to confirm adequate preparation, including adequacy of controls, prior
to authorizing all work, including nuclear and non-nuclear, to begin at the facility, project, or activity
level. DEAR 970.5223-1(b)(7) requires that DOE and the contractor establish and agree upon the
conditions and requirements to be satisfied for operations to be initiated and conducted. These
conditions and requirements are included in the contract and are therefore binding upon the contractor.
The formality and rigor of the review process and the extent of documentation and level of authority for
agreement should be based on the hazard and complexity of the work being performed. The process
should ensure programs addressing all applicable functional areas are adequately implemented to

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support safe performance of the work. A significant part of the work performed in EM is non-nuclear.
For nuclear activities EM delegates authority for selected field offices to perform SER approvals and
retains authority to perform these reviews for the remainder of the field offices and sites under its
cognizance. EM reviews the field office SER approvals for those sites where delegation has not been
granted. EM personnel maintain awareness of all facility activities through weekly teleconferences,
monthly reports, and periodic site visits and inspections. Safety is integrated into the design basis for
acquisitions. The EM Safety Basis Management System requires the safety standards, facility conditions,
and requirements to be fully satisfied for construction and/or operations to begin. Throughout the
operation of a project or field office, EM coordinates with outside authorities, such as Price Anderson
Enforcement and DNFSB to ensure regulatory compliance and improve safety. EM has oversight
authority for ongoing facilities, construction and procurement and performs assessments and oversight
of the field to verify their performance. EM tracks, plans, and participates in Operational Readiness
Reviews/Readiness Assessments and provides oversight.

lifting plans: Signifies confirmation by a BP site manager or designee that the lifting plan has been
completed, that the correct management processes have been followed during the applicable approval
and endorsement stages and has adequately considered and mitigated all personnel safety and process
safety. Table 2 provides an overview of the review, approval and authorization requirements for lifting
operations. Where site based personnel have not achieved the required level, then duty shall be
escalated to a suitably competent person nominated by the BP Regional Lifting Engineer or BP Segment
Technical Authority as appropriate
Content of Job Safety and Environmental Analysis (JSEA)
Job Safety Analysis (JSA) is a systematic procedure that breaks each job/task into key training sequences,
identifies safety elements of each job/task step, and coaches the employee on how to avoid potential
safety hazards. 
What is a Job Safety Analysis?
 Job Safety Analysis (JSA) is a systematic procedure that breaks each job/task into key training
sequences, identifies safety elements of each job/task step and coaches the employee on how
to avoid potential safety hazards.
 Another commonly used term for this process is called a Job Hazard Analysis or JHA. 
 Both a JSA and JHA are considered the same thing.
What are the benefits of a JSA?
 Ensuring consistent and safe work methods.
 Reducing injuries by helping employees know how to best perform a task without the likelihood
of injury.
 Provides a form of training documentation regarding the employee’s knowledge of the job
safety requirements.
 Complies with many OSHA requirements.
When is a JSA recommended?
 A job/task has a high injury rate.

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  A job/task has the potential to cause severe or disabling injuries or illness, even if there is no
history of previous incidents.
 An employee has a safety concern about a job.
 Jobs that are new to your operation or have undergone changes in processes and procedures.
What are supervisor responsible for concerning JSA?
 Writing the JSA (with input from those performing the task)
 Training affected staff at the time of hire, job rotation/transfer, changes in the job/task, or injury
 Enforcing work rules
What are employees responsible for concerning JSAs?
 Reviewing all JSA’s for their job
 Wearing all PPE required for the task
 Following the recommended steps to perform a task in a safe manner

Knowledge of how to write a lift plan

Just a quick reminder to our crane and rigging friends about lift planning. The international society has
basically adopted a boilerplate approach to load handling.
The items listed below are the points of consideration for the decision maker. The load is at Point A and
needs to be moved to Point B. A number of handling systems may be involved in its transition from take-
off to placement. These might include cranes, jacks, rollers, hydraulic gantries, a slide system, heavy-
haul transporters, strand jacks or other equipment. At the end of the day, we have to overcome gravity’s
pull and create movement in a controlled manner.
1) Weight of load.
2) Location of the load’s center of gravity.
3) Overall maximum dimensions of the load.
4) Location and quantity of approved lifting lugs / lifting points.
5) Selection of the appropriate rigging gear to suit lifting points and center of gravity.
6) Height restriction.
7) Risk Assessment.
8) Method Statement.
A new term to some folks is “method statement”. This includes the process, procedure, engineering
data, costing, public and site impact, and preparation requirements.
How does your planning process stack up? Overlooking one of these critical elements can certainly
result in major setbacks. Share this conversation with your “crew”. It’s the professional approach which
can easily be adopted for nearly any load moving activity.

Types of crane-related incidents

Types of Crane Accidents
Call today for a free case consultation
Everyone has seen the large tower cranes that are used to lift heavy loads several hundred feet into the
air at high-rise construction sites, and many of us are familiar with the smaller cranes used in less-
complex building projects. It is also known that crane-related accidents can cause serious, or even

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catastrophic, injuries to workers at job sites where cranes are in use. On this page, the crane accident
injury lawyer at the Doan Law Firm will review the various types of crane-related accidents. He will then
review the legal proceedings that are available to crane-related accident victims, and their families, that
may help to ensure that accident victims receive a fair settlement of their crane-related accident injury
claim.
What are the most common types of crane accidents?
Locating up-to-date, information on crane-related accidents is difficult for a number of reasons, none of
which will concern us here. However, a reading of sources such as news media accounts and online
accident investigation reports suggests that most crane-related accidents occur as a result of one or
more of the following events.
Complete or partial crane collapse
When they hear of a "crane collapse," most people will think of a large tower crane that reaches 100's of
feet into the air. However, those working in the construction industry know that tower crane collapses,
although spectacular, are relatively rare and that most crane-related accident injuries occur following a
sudden failure of smaller cranes such as truck-mounted cranes. No matter the crane's size, a collapse is
virtually always the result of negligence and the crane's owner may be found liable for any injuries
caused by the collapse.
Crane's load was greater than the maximum weight allowed
Every crane manufacturer conducts testing to determine how much weight a crane can safely lift. If a
crane accident occurs, and an investigation determines that the weight being lifted was greater than the
manufacturer's maximum safe lifting weight, the crane's operator/owner could be found liable for the
consequences of the accident.
Crane's load was improperly secured prior to lift
Since modern tower cranes can hoist weights in excess of 15 tons, it is vitally important that such loads
be properly secured and that the workers performing this task have training and experience to correctly
secure these loads. Even if the lift is handled by a smaller crane it is still important that every load be
properly balanced and secured by material that can tolerate the stresses during a lift.
Crane or crane's load damaged another structure causing that structure to fail
Anytime a crane is in use, a crane's load can accidentally strike another structure. If the load's impact is
strong enough, the damage will often cause "catastrophic" failure of that structure and injury to anyone
in the immediate area. This type of accident is particular common in oil refineries and chemical plants
that are undergoing routine maintenance or expansion of existing production facilities. These accidents
can cause explosions, fires, or the release of dangerous chemicals into the atmosphere.
In each of the accident causes listed above, it has been estimated that 80 to 90 percent are due to
human error. In fact, some accident investigators feel that every crane accident involves human error at
some point! If human error was a factor in a crane or crane-related accident the worker, or anyone else,
injured in such an accident is usually able to file a personal injury lawsuit alleging negligence by the
crane's owner.
I was injured in a crane-related accident, how much compensation can I collect?
Since every accident case is unique, it is impossible to provide even an estimate of the "dollar value" of a
worker's injury claim. Instead, we will look at how on-the-job injuries are handled by the Workman's
Compensation system.

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State Workman's Compensation
Workers who are injured on-the-job by a crane or crane-related accident will usually be covered by a
state Workman's Compensation program.
In general, Workman's Compensation will usually pay:
any medical expenses directly to a worker's injury
income support while the worker is unable to work (in most cases, around 60% of the worker's weekly
wages
any costs associated with retraining an injured worker (vocational rehabilitation)
ongoing payment for injuries that have led to a worker's permanent partial disability
compensation payments to the surviving family of a worker killed on the job
There are several advantages to the Workman's Compensation system. In general, Workman's
Compensation programs have a very short waiting period before their income support/replacement
benefit begins. Another advantage is that the injured worker's medical bills are paid "from day 1" and
the injured worker is not required to meet a deductible or to make out-of-pocket "co-pays." Although
the injured worker appears to be well-served by this system, there are several provisions in each state's
program that can severely limit the type and amount of compensation that an injured worker can
receive.
Most importantly, Workman's Compensation is considered to be a "faultless" system. This means that
an employer, and the injured worker, are assumed to be not "at fault" if the employee is injured on the
job. However, to receive Workman's Compensation benefits, the injured employee must sign a
document stating that the worker waives ("gives up") the right to file a civil lawsuit against the
employer. In doing so, the worker cannot receive payment for "pain and suffering" caused by the injury
and the employer is protected from having to pay punitive damages, no matter how negligent the
employer may have been in creating an unsafe work environment.
There are some situations, however, where an injured worker can receive Workman's Compensation
benefits and file a personal injury lawsuit. In law, these lawsuits are known as third party lawsuits and
are explained in the next section.
Third Party Lawsuits
In personal injury law, there are three "parties" that may be involved in a lawsuit. The first party is the
person who filed the lawsuit (you, or your family). The second party is your insurance company or your
state's Workman's Compensation program. The third party is someone whose negligence caused or
contributed to a crane or crane-related accident even though they were not directly involved in the
crane's operation when the accident occurred.
Due to their high cost, most construction companies do not own tower cranes or mobile, medium-lift
cranes, but rent them from companies that provide not only cranes but also crane operators and
"ground crew" such as loaders. If a crane accident injury occurs, the company that provided the crane
could be sued as a third party.
Contact a crane-related accident injury lawyer
As a worker who was injured in a crane-related accident, you already know about the never-ending
stream of paperwork that you have had to deal with since your injury.
From the information presented on this page you will have learned that you may need the services of a
crane-related accident injury lawyer who is familiar with:

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the legal rights of injured workers in your state
your state's Workman's Compensation laws and regulations
the evidence needed to prove the liability of a "third party" in accidental injuries
how to thoroughly investigate the circumstances that led to an accident
the processes necessary to ensure that an injured worker, or the worker's family, receive all the
compensation to which they are entitled
One such lawyer is the crane-related accident injury lawyer at the Doan Law Firm, a nationwide law
practice with offices located in major cities throughout the country.
When you contact the crane-related accident injury lawyer at the Doan Law Firm to arrange a review of
your crane-related accident injury case, your initial case review is always free of any charge and does
require that you hire our firm to represent you in court. If you decide that our firm should manage your
crane-related accident injury lawsuit, we are willing to assume responsibility for all aspects of preparing
your lawsuit for trial on a contingency fee basis. This means that we are willing to assume responsibility
for all aspects of preparing your lawsuit for trial in exchange for a previously agreed-upon percentage of
the final settlement that we will win for you.

Reporting Incidents
Definition of an Incident Report
An incident report is an official recording of the facts related to an incident on the worksite. An incident
is broadly defined as any event or accident that leads to personnel injury or damage to equipment or
property. 
Incidents also include events or accidents that have the potential to cause harm, or in other words, near
misses. 

The Importance of Incident Reporting in the Workplace?

Here are five reasons why it’s important to report incidents in the workplace and how it can benefit
both employees and employers.

1) Prevent more serious accidents

Comprehensive incident reporting can help any business understand what is going wrong or could go
wrong regarding workplace safety.
With these insights, an organisation can fix a health and safety issue before it becomes a bigger problem
that can cause serious harm or damage to employees or property. As the old adage goes, a stitch in time
saves nine.

2) Improve other health & safety measures in the workplace

You can think of incident reporting as something that can improve other health and safety measures in
the workplace, such as risk assessments and reporting potential hazards. 
Even by complying with all the best risk assessments and hazard reporting procedures with due
diligence, incidents can still happen. 
It’s like the “Swiss Cheese” model where each health and safety “layer” has its imperfections yet work
together to collectively prevent accidents from “going through”.

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 However, when an accident or near miss does happen, it makes the management aware of how the
“holes” of each “layer” (i.e. the health and safety procedures) have created a path for that incident. 
Giving this feedback through an incident report can help your company identify the weaknesses or blind
spots in your current health and safety procedures as well as risk mitigation solutions. By having this
information, you can take proactive steps to improve them.

3) Save time and resources

In their “Health and Safety at Work” 2020 summary statistics report in Great Britain, HSE reported:
 £5.6 billion in annual costs of workplace injury in 2019. Estimates based on Labour Force Survey,
RIDDOR and HSE Cost Model for 2017/18-2019/20
 £16.2 billion in annual costs of work-related injury and new cases of ill health in 2018/19,
excluding long-latency illness such as cancer.
 693,000 workers sustaining a nonfatal injury according to self-reports from the Labour Force
Survey in 2019/20.
 65,427 employee non-fatal injuries reported by employers under RIDDOR in 2019/20.
 6.3 million estimated working days lost due to non-fatal workplace injuries according to self-
reports from the Labour Force Survey in 2019/20.
Lost time and costs caused by injuries can be reduced with incident reporting because of how incident
reporting can help prevent more serious accidents and improve workplace health and safety
procedures.

4) Reporting incidents can protect companies

A lack of incident reporting doesn’t just put staff at huge risk. It puts companies at risk too. 
Companies in the UK can be penalised with fines and imprisonment if it is found that the incident was
caused by a breach of the UK’s health and safety laws.

5) Boost overall well-being

As the cherry on top, having a healthy incident reporting culture in the workplace shows you are
committed to your staff’s and customers’ safety, which can improve morale, teamwork, efficiency,
productivity, and overall well-being of the organisation and its staff.

What are the Types of Incidents that Need Reporting?

Every organisation’s incident reporting procedure should record four types of incidents:
1. Unexpected events
Any unexpected incident, accident, or situation that results in a serious psychological injury or non-fatal
and fatal physical injuries to employees or damage to company property. Examples include but are not
limited to slips, trips and falls, vehicle accidents, natural disasters, theft, and fire.
2. Near misses
Any unexpected incident, accident, or situation that had the potential to cause harm to employees or
damage to company property but no harm or damage occurred.
3. Adverse events

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These incidents relate to medicine, vaccines, and medical devices used to treat employees for a medical
condition or situation. Any unintended harm caused by the commission of treatment or omission of
procedure, instead of harm resulting from the existing disease or condition, must be reported as an
incident.
4. Awareness events
Any risks of potential incidents that can happen in the line of duty must be recorded and communicated
to all employees to be aware of the risks and safety measures required to mitigate the risks. Employees
must also be able to access these records so they can refer to them at any time.
Additionally, under the Reporting of Injuries, Diseases and Dangerous Occurrences Regulations 2013
(RIDDOR), employers must also report to the local authorities any RIDDOR reportable injuries.
In general, this regulation covers any work-related injury, illness, poisoning, and dangerous occurrences
at work. Specifically, the types of RIDDOR reportable injuries and dangerous occurrences fall into the
following categories:
1. Non-fatal injuries to workers 
2. Non-fatal injuries to non-workers
3. Work-related fatalities
4. Dangerous occurrences
5. Occupational diseases
6. Exposure to carcinogens, mutagens and biological agents
7. Diseases offshore
8. Gas-related injuries and hazards
For further details on RIDDOR reportable injuries and the procedures to report them, read our
article, What is RIDDOR & How Important is it for UK Organisations?

When Do You Need to Report an Incident?

An internal incident report of near misses or unexpected, adverse or awareness events should be
completed as soon as possible after the incident happens or within a reasonable time frame. 
By reasonable, it means those involved in or had witnessed the incident or event should still be able to
recall the details of what happened with clarity to complete the incident report. As an employer, you
may also stipulate a specific reporting time frame in your incident reporting procedures for your staff to
adhere to.
On the other hand, RIDDOR reporting timescales will depend on the type of injury or accident. They can
range from 10-15 days of the incident or upon receiving a diagnosis from a medical professional.

How to Write an Effective Incident Report

Before writing an incident report, it’s important to remember the objective of an incident report. Here’s
a quick recap:
1. To prevent more serious accidents
2. To improve other health & safety measures in the workplace
3. To save time and resources
4. To protect the company
5. To boost overall well-being of staff

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When you keep the objectives in mind, it becomes easier to evaluate which details are relevant to be
included in the report.
Next, it is best to create an incident report template that any employee can easily follow without
missing out on important details.
To make things easier, we have prepared a template document, you can download it here.
Your incident report template should include the following sections:
 Type of incident (unexpected events, near misses, adverse events, awareness events)
 Location
 Specific location (e.g. 3rd-floor laboratory) 
 Offsite location (provide the address and specific location)
 Date and time of the incident
 Name of the person(s) injured (or the names of the person(s) at risk in the case of a near miss)
 Witness name(s)
 Name of supervisor
 Description of injuries (or the potential injuries that could have happened in the case of a near miss)
 A detailed description of the incident covering:
 Sequence of events
 Results of the event
 Observations of anything unusual before, during, or after the incident
 Observations of safety equipment or procedures used
 The affected or involved person(s) version of the events
 Witness statements
 A detailed description of the treatment after the incident, which may include:
 The reasoning behind the decision to call or not call emergency services
 How the injury (if any) was treated
 How the area of the incident was controlled, cleaned up, or rectified
 A post-analysis of the incident
 The root cause(s) of the incident
 Any health and safety breaches that may have contributed to the incident
 The hazards identified 
 How to remove the hazards or mitigate the risks
 Photographs (if relevant and where possible)
Sample of an Incident Report
Here’s a sample of what an incident report could look like. 
Type of Location: Date: Name of Name(s) of Name of
Incident: 24 March 2021 Person(s) Witness: Supervisor:
Aisle F1 of Injured or at
Unexpected Warehouse A Time: 11:20am Risk: Iris West Bruce Wayne
Event Arthur
Barry Allen Curry
Description of 1) An employee got a concussion and took a 5-day medical leave.

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 injury and/or 2) Pallets and goods with an estimated value of $16,400 were damaged.
damage
Description of Mr. Allen was loading the shelves at aisle F1 of Warehouse A with a forklift. That
incident was when the pallet rack collapsed. The impact of the pallet racks and its contents
falling on the forklift jolted him forward and caused a concussion.
Witness Ms. West stated: I was in aisle G1 and heard a loud crash. I turned and saw the
statement pallets crashing down on the forklift Barry was driving.

Mr. Curry stated: I was beside the forklift helping Barry to direct the loading.
That’s when I noticed the top pallets were shaky, but before I could warn Barry, it
came crashing down. I ran away in time. The falling boxes just missed me.
Treatment Mr. Allen was conscious and able to talk and walk, although he felt a little dizzy.
post-incident Given his state, everyone decided it was not necessary to call an ambulance. Ms.
West took Mr. Allen to the hospital, where he was diagnosed with a concussion
and given 5 days medical leave.

The remaining employees in the warehouse carefully removed the rest of the
pallets and damaged boxes at the site of the incident under the supervision of Mr.
Wayne. After cleaning the area, they catalogued the items damaged and repacked
the undamaged items for storage.
Post-analysis After investigation, it was found that the pallet racks at the top shelf were loaded
of incident with items heavier than the items below. This imbalance caused it to collapse.
Although the warehouse policy is to stack and wrap heavy items below and lighter
items on top, the procedure was not followed in this case.

The next steps include retraining the warehouse staff as well as tightening
supervision and regular maintenance check of how safely and securely pallets are
stacked.
When writing an incident report, keep these tips in mind:
 Write in a third party voice except when quoting people.
 Stick as closely as possible to stating the facts. 
 Avoid writing emotional statements.
 Avoid finding someone to blame and stay focused on the objective of workplace safety.
 Include relevant details but write as concisely as possible.
 Validate the report by getting everyone who was mentioned in the report to sign off to confirm the
information is accurate.

Understanding incident severity levels

Identify and prioritize incidents for faster resolution
There are three cardinal truths of incident management. 
The first is that incidents are inevitable—especially for companies that are constantly growing and
innovating. 

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The second is that a strong incident management practice is vital to a healthy business (and a weak
one costs businesses big in both employee time and satisfaction and business revenues). 
The third is that not all incidents are created equal. Losing data from one database is not the same as
losing data from all of your databases. Dealing with an outage that impacts 20% of your users is a whole
different ballpark than dealing with an outage that impacts 90 or 100%. Handling a system outage during
peak hours is a lot more stressful than handling one when most of your customers are asleep. Even two
incidents that look identical on paper are unique under the surface.
What are severity levels?

Incident severity levels are a measurement of the impact an incident has on the business. Typically,
the lower the severity number, the more impactful the incident. 

For example: At Atlassian, we define a SEV (severity) 1 incident as “a critical incident with very high
impact.” This could include a customer data loss, a security breach, or when a client-facing service is
down for all customers.  

A SEV 2 incident is a “major incident with significant impact,” including when a client-facing service is
down for a sub-set of customers or a critical function within a system is not functioning.

And a SEV 3 incident is “a minor incident with low impact,” such as a system glitch that is causing
customers slight inconvenience. 

At Atlassian, SEV 3 incidents can be handled during daytime/working hours, while SEV 1 and SEV 2
incidents generate an alert for on-call professionals for an immediate fix no matter the time of day.
Severity Description Examples
1 A critical incident with very high A customer-facing service, like Jira Cloud,
impact is down for all customers
Confidentiality or privacy is breached
Customer data loss
2 A major incident with significant A customer-facing service is unavailable
impact for a subset of customers
Core functionality (e.g. git push, issue
create) is significantly impacted
3 A minor incident with low A minor inconvenience to customers,
impact workaround available
Usable performance degradation

Crane operator’s responsibility in reporting crane-related incidents

Many accidents that are attributed to operator error are often not the operator’s responsibility.
Inadequate planning on the part of site supervision often puts crane operators in the position of having

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to make judgements or decisions that are beyond what should be reasonably expected of them.
Generally, the operator is responsible for the safety of the crane operation as soon as the load is lifted
clear of the ground. Because of this responsibility, whenever there is reasonable cause to believe that
the lift might be dangerous or unsafe, the operator must refuse to lift until the concern has been
reported to the supervisor, any hazards are rectified, and safety conditions are met. The operator is
specifically responsible for
1. knowing the machine well. The operator must understand its functions and limitations as well as its
particular operating characteristics.
2. having a thorough knowledge of the information contained in the crane's operating manual.
3. being familiar with the crane's load chart. The operator must understand the correct meaning of all
notes and warnings and be able to calculate or determine the crane's actual net capacity for every
possible configuration of the machine.
4. inspecting and maintaining the crane regularly as prescribed by both the owner and manufacturer.
5. informing the owner of any problems, needed maintenance, or necessary repairs to the machine. This
should be done in writing, preferably in the machine's logbook or inspection report.
6. recording in the log or report the details of all inspections, maintenance, and other work done on the
crane while in the field.
7. supervising and training the apprentice if one is present.
8. being aware of any site conditions that could affect the crane operation. Be particularly cautious
around powerlines. The operator must refuse to operate if the crane, hoist rope, or load will come
closer to a powerline than the absolute limit of approach specified in law.
9. checking that the site is adequately prepared for the crane.
10. reviewing the planned operation and requirements with the site supervision.
11. finding out the load and rigging weight and determining where the load is to be placed. Although the
operator is not responsible for determining the weight of the load, if the operator lifts it without
checking the weight with site supervision, then the operator becomes fully responsible for the lift and
any consequences that result.
12. determining the number of parts of hoist line required.
13. checking the load chart to ensure that the crane has sufficient net lifting capacity for every lift.
14. selecting (from the range diagram) the best boom, jib, and crane configuration to suit the load, site
and lift conditions.
15. assembling, setting up and rigging the crane properly.
16. following the manufacturer's operating instructions in accordance with the load chart.
17. considering all factors that might reduce crane lift capacity and adjusting the load weight to suit. This
will include such factors as weather conditions and ground conditions.
18. knowing basics of rigging procedures and ensuring that they are applied (this is possible only when
the load is visible to the operator).
19. maintaining communication with signalpersons.
20. ensuring that the apprentice is in a safe place during operation.
21. operating in a smooth, controlled, and safe manner.
22. moving the crane.
23. shutting down and securing the machine properly when it is unattended.

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24. exercising the right to refuse to operate the crane if there is cause to suspect the lift might be
unsafe.

Calculating the Weight of a Load

Step 1: Determine the Volume of the Load
Rectangle/Square: Volume = Length x Width x Height
Hollow Cylinder: Volume = 3.14 x Length x Wall Thickness x (Diameter – Wall Thickness)
Complex Shapes: In some instances, imagine the whole object is enclosed in a rectangle and then
calculate the volume of that rectangle. Or, break the object into two or more smaller rectangles and
then calculate the weight of each part and add them together.
Step 2: Determine the Material You’ll Be Lifting
The table below can be used for approximate weight values of common loads and materials:
Material Pounds / Cubic Foot Material Pounds / Cubic Foot
Aluminum 165 Iron Casting 450
Asbestos 153 Lead 708
Asphalt 81 Lumber (Fir) 32
Brass 524 Lumber (Oak) 62
Brick 120 Lumber (RR Ties) 50
Bronze 534 Oil, Motor 58
Coal 56 Paper 58
Concrete 150 Portland Cement 94
Crushed Rock 95 River Sand 120
Diesel 52 Rubber 94
Dry Earth (loose) 75 Steel 480
Gasoline 45 Water 63
Glass 162 Zinc 437

Step 3: Determine the Weight of Object

Multiply the approximate pounds per cubic foot of the material times the calculated volume of the load
to get the weight of the object or load.

Example #1: Block of Aluminum

Here’s how you would calculate the load weight of a block of
aluminum that is 6 feet long, 3 feet wide, and 4 feet tall:
Volume = Length x Width x Height
Volume = 6 feet x 3 feet x 4 feet
Volume = 72 cubic feet
Aluminum weighs 165 pounds per cubic foot (based on the numbers
from the table above). Based on this information, you would perform the following calculation:
Block weight = 72 cubic feet x 165 pounds per cubic feet
Block weight = 11,880 lbs. / 5.94 tons
Example #2: Steel Pipe

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Here’s how you would calculate the load weight of a hollow
steel pipe that is 8 feet long, with a 3 foot outside diameter,
and wall thickness of 1.5 inches:
Volume = 3.14 x Length x Wall Thickness X (Diameter – Wall
Thickness)
Volume = 3.14 X 8 feet x 1.5 inches x (3 feet – 1.5 inches)
Convert inches to feet (1.5 inches = 0.125 feet)
Volume = 3.14 x 8 feet x 0.125 feet x (3 feet – 0.125 feet)
Volume = 3.14 x 8 feet x 0.125 feet x 2.875 feet
Volume = 9.03 cubic feet
Steel weighs 480 pounds per cubic foot (based on numbers from the table above). Based on this
information, you would perform the following calculation:
Steel tube weight = 9.03 cubic feet x 480 pounds per cubic foot
Steel tube weight = 4,334 lbs. / 2.17 tons

Example 3: Complex Shapes

Here’s how you would calculate the load weight of an irregular
shaped object made out of concrete. First, separate the object into
rectangles and then calculate the weight of each section individually
and then combine them, as shown below:

Volume1 (Top) = 4 feet x 2 feet x 3 feet

Volume1 = 24 cubic feet
Volume2 (Bottom) = 9 feet x 2 feet x 3 feet
Volume2 = 54 cubic feet
Total Volume = Volume1 (24 cubic feet) + Volume2 (54 cubic feet)
Total Volume = 78 cubic feet
Concrete weighs 150 pounds per cubic foot (based on numbers from the
table above). Based on this information, you would perform the following
calculation:
Complex concrete shape = 78 cubic feet x 150 pounds per cubic foot
Complex concrete shape = 11,700 lbs. / 5.85 tons

Using Load Cells or Dynamometers to Determine Load Weight

Additionally, other devices can be included in the rigging that will provide the operator with a read-out
and determination of the load weight when it’s lifted slightly off of the ground. These devices,
called load cells or dynamometers, are mounted in line with the crane hook, slings and hardware. The
load is then attached to the load cell and the load cell calculates the weight of the load by measuring the
force being applied to it using a strain gauge, or hydraulic or pneumatic pressure inside the device.
These devices can display the measured weight of the load in a variety of ways. Some are mechanical
with an analog display that utilizes a needle and dial—similar to how many bathroom or medical scales
operate. Others can have digital displays right on the device itself, and some even work with handheld

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digital devices or computer software to send the readout to an operator who may be performing remote
monitoring and diagnostics of the crane equipment.
Another type of load cell device is a loadshackle, which is essentially a fully-rated lifting shackle with
integrated electronics and microprocessors to determine the weight of a load once lifted into the air.
These types of devices also send data to a handheld device or remote workstation.
Many load cells and dynamometers come with overload sensors that alert the operator, safety
managers, or other designated personnel if the crane has been overloaded. An overload occurs when a
lift exceeds the crane’s rated capacity. Overloads are prohibited according to OSHA and ASME B30
standards, and can stress and damage the crane equipment—putting nearby employees in danger if the
crane were to fail.
When using load cells or dynamometers, always refer to the manufacturer’s recommendations
for scheduled maintenance and calibration to ensure your device is in compliance and continues to
provide accurate measurements.

Angular, static and dynamic loading:

Angular Loading: Angular loading is the loading any of load in an specific angle, Angular loading of
eyebolts should be avoided. Angular loading occurs in any lift in which the lifting force is applied at an
angle to the centerline of the shank of the eyebolt. Angular loading of the eyebolt less than 45 degrees
shall be prohibited. The eyebolt loading shall never exceed the concerned values When more than one
eyebolt is used in conjunction with multiple-leg rigging, it is recommended that spreader bars, lifting
yokes, or lifting beams be utilized to eliminate angular loading
Static Loading: Static tests of the crane are conducted under the load, which is 25% above its capacity
parameters according to the standard test methods.
Static tests of the jib-type crane having one or more load characteristics are periodically held in a
position corresponding to a maximum load lifting capacity of the crane and/or the largest loading
moment.
When static tests of jib-type cranes are carried out, the boom must be installed relatively to the leading
substructure in the position corresponding to the lowest rated stability of the crâne. The load must be
lifted to a height of 100-200 mm.
If the lifted load does not fall on the ground within 10 min, and there is no cracks, permanent
deformations or other damages of metal structures and mechanisms, than the crane positively passed
the test.
Static tests performed crane load, 25% above its nameplate load capacity. Dynamic load test is
performed, 10% greater than the capacity of the crane, or a work load, ie. the cargo, which is equal to
the mass of the crane lifting capacity. The dynamic test work load makes it easier to hold for heavy-duty
cranes. The dynamic test shall be performed only in case of positive result of the static test. In the
dynamic test is checked under a load of action mechanisms of the crane and its brakes.
Dynamic loading: Any calculation of the dead weight of a mobile crane includes the boom, the
machinery, the chassis and the counterweight. For an offshore pedestal crane, however, the dead
weight also includes the weight of the installation that the crane is fixed to. This could be a vessel or an
oil platform.

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When a mobile crane is overloaded, the centre of gravity moves from the area of stability towards the
load that is being lifted, thus raising the risk of the crane overturning. Offshore pedestal cranes are
different; their dead weight is so large that there is a greater reliance on the strength of the
components. Given the same overload, it is unlikely that the crane will overturn. The question is,
however, what impact do the stresses created by an overload situation have on this type of crane?
A severe overload could pull the crane off the pedestal in extreme cases. This is a very rare occurrence
because most cranes are now fitted with gross overload protection devices. Lesser overloads can stress
the boom strut welds, and over a period of time the crane boom might collapse. It would be interesting
to note how many boom failures have occurred due to stressed welds. Cranes offshore are also
subjected to environmental factors that can be hazardous, and therefore require good crane
management and competent operation to ensure a safe lifting operation.
Dynamic loading is the effect on the crane when it is shock loaded. This sometimes occurs when cargo is
transferred from a supply vessel deck to an installation. The average wave height when unloading
vessels in the North Sea is around 3m. If the crane operator gets it wrong, and hoists the cargo as the
vessel is dropping into the trough of a wave, the resulting shock load will create a dynamic effect that
can increase the load on the crane by up to three times the actual weight being lifted.
When the lifting operation is between two vessels such as a drilling semi and a supply vessel the effects
of pitch and roll are critical as the dynamic factors are further increased. This effect will continue for a
short time, depending on the boom length and angle.
Unless the risk of dynamic loading is addressed, this dynamic loading will result in a series of overloads.
To alleviate dynamic loading the operator should be hoisting the cargo from the deck just as the supply
vessel is rising or is at the top of the wave. More importantly, he should ensure correct selection and
setting of the appropriate sea state on the rated capacity indicator (RCI). This should be done
throughout the lifting operation, and the wave height should be updated by an appointed person. These
sea state duties will de-rate the crane’s safe working limit (SWL), depending on the wave height. For
example, when the duties for a National OS 435 main hoist at high speed are selected for a static lift (sea
state 0) they have a SWL of 23t up to a 25m radius. When the duties are set for a dynamic lift at a sea
state of seven, the SWL is 9t for the same radius. This reduction in capacity is an allowance for the
dynamic effect; an increase between actual load moment and peak load moment.
There are still some offshore cranes on installations operating dynamic lifts from supply vessels that
have an RCI with duties only suitable for static lifting. In such cases, the operator must use a duty chart
to determine the safe working load of the crane when lifting dynamically, and as the crane duties on the
RCI are for static lifting there is no audible or visual warning of an overload. There are a number of
references to dynamic lifting in the UK’s Lifting Operations & Lifting Equipment Regulations (LOLER)
1998. One of these, Regulation 4, clearly states: ‘Where there is a significant risk of overturning and/or
overloading arising from the use of the equipment, it should be provided where appropriate with
equipment or devices such as rated capacity indicators and rated capacity limiters. Such devices provide
audible and/or visual warning when the safe lifting limits are being approached.’
Another reference to this type of lifting can be found in the Approved Code of Practice for Safe use of
cranes British Standard S7121-11: 1998. Here, Part 5.2 clearly states: ‘The rated capacity indicator and
limiter should be maintained in working order. The crane operator should:

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Ensure correct selection of duties for inboard lifting operations on the installation, and if applicable, the
correct duties for lifting over the sea from supply vessels allied to the prevailing sea state.
Ensure correct selection and setting of the sea status throughout the lifting operation, from continuous
updates provided by the appointed person.’
If the operator relies only on the RCI with static duties to indicate the SWL of the crane during dynamic
lifting, then the crane is at risk of severe overloading, and components are likely to fail as a result

Qualified Inspector
The Qualified Inspector is an inspector who, in support of and under the direction of quality engineers,
supervisors, or technicians, can use the proven techniques included in the body of knowledge. Under
professional direction, the quality inspector evaluates hardware documentation, performs laboratory
procedures, inspects products, measures process performance, records data and prepares formal
reports.

Duties
 Review design drawings and the traveler or process sheet in order to understand the scope of
the intended work.
 Review the method and extent of material defect repairs, and when found acceptable, allow
initiation of such repairs.
 Verify that weld joint preparation will allow full penetration when full penetration welds are
specified or required.
 Verify that the stamping, including the National Board stamping, is correct and the nameplate is
properly attached.
 Verify the manufacturing organization’s representative has signed the manufacturer’s data
report and that it is correct before applying the date, his/her signature and National Board
Certification Number.
 Record entries in the Inspector Diary

Qualified Inspector’s Diary

Each Qualified Inspector involved with new construction must maintain a diary of activities. The diary
must be bound (not loose-leaf) or alternatively, the inspector may use an electronic diary, controlled by
the Qualified Inspection Organization. The purpose of the diary is to provide a record of the Inspector’s
activity and to support the continuity of inspections. The inspector’s diary is the property of the
Qualified Inspection Organization and must be available at the location of the inspection. 6.1 Entries in
the inspector’s diaries must:
 provide a clear indication of the nature and extent of the inspector’s activities;
 be completed daily or at each inspection visit by the inspector;
 include the date, the inspector’s National Board certification number and the inspector’s
signature or initials;
 be available for reviews and investigations.

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Electronic diaries must also:
 be secured in such a way as to prevent revisions, additions, or deletions to data which has been
previously logged in the diary;
 provide a means for other qualified inspectors, within the Qualified Inspection Organization, to
review diary entries, as required;
 include a provision for signatures by a PIN or other secure means.

 Qualified Rigger
OSHA only loosely specifies who meets the criteria of a qualified rigger, leaving the final determination
up to the employer.  A qualified rigger “possesses a recognized degree, certificate, or professional
standing, OR who by extensive knowledge, training and experience, can successfully demonstrate the
ability to solve problems related to rigging loads”. Qualified riggers do not, however have to be certified
by accredited organization or third party.  Under these criteria, a rigger with extensive hands-on
experience, but no formal training or certifications, may be considered a qualified rigger. 
A qualified rigger is a rigger who meets the criteria for a qualified person. Employers must determine
whether a person is qualified to perform specific rigging tasks. Each qualified rigger may have different
credentials or experience.
 A qualified rigger is a person that: | Possesses a recognized degree, certificate, or
professional standing, or | Has extensive knowledge, training, and experience, and | Can
successfully demonstrate the ability to solve problems related to rigging loads.
 The person designated as the qualified rigger must have the ability to properly rig the
load for a particular job. It does not mean that a rigger must be qualified to do every type of
rigging job.
 Each load that requires rigging has unique properties that can range from the simple to
the complex. For example, a rigger may have extensive experience in rigging structural
components and other equipment to support specific construction activities. Such experience may
have been gained over many years. However, this experience does not automatically qualify the
rigger to rig unstable, unusually heavy, or eccentric loads that may require a tandem lift, multiple-
lifts, or use of custom rigging equipment. In essence, employers must make sure the person can
do the rigging work needed for the exact types of loads and lifts for a particular job with the
equipment and rigging that will be used for that job.
 Riggers do not have to be certified by an accredited organization or assessed by a third
party. Employers may choose to use a third party entity to assess the qualifications of the rigger
candidate, but they are not required to do so.

Rigging Safety Tips

 Check the weather conditions before the lift. If the weather is extreme, postpone the lift until the
weather becomes cooperative.

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  Make sure the system of communication you have in place with the operator is effective and is
functioning properly.
 Check the lift area and load path for obstructions such as buildings, poles, towers, power lines,
antennas, satellite dishes, etc.
 Make sure the receiving area is firm, flat, and free from loose objects that could fly up when the
load is delivered.
 Be sure to establish the weight of the load and determine the load’s center of gravity.
 Determine the proper type of hitch based on the type of load.
 Inspect all rigging hardware before you use it. Never use defective hardware. Take defective
hardware out of service immediately.
 Remember to protect slings from cuts and tears when lifting items with sharp edges.
 Never make a shackle to shackle connection.
 Always wear a hard hat and sturdy work gloves.
 Be sure that your work boots or work shoes have built in toe protection. It is especially important
to have this protection when you are receiving a load.
 Whenever possible plan to rig the load so that it will be lifted straight up, which will help prevent
the load from swinging.
 Never tie two or more slings together.
 Always connect two slings with an appropriate-sized shackle.
 Never attach a sling directly to a lifting lug, always use a shackle. Never run a sling through a set of
lifting lugs or eyebolts. Doing so creates too much tension on the lugs or eyebolts.
 Never choke below the threads on synthetic web slings.
 “Never saddle a dead horse.” When using wire rope clips be sure to attach the wire rope clips with
the inside curve of the U-bolt up against the very end (dead end) of the wire, and the inside of the
U-bolt clip (saddle) up against the live end of the wire.
When is a qualified rigger required?
Employers must use qualified riggers during hoisting activities for assembly and disassembly work .
Additionally, qualified riggers are required whenever workers are within the fall zone and hooking,
unhooking, or guiding a load, or doing the initial connection of a load to a component or structure
Who can be a qualified rigger?
A qualified rigger is a rigger who meets the criteria for a qualified person. Employers must determine
whether a person is qualified to perform specific rigging tasks. Each qualified rigger may have different
credentials or experience. A qualified rigger is a person that:
• possesses a recognized degree, certificate, or professional standing, or
• has extensive knowledge, training, and experience, and
• can successfully demonstrate the ability to solve problems related to rigging loads. The person
designated as the qualified rigger must have the ability to properly rig the load for a particular job. It
does not mean that a rigger must be qualified to do every type of rigging job. Each load that requires
rigging has unique properties that can range from the simple to the complex. For example, a rigger may
have extensive experience in rigging structural

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components and other equipment to support specific construction activities. Such experience may have
been gained over many years. However, this experience does not automatically qualify the rigger to rig
unstable, unusually heavy, or eccentric loads that may require a tandem lift, multiple-lifts, or use of
custom rigging equipment. In essence, employers must make sure the person can do the rigging work
needed for the exact types of loads and lifts for a particular job with the equipment and rigging that will
be used for that job.
Do qualified riggers have to be trained or certified by an accredited organization or assessed by a third
party?
No. Riggers do not have to be certified by an accredited organization or assessed by a third party.
Employers may choose to use a third party entity to assess the qualifications of the rigger candidate, but
they are not required to do so.
Does a certified operator also meet the requirements of a qualified rigger?
A certified operator does not necessarily meet the requirements of a qualified rigger. Determining
whether a person is a qualified rigger is based on the nature of the load, lift, and equipment used to
hoist that load plus that person’s knowledge and experience. A certified/qualified operator may meet
the requirements of a qualified rigger, depending on the operator’s knowledge and experience with
rigging.

Qualified Operator
 As a crane operator you will be responsible for the safe operation, control, and maintenance of
cranes.
 The job role of a crane operator includes the following duties: 
 Conducting machine safety checks each day
 Setting up cranes and operating them
 Moving material around site according to a plan or schedule
 Monitoring crane stability and load weights
 Working with a banksman to ensure site safety
 Making minor repairs to machinery
 Reporting any issues to the supervisor
 Keeping records of the materials you’ve moved
 Ensuring that travel routes are clear
 Working on-site, in noisy conditions.
 Each provider of rail flaw detection shall have a documented training program in place and shall
identify the types of rail flaw detection equipment for which each equipment operator it employs
has received training and is qualified. A provider of rail flaw detection may be the track owner. A
track owner shall not utilize a provider of rail flaw detection that fails to comply with the
requirements of this paragraph.
 A qualified operator shall be trained and have written authorization from his or her employer to:
 Conduct a valid search for internal rail defects utilizing the specific type(s) of equipment for which
he or she is authorized and qualified to operate;
 Determine that such equipment is performing as intended;

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 Interpret equipment responses and institute appropriate action in accordance with the employer's
procedures and instructions; and
 Determine that each valid search for an internal rail defect is continuous throughout the area
inspected and has not been compromised due to environmental contamination, rail conditions, or
equipment malfunction.
 To be qualified, the operator must have received training in accordance with the documented
training program and a minimum of 160 hours of rail flaw detection experience under direct
supervision of a qualified operator or rail flaw detection equipment manufacturer's representative,
or some combination of both. The operator must demonstrate proficiency in the rail defect
detection process, including the equipment to be utilized, prior to initial qualification and
authorization by the employer for each type of equipment.
 Each employer shall reevaluate the qualifications of, and administer any necessary recurrent training
for, the operator as determined by and in accordance with the employer's documented program.
The reevaluation process shall require that the employee successfully complete a recorded
examination and demonstrate proficiency to the employer on the specific equipment type(s) to be
operated. Proficiency may be determined by a periodic review of test data submitted by the
operator.
 Each employer of a qualified operator shall maintain written or electronic records of each
qualification in effect. Each record shall include the name of the employee, the equipment to which
the qualification applies, date of qualification, and date of the most recent reevaluation, if any.
 Any employee who has demonstrated proficiency in the operation of rail flaw detection equipment
prior to January 24, 2014, is deemed a qualified operator, regardless of the previous training
program under which the employee was qualified. Such an operator shall be subject to paragraph
(d) of this section.
 Records concerning the qualification of operators, including copies of equipment-specific training
programs and materials, recorded examinations, demonstrated proficiency records, and
authorization records, shall be kept at a location designated by the employer and available for
inspection and copying by FRA during regular business hours.

Static or Dynamic Load Rating

Static Load rating –  the static load rating is
that load which produces a total permanent
deformation of the rolling element or raceway which
is approximately 0.0001 of the rolling element
diameter. Deformation greater than this amount
may result in noisy operation and premature failure.
The basic static load rating is defined as the
maximum load that can support when stationary at
room temperature without inadmissible permanent
deformation of the sliding layer and jeopardizing its
performance. It is assumed that the bearing is

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adequately supported by the associated components of the bearing arrangement. In order to fully
exploit the static load rating of a bearing it is generally necessary to use shafts and housings made of
high-strength materials. The basic static load rating should also be considered when bearings are
dynamically loaded and are subjected to additional heavy shock loads. The total load in these cases must
not exceed the basic static load rating.
Dynamic Load rating: A Basic Dynamic Load Rating is a theoretical, statistically based value of load that a
bearing can carry for 1,000,000 revolutions with 90% reliability. For a radial bearing, this rating was
based on the amount of pure radial load that a rotating inner ring could tolerate for 500 hours at a 33-
1/3 RPM.
For composite materials the basic dynamic load rating is used together with other influencing factors, to
determine the basic rating life of a bearing. As a rule it represents the maximum load that a bearing can
sustain at room temperature when the sliding contact surfaces are in motion. The maximum permissible
load in any individual application should always be considered in relation to the desired rating life. The
basic dynamic load ratings quoted in the product tables are based on the effective projected sliding
surface and the specific load factor that takes the different composite materials into consideration.
In this definition it is assumed that the load acting on a bushing or flanged bushing is purely radial and
that the load acting on a thrust washer is purely axial and applied at the centre. Dynamic load conditions
are essentially oscillating movements or rotations under load, but can include micro sliding under
variable load (e.g. as a result of vibration) or operation under high frequency alternating loads. Where
oscillating movements or rotation under load usually produce wear, the other conditions may result in
fatigue.

Lifting
Lifting equipment includes any equipment or machinery used at work for lifting or lowering loads or
people, including accessories and attachments used for anchoring, fixing or supporting the
equipment [2]. There is a wide range of lifting equipment in the construction industry. Typical examples
are:
A hoist: is a device used for lifting or lowering a load by means of a drum or lift-wheel around which
rope or chain wraps. It may be manually operated, electrically or pneumatically driven and may use
chain, fibre or wire rope as its lifting medium.
A crane: is a type of machine, generally equipped with a hoist, wire ropes or chains, and sheaves, that
can be used to lift and lower heavy materials and to move them horizontally. Different types that can be
found in construction are:
A tower crane: is a balance crane that consists of the same basic parts. Fixed to the ground on a
concrete slab, tower cranes offer height and high lifting capacity. The base is then attached to the mast
which gives the crane its height. The mast is attached to the slewing unit (gear and motor) that allows
the crane to rotate.
Telescopic crane: has a boom that consists of a number of tubes fitted one inside the other. A powered
mechanism extends or retracts the tubes to increase or decrease the total length of the boom. These
types of booms are highly adaptable, are often truck mounted and used for short term construction
projects.

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A mobile crane: is a cable-controlled crane mounted on crawlers or rubber-tired carriers or a hydraulic-
powered crane with a telescoping boom mounted on truck-type carriers or as self-propelled models.
They are designed to easily transport to a site and use with different types of load and cargo with little
or no setup or assembly.
All terrain crane: is a mobile, truck mounted crane with the necessary equipment to travel at speed on
public roads, and on rough terrain at the job site using all-wheel and crab steering.
A crawler crane: is a crane mounted on an undercarriage with a set of tracks (also called crawlers) that
provide stability and mobility. They need little set-up and can travel with a load but are very heavy and
cannot easily be moved from one job site to another.
A power shovel (also stripping shovel or front shovel or electric mining shovel) is a bucket-equipped
machine, usually electrically powered, used for digging and loading earth or fragmented rock and for
mineral extraction conveyor systems.
A telescopic handler, or telehandler, is a type of crane, with the versatility of a single telescopic boom
that can extend forwards and upwards from the vehicle. On the end of the boom several attachments
can be fit, such as a bucket, pallet forks, muck grab, or winch.
A fork lift truck is a powered industrial truck with hydraulic lift system and forks to pick up and transport
materials.

Lifting equipment for lifting people:

An aerial work platform, elevating work platform, or mobile elevating work platform (MEWP), is a
mechanical device used to provide temporary access for people or equipment to inaccessible areas,
usually at height. There are distinct types of mechanized access platforms and the individual types may
also be known as a "cherry picker" or a "scissor lift". They can be vehicle-mounted, self-propelled or
trailer-mounted.
A passenger lift or passenger hoist or construction elevator is commonly used on large scale
construction projects, such as high-rise buildings to transport persons.

Lifting accessories
Lifting accessories means a component or equipment not attached to the lifting machinery, allowing the
load to be held, which is placed between the machinery and the load or on the load itself, or which is
intended to constitute an integral part of the load and which is independently placed on the market;
slings and their components are also regarded as lifting accessories. These accessories include amongst
others chains, ropes, slings, shackles, eyebolts, lifting/runway beams, lifting frames and vacuum lifting
devices.

The load
The load includes any material and people (or any combination of these) that is lifted by the lifting
equipment. Loads are often provided with permanent or semi-permanent fixed or attached points for
lifting. In most cases, these are considered to be part of the load. Examples of loads include:
 loose bulk materials
 sacks, bags, pallets and stillage’s

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  discrete items (such as a large concrete block)
 machinery and any permanently attached lifting eyes
 a skip and the lugs fixed to its side.

Light Lifting
The incorrect use of light lifting equipment can be hazardous. This is because light lifting equipment is
sometimes not subjected to the same rigorous inspection schedules as heavier lifting equipment such as
cranes, etc . However the same basic principles must apply :
 The SWL of the equipment should always be known.
 All light lifting gear must be thoroughly examined and tested. All tests and examinations must be
properly documented. All documents shall be maintained and quickly accessible for internal or
external auditing by company, contractor or third party.
 All equipment should have the appropriate colour coding.
 Only trained and competent persons should be in charge of a lifting operation.

General Instructions
 All equipment used in light lifting operations whether fixed or portable must be inspected
and/or tested to confirm that it is fit for its intended use. A color coding system is used to
ensure that all equipment in use has been either inspected or tested. The color code is changed
every three months. No equipment other than those bearing the valid color displayed is allowed
to be used in lifting operations Every lifting appliance or piece of lifting gear must be clearly
marked with its working load or loads and must be used within these parameters.
 If No Safe Working Load, Identification Number or the correct Color Code adequately marked,
then DO NOT USE IT.
 Lifting appliances and associated lifting gear must be examined and where necessary tested by
an approved inspector as follows : - Before it is used initially.
 Whenever the equipment has been substantially modified or repaired and before it is used
again. - At intervals and times laid down by TPA and/or in accordance with the relevant
legislation.
 Color coding system shall apply for all machines & equipments in site such cranes, lift trucks,
forklifts, chains, slings, shackles, …by contractor HSE. (Every three month).
 Particular, daily, weekly, monthly and pre use inspections for lifting devices & equipment should
be done and approved by a certified third party in compromised specific periods.
 Of course above mention system is so different for wire rope and critical lifting.
 PM (Preventive Maintenance) as a essential system should be deployed at the whole system.
 All examinations and tests must be recorded in a lifting equipment register (attachment 3). A
current copy of the register must be available on the site. All lifting gear is to have an
identification number clearly marked.
 Any appliance or piece of lifting gear that fails the examination or test must not be used until it
is repaired and retested.

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  Any lifting gear which fails during an operation must not be moved until an investigation has
been carried out. This does not apply in emergency situations.

Pre-lift Meeting
Staff should participate in the meeting hold which is called Pre-lift Meeting to review the plan/procedure
before making a critical or pre-engineered lift. All participants should be briefed as follows (and as a
minimum):
 Intended lift sequence and load path;
 Establishing a Work Control Zone and keeping no participants out;
 Identified hazards;
 Methods of hazard mitigation;
 Load securement;
 Stop Work Authority

Lifting Supervisor
 To ensure that the crane operation team carry out their duties safely.
 To carry out the assessment of the lifting operation to provide such planning, selection of
crane(s), lifting gears and equipment, instruction and supervision as necessary for the task to be
undertaken safely.
 To ensure that adequate inspection and maintenance of the equipment has been carried out.

lift plan Regulations

 A lift plan should be prepared prior to lifting tilt-up or pre-cast panels. The plan should show a
dimensioned site plan with the following information detailed: - crane set-up position(s) on site;
- locations where the panels are to be lifted from and to, with the operating radius of the crane
shown; - areas on site where obstacles such as walls or braces may be in the traveling or slew
path of the crane; and Areas where the crane cannot be set up (i.e. trenches and covered
penetrations on site).
 The lift plan should specify the type and set up of lifting gear to be used.
 Responsibilities for rigging, dogging and spotting duties (i.e. ensuring the crane does not contact
obstacles) should be specified

Heavy Lifting
General requirements
All requirements of light lifting is applicable for this section also. For the purposes of assessing the
handling equipment required, the weight of the individual components identified as being capable of
being handled as a unit, have been considered. Each identifiable component should be listed with its
corresponding unit weight and the model of construction crane suitable for the operation. This
document shall be reviewed and revised during construction upon changes in machinery or equipment
dimensions and weights or when any changes are met in the attached classification listing. The
manufacturer’s specifications and limitations applicable to the operation of any and all cranes and

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derricks shall be complied with their specifications. Rated load capacities, recommended operating
speeds, special hazard warnings, or instructions must be visible to the operator while he is at the control
station. All lifting and rigging equipment such as cranes, slings, ‘D’ shackles, hooks, etc. shall be certified
by HSE at least for 6 months and all relevant certificates shall be copied to the HSE department. Rigging
equipment must be inspected by HSE every 3 months, also operator should check the equipments prior
to use on each lifting operation and as necessary during its use to ensure that it is safe. Defective rigging
equipment must be tagged out of service and removed from the site. Contractor lifting supervisor and
HSE Manager shall make a thorough, monthly inspection of the hoisting machinery. The operator shall
maintain a record of the dates and results of inspections for each hoisting machine and piece of
equipment. Standard operating signals should be agreed upon and should be used to direct all
operations. No modifications or additions, which affect the capacity or safe operation of the equipment,
shall be made without the manufacturer’s written approval. Accessible areas within the swing radius of
the rear of the rotating superstructure of the crane must be barricaded to prevent any personnel from
being struck or crushed by the crane. All cranes and lifting appliances shall be plainly marked on each
side of the appliance as to its rated load capacity. The following restrictions during lifting operations
shall be observed:
 Personnel shall not ride on the hook or load.
 Personnel shall not stand, walk or crawl beneath a slung load.
 The hoist rope shall be in a vertical position when tensioned to prevent swinging of the load.
 The twisting or kinking of the wire rope shall be avoided.
 Bolts and nuts shall not be used to join a broken chain.
 Lifting appliances shall not be dropped from a height.
 Tension shall not be applied to any kinked wire rope. No heavy lifting operations shall proceed
until a detailed lifting plan has been prepared by mechanical department and approved by the
HSE. A Heavy Lift shall be categorized as that in which the load exceeds 20 tons. If no Safe
Working Load (SWL), Identification Number or correct Color Code is adequately marked, then do
not use. Every lifting appliance or piece of lifting gear must be clearly marked with the SWL and
must be used within these parameters. Lifting appliances and associated lifting gear must be
examined and where necessary tested by HSE inspector as follows:
 Before it is used initially.
 Whenever the equipment has been substantially modified or repaired and before it is used
again.
 At intervals and times according to Inspection Procedures and/or in accordance with the
relevant legislation. All examinations and tests must be recorded in a lifting equipment register.
A current copy of the register must be available on the site. All lifting gear is to have an
identification number clearly marked. Any appliance or piece of lifting gear that fails the
examination or test must not be used until it is repaired and re-tested. Any lifting gear that fails
during an operation must not be moved until an investigation has been carried out. This does
not apply in emergency situations.

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Daily & pre-operational check
It is the duty of the crane driver to inspect his crane daily when lifting operations are to take place. The
daily checks should be documented and logged. The inspection includes but is not limited to,
 Obstruction on tracks (if applicable),
 Signal lights & horns,
 Limit & overload switches & alarms,
 Radio & hard wire communication means (if any),
 Crane motion controls,
 Emergency devices control. Before leaving the crane, the crane driver shall ensure that,
 The load is removed and the hook(s) is (are) raised to the highest position,
 There is no risk of spurious move of the crane,
 The power supply is shut off,
 The windows and door of the cab are closed and locked. The engineering/maintenance
department shall check each crane, regularly and at the beginning of a contract. Reference
should be made to the inspection & maintenance procedures.

Categories:
Categorizing Lifting Operations As an aid to identifying risks and suitable controls, lifting operations are
categorized to reflect increasing risk and increasing level of control required as per categorization
scheme as given below:

Routine Lifts
This classification comprises:
 Routine crane operations
 Repetitive lifting operations using the same equipment (e.g. drilling activities), and
 Routine lifting operations with Loose Lifting Equipment
A generic risk assessment and Lift Plan may be used for Routine Lifts. However, classifying a lifting
operation as ‘routine’ does not automatically make it a ‘safe’ lifting operation – most incidents
associated with lifting occur during routine operations. The risk assessments and Lift Plans shall always
be reviewed during the Toolbox Talk for continued applicability. The control requirements for each
category of lift are as follows:

Category of Lift Documentation/Controls Competent Personnel

Routine Crane Operations
when:
 Gross load is less than 5
tones, or
 Gross load represents less
than 50% of the load chart at
working radius
 Within the normal operating
 Risk Assessment (generic)   Crane Operator
 Lift Plan (generic)  Banks man and / or Slinger/
 Job Safety Analysis Rigger
 Work Permit  Drilling Crew
 Toolbox Talk
 Safety checklist
 10 questions for a safe lift

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 parameters of the crane
 Lifting over non-sensitive
areas
 Suitable environmental
conditions
 Familiar, competent Crane
Operators
 Load has known and
evaluated weight, shape and
centre of gravity
 Standard rigging
arrangements
 Repetitive functions with
same equipment and with
same operators

Non-Routine Lifts Non-routine lifting operations can be further sub-divided to reflect increasing risk:
 Simple lifting operations using Loose Lifting Equipment
 Complicated lifting operations eg tandem lifting
 Complex / Critical / Heavy lifting operations requiring a Lift Plan with engineering input

The control requirements for each category of lift are as follows:

Category of Lift Documentation/Controls Competent Personnel
Non-Routine – Simple Risk Assessment Maintenance Technicians
when:  Lift Plan initiated by  Riggers
 Gross load is less than 25 executing department/
tones, or prepared by contractor
 Gross load is greater than  Job Safety Analysis
50%, but less than 75% of  Work Permit
the load chart at working  Safety checklist
radius  Toolbox Talk
 Equipment specifically  10 questions for a safe lift
installed by a competent
operator
 Load has known and
evaluated weight
 Centre of gravity below
the lifting point
 Use of a certified lifting
point directly above the
load

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  Ample headroom
 Out with sensitive,
difficult or restricted areas
 Single lifting appliance
 Unlikely to be affected by
changing environmental
conditions
 Experienced and
competent Lifting
Appliance Operator
 Standard rigging
arrangements
 Suitable lay down area
available
Non-Routine – Complicated  Risk assessment  Crane Operator
when:  Specific Lift Plan initiated  Banksman (Signaller)
 Gross load is greater than by executing  Slinger / Rigger
25 tones, or department/prepared by
 Gross load represents contractor
more than 75% of the  Job Safety Analysis
load chart at working  Work Permit
radius, or  Safety checklist
 Gross load is greater than  Toolbox Talk
30 tones and is also  10 questions for a safe lif
greater than 80% of the
manufacturer’s load chart
 Continuation of a lifting
operation with different
equipment (due to
malfunction, inadequacy
or unsuitability)
 Use of two or more Lifting
Appliances (tandem
lifting)
 Within sensitive, difficult
or restricted areas
Non-Routine – Complex /  Formal work pack with  Crane Operator
Critical / Heavy Lift when: method statement,  Banksman
 Gross load is greater than including calculations (Signaller)
75 tones, or  Lift Plan prepared and  Slinger/Rigger
 Gross load represents reviewed by a qualified

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 more than 90% of the engineer
load chart at working  Risk assessment
radius, or  Job Safety Analysis
 Gross load is greater than  Work Permit
50 tones and is also  Safety checklist
greater than 80% of the  Toolbox Talk
load chart.  10 questions for a safe lift
 Continuation of a lifting
operation with different
personnel; for example,
shift changeover
 Lifting of personnel,
including drill floor Man
Riding operations
 Over or in sensitive areas
 active or energized
hydrocarbon-containing
process equipment, near
overhead electrical power
lines
 Tandem lift with two
cranes
 Lifting with a helicopter
 Transferring the load from
one lifting appliance to
another
 In environmental
conditions likely to affect
equipment performance
 Operator under training
 Load with unknown /
difficult to estimate
weight and / or centre of
gravity
 Load is special and / or
expensive whose loss
would have a serious
impact on production
operations
 Mobile crane on
untested / uneven ground

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  Non-standard rigging
arrangements
 Load lowered into or lifted
from a confined space

job safety analysis (JSA)

A  job safety analysis (JSA), is a process to identify the dangers of specific tasks within jobs in order to
reduce the risk of injury to workers.  A JSA is also often referred to as a Job Hazard Analysis
(JHA).  When you complete a JSA, you're taking important steps to protect your employees and ensure
that your workplace is compliant with standard safety regulations.
The process of creating a job safety analysis report is generally broken down into four steps, which
makes it easier to ensure you complete every portion of the requirements a reap the benefits a JSA
offers.
This article will give you a quick overview of how to conduct a JSA.

Choose a job to analyze

At some point you would ideally do a JSA for every job performed in your workplace. But the reality is
that you can't take care of them all at once, so you'll need to prioritize which tasks you'll look at first. For
example in the construction industry, jobs involving fall protection can really benefit from a job safety
analysis due to the high rate of fatalities from falls. To decide where to begin, the Canadian Center for
Occupational Health and Safety recommends considering the following factors:
 Accident frequency and severity: The frequency - or severity - of past injuries can suggest where to
begin your JSAs.
 Newly established jobs: Tasks that are new may present more risk because your workers are not yet
accustomed to these jobs.
 Potential for severe injuries or illnesses: Jobs that involve hazardous materials or dangerous
conditions may have greater potential for accidents.
 Infrequently performed jobs: Like new tasks, jobs that are performed infrequently may present
greater risk because staff members don't know which hazards to anticipate.

Break the job down into specific tasks

Once you've determined which job you want to look at, break that operation into the specific tasks that
go into completing it. You'll want to list each and every step from start to finish.
For example, operating a piece of machinery may include preparing for the job, turning on the piece of
equipment, performing the task, shutting down the machine and completing any necessary clean-up.
Breaking down a job into each and every step may seem like a tedious process, but it is critical for
properly analyzing the overall risk associated with the job. If you're using job safety analysis software,
this step can be made much easier by using a catalog of previous jobs you have entered.

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With such software, you can copy the tasks of a previous job, and edit them to match the new job. This
will save considerable time when creating JSA's for jobs that share similar tasks (such as
conducting crane inspections and aerial lift inspections).
Numerous organizations throughout North America rely on Vector EHS Management Software to
identify, analyze, and resolve job hazards throughout their worksites.
Learn more about how we can help.

Determine hazards and risk present in each task

Next, you'll want to identify any hazards that may be present at any give time during each task. The
Department of Labor emphasizes that it's important to examine the entire environment to determine
any possible hazard that might exist. So the hazard may not necessarily be found in the task itself, but
the area where the activity is performed.
When determining hazards, you also need to assess the risk of injury each hazard poses. Most safety
professionals utilize risk matrix calculations of the probability and severity of the hazard to determine
overall risk. You may want to use different levels of a risk matrix depending on how detailed you want
your risk calculations to be.
If you're unsure about this step in the JSA process, we've put together a guide on risk matrix calculations
and hazard assessment to assist.
We also recommend using safety software to help you with this process by automatically calculating risk
through your own defined levels of probability and severity. This way you'll be able to have consistent
risk calculations across your organization, while also streamlining the JSA process.

Identify preventative controls and residual risk

The final step in a job safety analysis is to identify controls you can take to prevent these hazards from
causing potential accidents. This includes documenting any personal protective equipment (PPE) that
can help mitigate the hazards you've identified.
Once controls and PPE are taken into factor, you'll conduct another risk assessment of each hazard to
determine the amount of risk remaining, also known as residual risk. You should use the same risk
assessment matrix as before, only now the probability and severity should be lower thanks to the
controls and PPE.
If you can't eliminate the hazard, find ways to change the job procedure or limit the risk as much as
possible. This includes providing tools such as a safety data sheet (SDS) on a hazard that give
information to help understand the potential risks. You'll also want to use this time to gather feedback
from fellow supervisors and employees who may find controls or risks that you weren't aware of.
Once all controls and residual risk is calculated you will determine the overall final risk of the job. You
can use this information to identify which jobs pose the most risk to employees, even after controls are
implemented. You may also use this data to see if additional controls are needed to further reduce risk
of injury.
Job safety analysis software can make this important process easier for everyone involved. For example,
the Vector EHS Job Safety Analysis (JSA) Module helps you to track potential hazards in the workplace,
and calculate the risks of each hazard automatically. Most importantly, our JSA module comes with
easy-to-use reporting tools that will help you get the most out of your JSAs.

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Job Safety and Environmental Analysis (JSEA)
A Job Safety and Environmental Analysis (JSEA) is a written document that sets out the high risk work
activities to be carried out at a workplace, the hazards and risks arising from these activities and the
measures to be put in place to control the risks. A JSEA considers the environmental as well as health
hazards. Its primary purpose is to help supervisors and workers implement and monitor the control
measures established at the workplace to ensure high risk work is carried out safely. 
Considering the Environmental hazards and controls when completing a Job Safety and Environmental
Analysis (JSEA) or a Safe Work Method Statement (SWMS) is very important!

In Australia the maximum penalty for breaching the WHS act is $600,000. or imprisonment for 5 years or
both. For Causing serious harm to the environment $2,000,000. or 15 years imprisonment or both. 
 Some of the common environmental hazards included in the JSEA
 Blocking creeks or waterways
 Damage to property
 Disposal or Transport of Wastes from site
 Disturb Cultural Heritage Sites
 Disturbance to Plants or animals - removal of vegetation
 Dust
 False alarm
 Fire
 Fire from engine exhaust
 Inefficient electricity use/ Production of greenhouse Gas
 Inefficient resource use
 Inefficient resource use – wasting water
 Noise/ disturbing the peace
 Noise/ vibrations (offsite Impacts)
 Release of Emissions to air
 Spillage
 Spills to land contamination
 Spills to water - stormwater
 Spreading of Weeds and pests
 Swarf causing damage to property
 Use of pesticides/ Insecticides
 Waste Generation

hands off - in activities associated with drilling, running casings, cementing or logging, etc. Hands Free
Lifting refers to personnel not touching a load (with any part of their body) that is connected to a
mechanical lifting device and is a key constituent of the hands-off policy.
The Gulf of Mexico TLP/Spars and the Well Services Group will conduct all crane lifting operations using
“hands-off” techniques. The only exception of the “hands-off” policy is in the event a load or piece of

121
equipment cannot be safely controlled by any other means than direct hands-on contact. For these
exceptions, the requirements for doing so must be strictly adhered to.

Simultaneous operation
General Requirements
It is the intent of this procedure to establish guidelines for planning and coordination, and to outline
safety rules for use where SIMOPS are conducted. B. Prior to commencing SIMOPS, there will be a
survey of the existing site or facility. Revisions or modifications may be recommended. Requirements for
shutting down work in affected areas will be reviewed. These activities should involve each respective
department (development, construction, operations, etc.). C. Applicable Incident Management drills
should be conducted as soon as possible prior to commencing SIMOPS operations. D. A SIMOPS meeting
shall occur at least once per shift and shall be documented. 1. Additional meetings will be required if the
original scope of work changes. 2. The meetings shall be documented and contain the scope of work for
each SIMOPS activity, the person in charge of that operation and the approval of the Person In Charge
(PIC). E. All personnel shall understand the site Incident Management System and responsibilities. F. All
identified roles shall have defined accountabilities. G. Competent personnel will be on duty and in
attendance during SIMOPS.
Key Responsibilities
Proper coordination and control is critical to the safe conduct of SIMOPS. The Site/Facility Manager will
have complete authority to determine which operation or phase of the work has precedence at any
given time. B. The Site/Facility Manager will be the PIC. 1. The PIC will be responsible for confirming that
all aspects of the SIMOPs plan are fully implemented. 2. The PIC will work with the other project and site
representatives (i.e., development, construction, and operations) to understand each job scope prior to
commencing SIMOPs. In the event of an emergency, the expert representative will have the support of
the PIC to control any issue that may arise. If there is difficulty in maintaining control of work, joint
communications shall occur with all parties to determine if operations should be shut down. C. Proper
communication must be established among all personnel involved in SIMOPS. A communications
system, such as intercom, or radios, shall be set up to facilitate communication. A personnel manifest or
roster shall be compiled by the PIC and distributed to other project and site representatives. D. The PIC
shall communicate with responsible personnel from the various operations to discuss the expected
activities at the commencement of work, at the beginning of each shift, and at other times during the
operation, as conditions require, and to resolve any conflicts due to SIMOPS. The PIC must inform all
involved parties of any special problems that might be encountered and the appropriate actions to take
if such problems should occur

Softener:
A material used to protect the rigging or hoisting cable from being damaged or cut by a sharp surface.
Softeners are of two basic types – cut protection and abrasion protection. rigging softeners, acts as a
buffer to protect slings from edges of loads.

Improve sling efficiency:

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Reducing the angle of a choke with a wooden block, or blocks, between the hitch and the load This also
increases the angle between the two legs to improve sling efficiency

Working with loads:

Safe Working Load (SWL) sometimes stated as the Normal Working Load (NWL) is the maximum
safe force that a piece of lifting equipment, lifting device or accessory can exert to lift, suspend, or lower,
a given mass without fear of breaking. Usually marked on the equipment by the manufacturer. It is a
calculation of the Minimum Breaking Strength (MBS) aka Minimum Breaking Load (MBL) divided by a
safety factor, usually ranging from 4 to 6 on lifting equipment. The factor can be as high as 10:1 or 10 to
1, if the equipment poses a risk to a person's life.
Working Load Limit (WLL) is the maximum working load designed by the manufacturer. This load
represents a force that is much less than that required to make the lifting equipment fail or yield. The
WLL is calculated by dividing MBL by a safety factor (SF). An example of this would be a chain that has a
MBL of 2000 lbf (8.89 kN) would have a SWL or WLL of 400 lbf (1.78 kN) if a safety factor of 5 (5:1, 5 to 1,
or 1/5) is used.
The current American standard for lifting and handling devices is Reference , which provides minimum
structural and mechanical design and electrical component selection criteria for ASME B30.20 below-
the-hook lifting devices. The provisions in this Standard apply to the design or modification of below-
the-hook lifting devices.
As such:
WLL = MBL / SF
SWL is no longer used to identify the maximum capacity of equipment due to it being too vague and
leaving it open for legal issues. The US and European standards switched to The Working Load Limit'
standard shortly after.

Cleanliness and Orderliness

Order and cleanliness are extremely important for safety at work. Lack of organisation is often one of
the reasons behind incidents and occupational accidents. Orderliness also makes work lighter, as it
makes it easier to use assistive devices such as handcarts.
Cleanliness and regular cleaning are also prerequisites for healthy indoor air. In addition to workspaces,
personnel rooms also need to be kept tidy and clean.
It takes relatively little to make a workspace neat and tidy. Maintaining order requires careful planning
of work and activities, teaching employees the correct procedures and ensuring that the agreed
procedures are followed in practice.
Workspaces must be cleaned sufficiently often
Good order in a workplace means that
 all access routes, passageways, exits and work surfaces are safe and well maintained
 all goods in the workplace are handled, transported and stored in an orderly manner, and
 all tools, equipment and waste are kept in their designated places.

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Appropriate safety labelling promotes order and cleanliness. All fire extinguishers and electrical
enclosures must be accessible at all times in order to ensure overall safety. In addition, all exits and
access routes must be clearly marked and kept free of any obstacles.
Cleanliness also includes removing dirt, dust and rubbish from workspaces. The need for cleaning, i.e.
the thoroughness and frequency of cleaning, depends on the circumstances in the workplace.
It must be possible to clean the premises without putting employees in danger. If necessary, cleaning
must be carried out outside of employees’ normal working hours. Cleaners should receive thorough
information on the conditions at the workplace, correct procedures and chemical safety.

Hand Signals
The Standard overhead crane and hoist hand signals adopted by ANSI standards are to be used. If
compliance with these hand signals is impractical for the job being performed, other hand signals shall
be agreed on by the operator and signal person. Radio communication may be substituted for hand
signals when agreed on between the operator and the signal person. No crane or hoist movement shall
be made unless signals are clearly understood. The operator shall respond to signals only from the
designated signal person. However, a stop signal shall be obeyed regardless of who gives it.
Tips when using hand signals
 Exaggerate each signal and make a distinct move when choosing to STOP that command before
going to the next action.
 The operator should be able to see the signaler and the load within the same field of view when
not operating in the blind.
 The signaler should train himself/herself to perform signals in an exact repeatable fashion.
(Every "Hoist the Load" signal he/she gives should look exactly alike). This will reduce or
eliminate
confusion
between
signaler and
operator.
 When signaling for the operator to "travel" on an overhead crane, anticipate and give the STOP
signal in
advance so
that the load
doesn't pass
beyond its
landing spot.

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Basic principles of hand signals
Rescue personnel must have a basic knowledge of hand signals normally used to communicate with the
crane operator.
on-standard hand signals. When using non-standard hand signals, the signal person, operator, and lift
director (where there is one) must contact each other prior to the operation and agree on the non-
standard hand signals that will be used. (d) New signals. Signals other than hand, voice, or audible
signals may be used where the employer demonstrates that: (1) The new signals provide at least equally
effective communication as voice, audible, or Standard Method hand signals, or (2) The new signals
comply with a national consensus standard that provides at least equally effective communication as
voice, audible, or Standard Method hand signals. (e) Suitability. The signals used (hand, voice, audible,
or new), and means of transmitting the signals to the operator (such as direct line of sight, video, radio,
etc.), must be appropriate for the site conditions. (f) During operations requiring signals, the ability to
transmit signals between the operator and signal person must be maintained. If that ability is
interrupted at any time, the operator must safely stop operations requiring signals until it is
reestablished and a proper signal is given and understood. (g) If the operator becomes aware of a safety
problem and needs to communicate with the signal person, the operator must safely stop operations.
Operations must not resume until the operator and signal person agree that the problem has been
resolved. (h) Only one person may give signals to a crane/derrick at a time, except in circumstances
covered by paragraph (j) of this section. (i) [Reserved.] (j) Anyone who becomes aware of a safety
problem must alert the operator or signal person by giving the stop or emergency stop signal. (Note: §
1926.1417(y) requires the operator to obey a stop or emergency stop signal). (k) All directions given to
the operator by the signal person must be given from the operator’s direction perspective. (l)
[Reserved.] (m) Communication with multiple cranes/derricks. Where a signal person(s) is in

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communication with more than one crane/derrick, a system must be used for identifying the crane/
derrick each signal is for, as follows: (1) for each signal, prior to giving the function/direction, the signal
person must identify the crane/derrick the signal is for, or (2) must use an equally effective method of
identifying which crane/ derrick the signal

Essentials for hand signals

A crane signal person is essential for all crane operations. From inside the crane booth, an operator’s
range of vision and awareness of the environment is significantly limited. Couple this with the serious
consequences of a crane accident, and it is easy to see why a having another person with eyes and ears
on the ground would be critical for safety and success at the job site. Therefore, knowing the proper
hand and voice signals to give the crane operator during a job is of the utmost importance.

126
Use of verbal communication during hand signaling operations

127
128
Types of hand signal

Commonly Used Crane Hand Signals

The Occupational Safety and Health Administration (OSHA) standard method of signaling must be used
when operating a crane unless non-standard crane hand signals are discussed during the pre-job
meeting. 
OSHA enforces standards and training requirements for safe working environments across multiple
industries, including construction in the United States.

Stop signals
Stop signals are one the most important crane hand signals used on a construction site. When stop
signals are used operation of the equipment must be halted.
 Emergency stop – A signal person will communicate an emergency stop by extending both
arms horizontal of the body with palms faced down, from this position they will swing their
arms back and forth.
 Stop – In order to pause or stop an action, the signal person will extend a single arm and
face their palm down; they will then begin to swing the extended arm back and forth.
 Dog everything – This signal will stop all activity and is performed by clasping hands
together and placing them at waist level.

Boom signals
Boom signals will inform the crane operator of which maneuver they should perform with the boom.
4. Raise boom – To raise the boom, a signal person will extend an arm horizontally to the side of
their body and signal thumbs up, with a closed fist.
5. Lower boom – In order to lower the boom the signal person will extend an arm horizontally and
signal thumbs down, with a closed fist.
6. Swing boom – To swing the boom, the signal person will extend an arm out horizontally, using
their index finger to point in the direction the boom is to swing.
7. Extend boom – To lengthen the boom, the signal person will place their hands at the front of
their waist and point thumbs outwards with remaining fingers in a fist.

Load signals
Load signals will dictate what the operator should do with a load once it has been lifted by the crane.
8. Hoist load – In order to lift the load upwards the signal person will extend their arm vertically
towards the ceiling/sky, point with their index finger and make small circles with their hand and
index finger.
9. Lower load – To lower the load downward, the signal person will extend their arm horizontally,
pointing their index finger towards the ground, once in this position they will make a circle
motion with their finger.
 
Speed signals

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The signal person can also control the pace of any movement using speed signals.
10. Move slowly – In order to slow the rate of an action, the signal person will a place their hand
above the hand which is giving the action signal.
See the full list of OSHA standard method hand signals

Blind Lift Signalling

 Crane safety depends on the best communications. The crane signalperson is the “great
communicator,” who has to be in contact with the crane operator at all times while the crane is
moving. When the signalperson is in the line of sight of the operator, hand signals are typically
used. However, during non-routine operations, such as critical lifts or when an operator is
working “in the blind”, voice communication through electronic means has become the
preferred method. Voice communication has many advantages over typical hand signals.
However, voice signaling is not without specific hazards that can cause unintended
consequences. Recently, an incident occurred where a signalperson, while signaling one crane,
gave direction on the wrong frequency to another crane. Fortunately, the crane operator didn’t
recognize the voice and did as he was trained – he stopped! This incident highlights the inherent
hazards with voice communication and how, without line of sight, an operator could easily
become confused and respond to incorrect direction. Bleed over, garbled radio traffic,
interference from high voltage transformers, or multiple crews using a single channel are other
potential hazards. Fortunately, there are steps that can be taken to minimize this risk.
 Prior to beginning lifting operations using voice signals, the signals shall be discussed and agreed
upon by the person directing lifting operations, the crane operator, and the appointed
signalperson.
 Telephones, radios, or equivalent, if used shall be tested before lifting operations begin. If the
system is battery powered, extra batteries should be available at the job site.
 Prior to commencing the lift, the operator and signal person shall contact and identify each
other. o Begin by calling the operator by name o Operator will acknowledge with the
signalperson’s name
 Signal transmission must be through a dedicated channel, except: o Multiple crane / derrick lifts
where one or more signalpersons may share a dedicated channel for the purpose of
coordinating operations
 The operator’s reception of signals must be by a hands-free system.
 All direction must be given from the operator’s perspective.
 Once the task has begun the signalperson should never break communication with the operator-
this is referred to as maintaining “constant communication.”
 All voice commands must be clear, clean, and constant
 The signalperson should maintain constant communication to let the operator know everything
is all right.
 If the signalperson breaks communication, the operator should stop immediately. The operator
will then acknowledge the signalperson by name and will continue only when signalperson
regains constant communication and identifies themselves.

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  If the operator sees something and needs to communicate with the signalperson, the operator
will stop and give one blast of the horn to alert the signalperson. The signalperson can then
break constant communication and the operator will notify the signalperson of the problem.
The above steps are the most basic means to help ensure reliable voice communication when
signaling a crane. Additional steps such as using dedicated single channel radios assigned to
specific cranes can be used in certain circumstances. As a response to this alert, we ask that our
contractor partners involved in crane operations:
 Ensure reliable voice communication is addressed in their site-specific safety plans and submit
to the E&CS construction site manager for review.
 Review signalperson training and ensure it meets the requirements of 29 CFR 1926.1428 and
make the training records available at the site for review if requested.
 Ensure dedicated radio channels are set up for specific crane activities respectively,
incorporating a method in which the safe execution of these lifts can be performed without
interruptions from personnel not associated with a specific lift. We thank you in advance for
your assistance to help ensure crane operations are safe and reliable so that everyone goes
home safe – everyday.

Standard Signals
The standard signals for DOE use shall be as specified in the latest edition of the American National
Standards Institute (ANSI) B30 chapters, for the particular type of crane or hoist being used.

Verbal communication
Prior to Lifting Operations
Prior to beginning lifting operations using voice signals, the signals shall be discussed and agreed upon
by the person directing lifting operations, the crane operator, and the appointed signalperson.
Telephones, radios, or equivalent, if used, shall be tested before lifting operations begin. If the system is
battery powered, extra batteries should be available at the job site. Prior to commencing a lift, the
operator and signalperson shall contact and identify each other.
• Begin by calling for the operator by name
• Operator will acknowledge with the signalperson’s name

Voice Command Basics

The devices used to transmit signals shall be tested on site before beginning operations to ensure that
the signal transmission is clear and reliable. Signal transmission must be through a dedicated channel.
Exception: Multiple cranes/derricks and one or more signalpersons may share a dedicated channel for
the purpose of coordinating operations. The operator’s reception of signals must be by a hands-free
system. Cautions regarding radio use may include the following:
• Awareness of any explosive devices in general area (radio transmissions have been known to cause
premature detonation of explosives that use electric detonators)
• Other electronics (potential for interference)
• Other radios nearby operating on the same frequency

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Elements of Voice Signals
Each series of voice signals shall contain three elements stated in the following order: 1. Function and
direction 2. Distance and/or speed 3. Function stop Function names should be the same as the ASME
B30 standard hand signal names. Here are some examples of correct voice signals:
• Swing right 50 feet, 25 feet, 15 feet, 10 feet, 5 feet, 2 feet, swing stop
• Lower load 100 feet, 50 feet, 40 feet, 30 feet, 2 feet, lower stop
• Hoist load slow, slow, keep hoisting, slow, hoist stop When giving swing command, the signalperson
will give directions from the operator’s perspective. When describing distance, give the distance
remaining, not the distance traveled.
• Lower 50 feet, 40 feet, keep lowering 30 feet, 20 feet, 10 feet 5 feet, 3, 2, 1, lower stop Let the
operator know when he/she is close to the spot that he/she is to stop.
• … about three feet, two feet, one foot, swing stop Once the task has begun the signalperson should
never break communication with the operator – this is referred to as maintaining “constant
communication.” All voice commands must be clear, clean, and constant. Never unkey the microphone
while the load is moving. The signalperson should maintain constant communication to let operator
know everything is all right.
• slowly down, slow, slow, slow…
If signalperson breaks communications, the operator should stop immediately. The operator will then
acknowledge the signalperson by name and will continue only when signalperson regains constant
communication. If the operator sees something and needs to communicate with the signalperson, the
operator will stop and give one blast of the horn to alert the signalperson. The signalperson will break
constant communication and the operator will notify the signalperson of the problem. It is helpful for
the signalperson to give a detailed ongoing description of the parts of the lift that the operator cannot
see (i.e., operating “in the blind”). The goal is to “paint a picture” for the operator in these situations.

Acceptable Voice Signal Terminology

The words and word order must be followed exactly when giving signals in an effort to remain
consistent. Transposing the function and direction (e.g., “Up hoist”) or function and stop (e.g., “Stop
Hoist”) will be considered incorrect. When initiating a function, articles such as “the” or “a” may be used
as well as a combination of the acceptable terms (e.g., “Hoist the load” or “Hoist up the load hook” are
both considered correct). When terminating a function, the signalperson must communicate to the
operator using only “[Function] stop” to ensure the operator ends the operation. Any additional words
are considered incorrect signals. See the following table for the correct terminology to stop each
function. Some voice signal functions inherently give a direction as well (e.g., “Hoist” or “Lower”). For
those that are simply a function, be sure to include a direction when initiating the function (e.g., “Swing
RIGHT” or “Trolley OUT”). NOTE: “SLOWLY” can be used at any time with any signal. “SLOWLY” is always
at the end of the command (e.g., “Hoist load SLOWLY).

Identification of Signalers
 All personnel acting as signalers during crane operations shall be clearly identified to the crane
operator by the use of the following (one or more, as required by the cognizant manager):

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 orange hardhat; orange gloves; and/or orange vest. At WVNS, riggers are required to wear
orange vests when lifting outside. Additionally, the orange rain coat used during inclement
weather may be used in lieu of the orange vest. Also, a hat or orange gloves must be used by the
signaler(s) for identification purposes. This requirement may be waived by the cognizant
manager when the lift is very closely controlled or personnel are required to wear special
clothing for protection from a hazardous environment.
 In those cases where the crane operator cannot see the signaler, a second person (relay
signaler) shall be stationed where he/she can see both the signaler and the crane operator and
relay the signals to the operator
 Where voice (direct or two-way radio) communication is used, the signaler shall communicate
directly with the operator: not through a third person.
 The operator shall recognize signals only from the designated signaler, except that a signal for a
stop shall be obeyed when given by anyone.

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 Chapter 3

Rigging gear and inspection criteria

Wire Rope Sling

Wire rope slings, sometimes referred to as wire cable slings are more robust and durable than nylon
slings and also have higher temperature limits. Wire rope slings with an independent wire rope core
(IWRC) can withstand contact and exposure temperatures up to 400 degrees (F).

a 5:1 ratio
The Design Factor for wire rope slings is a 5:1 ratio, meaning the breaking strength of the sling is five
times higher than the rated Working Load Limit. Although metal mesh slings have a design factor, the
user should never exceed the rated Working Load Limit.

Proper Use of Industrial Wire Rope Slings

Wire rope slings have been used extensively for years and were once the industrial lifting sling of choice.
Wire rope slings, sometimes referred to as wire cable slings are more robust and durable than nylon
slings and also have higher temperature limits.
Wire rope slings with an independent wire rope core (IWRC) can withstand contact and exposure
temperatures up to 400 degrees (F). Wire cable slings with fiber cores should never be exposed to
temperatures in excess of 180 degrees (F). Wire rope slings of all types should never be used at
temperatures below -40 degrees (F). Wire rope rigging slings with fiber cores (FC) are rated at reduced
capacities when compared with an equivalent size, wire choker with an independent wire rope core
(IWRC). They are generally fabricated from 6 x 19 or 6 x 37 construction wire cable. The constructional
numbers refer to the number of strands (6) that are helically wound around a core. The core supports
the strands of the wire rope lifting sling and can either be an independent wire rope core (IWRC) or a
fiber core (FC) made from hemp or sisal. Smaller diameter wire rope slings feature 6 strands with 19
wires in each strand. Larger diameter industrial lifting slings will generally feature 6 strands with 37
individual wires in each strand. The 6 x 37 construction is more flexible than the 6 x 19 construction, but
not as abrasion resistant.

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Wire cable lifting slings used by the crane, rigging and material handling industries are available in many
different styles and constructions to meet your needs. Custom made slings and special order slings are
shipped daily from our factory. The most popular wire lifting slings are Single Body slings featuring a 6 x
19 or 6 x 37 Construction, Extra Improved Plow Steel (EIPS) Wire Rope with an Independent Wire Rope
Core (IWRC). These slings are sometimes referred to as wire chokers, Permaloc wire rope slings, wire
cable slings, Flemish eye slings, single leg slings, eye and eye slings or eye & eye slings due to the loop or
eye that is formed on each end of the wire sling.

Wire Rope Sling Safety

There are different grades and strengths of steel used to manufacture the individual wires that make up
the sling. The most popular for sling fabrication is (EIPS). Metallurgists continue to improve the tensile
properties of steel with new, corresponding designations such as EEIPS (Extra-Extra Improved Plow
Steel). Single leg, Flemish Eye/Mechanical Splice, Wire Slings provide additional security, superior to
return loop wire slings should the swage sleeve become damaged during use. Single Body Wire Cable
slings are available in 15 different types which feature different combinations of plain loops, three types
of thimbles (crescent, standard and slip through) and rigging hooks. Thimbles greatly improve sling
longevity by protecting the rope at connection points. We offer two types of single leg wire slings that
feature a sliding choker hook that is placed between the sling eyes. Industrial lifting slings with sliding
choker hooks make removal of the cable sling from the load, quick and easy. Type 14 lifting slings
feature a lifting loop on one end and a thimble on the opposite end to engage the sliding choker hook.
Type 15 lifting slings features plain loops each end. View the 15 single leg wire sling types available .
We will not sell you a sliding choker hook without a hook latch, but there are many that will! Stainless
Steel Wire Rope Slings provide the sling user with improved corrosion resistance and are also readily
available. Cable Laid Wire Rope Slings with a galvanized finish are also available. Cable Laid Wire Slings
are much more flexible than equivalent sized, single body wire slings. The flexibility of industrial lifting
slings that feature a cable laid construction is a direct result of the small diameter, aircraft cable used in
the fabrication of the wire sling. Size for size, cable laid lifting slings are not as strong as equivalent sized,
single body, wire chokers. Cable laid wire slings can be equipped with many of the same options
available for single body slings.

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Single Leg Wire Rope Double Leg Wire Three Leg Wire Rope
Four Leg Wire Rope
Sling Rope Sling Sling
Sling

Slings What should you know or determine before choosing a sling?

 Always determine:
 The weight of the load.
 The centre of gravity of the load.
 The best slinging configuration that provides the proper balance for the load.
 The working load limit of the sling.
 The work rated load of the attachments and components of the sling.
 Other physical characteristics of the load (geometry, sharp edges, surface temperature, etc.).
 The environmental conditions (temperature, humidity, presence of corrosive agents).
 The characteristics of different types of slings.

What should you know when using any type of sling?

 Be sure you know the correct use of the equipment, the slinging procedures and the sling
strength factors to be applied before lifting. Always check the manufacturers' information
before using.
 All slings (new, altered, modified, or repaired) should be inspected by a competent person
before they are used in the workplace to make sure they are built to specfiications, not
damaged, and will be appropriate for the work being performed.
 Please see the individual documents (as listed above: wire rope, fibre rope, chain, synthetic,
metal mesh) for information about:
 How to care for the sling.
 How to inspect the sling.
 How to store the sling.
 When to remove a sling from use.

Sling Configurations

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Weights per Square Feet
The formula to figure square feet is length x width.
The basic weight is that of 1 square foot of steel an inch thick is approximately 40 Ibs. For example, the
weight of two plates of
steel measuring 1-112 'I x 3' x 6' would weigh: 2 x 3 x 6 x 60 = 2160 (see above).
2 = number ofsheets
3 = width
6 = length
60 = number of pounds per 1 square
foot of 1 1/21' steel
The weights of angles also can be approximated close enough for safe job use. This is done (in your
mind) by flattening out the angle to make it a plate (45). Weights of
any structural shape can be computed in this manner by separating the parts and
flattening them into rectangles which, in turn, become parts or multiples of a square foot of steel an
inch thick.

On any given day a load can be rigged and moved in a variety of ways. At left are a
group of
and bridle types which represent good, poor, and unacceptable
rigging methods. You must also be concerned with the radius of contact of the sling when it is rigged
around the corner of an object. The radius of contact should equal one rope lay giving approximately
80% efficiency. Softeners are often used to create a better ratio.

Types of sling materials

 Wire rope slings
 Fibre rope slings
 Chain slings
 Synthetic web slings
 Metal mesh slings
Wire rope slings
 Wire Rope consists of three components: The CORE is the center of the wire rope. The core
serves as the foundation to hold the rope together.
There are three types of cores:
 Fiber - synthetic or sisal, which is the weakest,
 Strand - the core is a wire strand, just like the other strands of the rope. independent Wire Rope
(IWRC) -this is a separate wire rope.
 It is the strongest of the three types. The core provides 7-1/2% strength of the wire rope. This is
the core used in the wire rope slings
 provided on site.
 The WIRE is the basic unit of the wire rope.

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  The wires form the strand. Most wire is high carbon steel, but other material types are
available .
 The STRAND is made up of a specific number of wires, laid helically around a wire core.
 The most common type used at WVNS and in industry is 6 x 19. This is six strands comprised of
approximately 19 wires (2), but may have 16 through 26 wires per strand. It has a good
combination of flexibility and wear resistance.
 The term rope lay signifies the direction of rotation of the wires and the strand.
 Rotation is either to the right (clockwise) or left (counterclockwise).
 The standard is right regular lay. Left-lay rope is for special-purpose applications.
 The lay-length is the distance measured along a rope in which a strand makes one complete
revolution around the axis. Wire rope slings have great strength combined with flexibility.
 They do not wear as rapidly and the indication of broken wires and appearances show its true
condition. Wire rope should be protected with softeners or blocking when used at corners or
sharp bends.
 These softeners are available at the tool crib. It's a good rule to make sure that the length of the
arc of contact of the rope is at least equal to one rope lay (above seven times the rope
diameter).
 This is the most common cause of damage to wire rope. Practice proper rigging and use
softeners at corners or sharp bends. This is especially important when the load approaches the
capacity of the rigging.

FATIGUE RESISTANCE
Fatigue resistance involves metal fatigue that make up a rope. To have high fatigue
resistance, wires must be capable of bending repeatedly under stress - as when a rope passes over a
sheave. increased fatigue is achieved in a rope design by using a large number of wires. It involves both
the basic metallurgy and the diameters of wires. In general, a rope made of many wires will have greater
fatigue resistance than a same-size rope made of fewer larger wires, because smaller wires have greater
ability to bend as the rope passes over sheaves or around drums. To overcome the effects of fatigue,
ropes must never bend over sheaves or drums with a diameter so small as to kink wires or bend them
excessively. There are precise recommendations for sheave and drum sizes to properly accommodate all
sizes and types of ropes. Every rope is subject to metal fatigue from bending stress while in operation,
and therefore, the rope's strength gradually diminishes as the rope is used.
STRENGTH
Wire rope strength is usually measured in tons of 2,000 pounds. The catalog term "Breaking Strength"
-- is the nominal strength given the rope by engineers. When put under tension on a test device, new
ropes will actually break at a figure equal to, or higher than, the catalog figure. The catalog figure applies
to new, unused rope. A rope should never operate at the catalog strength . During its useful life, a rope
loses strength gradually due to natural causes such as surface wear and metal fatigue. Therefore, a
Factor of Safety is applied during the selection of a rope in order to build service life into a rope
installation.

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Sling Eye Design
Sling eyes are designed to provide what amount to "small inverted slings" at the ends of the sling body.
Therefore, the width of the eye opening will be affected by the same general forces which apply to legs
of a sling rigged as a basket. A sling eye should never be used over a hook or pin with a body diameter
larger that the natural width of the eye. Never force an eye onto a hook. On the other hand, the eye
should always be used on a hook or pin with at least the nominal diameter of the rope-since applying
the D/d Ratio shows an efficiency loss of approximately 50% when the relationship is less then 1/1 .

D/d Ratios Apply to Slings

When rigged as a basket, diameter of the bend where a sling contacts the load can be a limiting factor
on sling capacity. Standard D/d ratios-where "D" is the diameter of the bend, and "d" the diameter of
the rope-are applied to determine efficiency of various sling constructions, as indicated at left:

Choker Hitch Rated Capacity Adjustment

For wire rope slings in choker hitch when angle of choke is less than 135 degrees. When a choker hitch is
drawn tight at an angle of less than 120 degrees, the Choker Hitch Rated Capacity shown in the sling
Rated Capacity Tables must be reduced to allow for loss of Rated Capacity. In controlled tests, where the
angle was less than 120 degrees, the sling body always failed a the point of choke when pulled to
destruction. Allowance for this phenomenon must be made anytime a choker hitch is used to shift, turn
or control a load, or when the pull is against the choke in a multi-leg lift.

FREQUENT (PRE-USE) INSPECTION

Slings shall be visually inspected by the person using the sling each day of their use. This visual
observation should be concerned with discovering damage that may be an immediate hazard.
Be sure to be aware of wire ropes in acid type environments. Such an environment can have a rapid
corrosive affect on the wire rope.

Kinks
Kinking is caused by loops that have been drawn too tightly as a result of improper handling. Kinks are
permanent distortions and will require the rope or the damaged section to be removed from service.
The following should be looked for in a pre-use inspection:
 Broken wires.
 Severe localized abrasion or scraping.
 Kinking, crushing, birdcaging, or any other damage resulting in distortion of the rope structure.
 Evidence of heat damage.
 End attachments that are cracked, deformed, or worn to the extent that the strength of the sling
is substantially affected .
 Severe corrosion.

Synthetic web slings

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Synthetic web slings have a number of advantages which include:
 Pliable, flexible, and tend to mold themselves to the shape.
 Minimize twisting and spinning.
 Do not rust and are non-sparking.
 Won't mar or crush the load.
 Are elastic and stretch.
There are two type of synthetic web slings at WVNS:
nylon and polyester.
Nylon is the most common type used on site. It has an elastic stretch of 6% at noted capacity.
Polyester has less stretch, approximately 3 percent. The stretching of slings allows a cushion against
sudden shock. Both types are sensitive to heat and certain chemicals. Neither should be exposed to
temperatures above 180 degrees F, and will soften on prolonged sunlight exposure. Therefore, the slings
should be stored inside or under cover.
The size of the sling is determined by the width of the web. Each sling has a tag sewn to it with the type,
size and rated capacities Note the capacity for the vertical, choker and basket hitch are different. The
use of synthetic web slings in radiation areas should be avoided if possible. If it is necessary to use a
nylon sling in a radiation area, the responsible person shall ensure radiation exposure to the sling does
not exceed 100,000 rad during the life of the sling. Polyester fiber slings shall never be used in a
radiation area.

FREQUENT (PRE-USE) INSPECTIONS

Slings shall be visually inspected for defects by the person using it before actual use. Red colored yarns
(9) are woven into the inner layer of most slings and, when exposed, indicate the sling should be
removed from service.
Causes of wear or damage to synthetic web
slings include :

Acid or Caustic Attack

Acid or caustic attack is normally evident by discoloration of the fabric. It can also cause the fabric to
appear to be rotten.

Melting or Charring
Melting or charring on any part of the sling is sufficient enough reason to take a sling out
of service. Damaged areas will be blackened, hard and melted like plastic, or speckled as when damaged
from weld spIatter.

Holes, Tears, Cuts or Snags

When holes, tears, cuts or snags appear on synthetic web slings, it is a judgement call on whether or not
the sling is to be taken out of service. It must be determined how much of the inner thread damage
there is to the sling, for they compose 80% of the sling's strength. This type of damage can be found on
any port of the sling. When red guard

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warning yarn is exposed (red thread that is sewn in by the manufacturer) the sling must be taken out of
service.

Excessive Abrasive Wear

Abrasive wear is characterized by frayed fibers on the surface webbing of the sling that hold in place the
load-bearing (longitudinal) fibers. This type of abrasive wear is caused when a load slips in a sling or
when slings are allowed to be pulled from under a load.

Broken or Worn Stitching

Slings must be inspected for broken or worn stitching in the load bearing splices of the sling. Broken or
worn stitching in any other part of the sling is not of a critical nature. However, broken or worn stitching
in load bearing splices can cause significant reduction of sling capacity.

Knots
Slings with knots in any part of them shall not be used. A knot in a sling can reduce the sling capacity up
to 50% in the area of the knot.

End Fittings
Be sure to check for excessive pitting or corrosion, cracked, distorted or broken end fittings. Check for
any other visible damage that causes doubt as to the strength of the sling.

CHAIN SLINGS
Chain slings must be made of alloy steel.Chain has the advantage of being better suited for lifting rough
loads and withstanding high temperatures.
When possible use a wire rope sling instead of a chain sling. The failure of a single link of a chain can
result in an accident. When overloaded it will stretch a bit and fail suddenly without warning. Another
difficulty of chain is that inspection is difficult due to the necessity to inspect each link.

FREQUENT (PRE-USE) INSPECTION

As required for all slings, Alloy Steel Chain slings shall be visually inspected by the person using the sling
each day of its use. This visual observation should be concerned with discovering damage that may be
an immediate hazard and a check of the equipment tag to verify the inspection due date.
Defects to look for on chain slings are as follows:

Length
Check overall length to see it matches up with the length on the tag. If a sling is shorter or longer
(considering allowable tolerances) than the length on the tag. The sling must be taken out of service

Link Inspection
Master Link
Check the master link for elongation and wear on its bearing points.

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Identification Tag
Be sure that the identification tag is legible with the proper information on it.

Connecting Link
Check the connecting link to see if it's bent,
twisted, or deformed in any way.

Links
 Chain links must be checked for cracks, nicks, and gouges.
 Elongation
 Bends or twists
 Heatdamage
 Excessive wear
 Hooks

METAL MESH SLINGS

GENERAL REQUIREMENTS
Only commercially manufactured slings shall be used. Attachments End fittings shall be designed to
ensure that the rated load of the sling is not reduced and the load is evenly distributed across the width
of the fabric. No nonstandard (home-made) attachments shall be used.

FREQUENT (PRE-USE) INSPECTION

As with all slings, metal mesh slings shall be visually inspected by the person using it each day of its use.
Metal mesh slings should be inspected for the following
deficiencies:
 Broken welds or broken brazed joints along the sling edge.
 Broken wire in any part of the mesh.
 Reduction in individual wire diameter of 25% due to abrasion or 15% due to corrosion.
 Lack of flexibility due to distortion of the mesh.
 Distortion of the choker fitting so the depth of the slot is increased by more than 10%.
 Distortion of end fitting so the width of the eye opening is decreased by more than 10%.
 A 15% reduction of the original cross-sectional area of metal at any point around the hook
opening of end fitting. Visible distortion of either end fitting out of its plane. Cracked end
fittings.

GENERAL OPERATING PRACTICES OF

SLINGS
 The weight of the load shall be within the rated capacity of the sling.
 Slings shall not be shortened or lengthened by knotting, twisting, with wire rope clips or other
methods not approved by the sling manufacturer.
 Slings that appear damaged shall not be used.

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  Sharp corners in contact with the sling should be padded to prevent damage to the sling.
 Shock loading should be avoided.
 Sudden starts and stops increase (out of all proportion to the load), stress in the sling and crane
hoist rope.
 Slings should be stored in an area where they will not be subjected to mechanical damage,
corrosive action, moisture, extreme heat, or kinking.
 In a choker hitch, wire rope slings shall be long enough so that the choker fitting
 will choke on the rope body and never on the fitting.
 Sling angles less than 45 degrees
 should be avoided.

Rigging Components:

Sheaves
Besides being an integral part of blocks, sheaves are also used in a wide variety of applications, not only
limited to cranes. sheaves are mostly used for wireropes. Standard production method is cast ductile
iron with graphite lubricated grooves, however, cast steel, nylon and welded fabricated production is
also possible

Types of sheaves:
Normal Duty Sheaves
 As the name implies, normal duty sheaves are
designed for moderate weight loads and “normal”
duty applications. These sheaves are available in
76mm through 406mm (3” to 16”) wide sheaves
and are often protected with sheave guards so the
rope or wire being used stays in place.
 A normal duty sheave block is best for lighter
loads and slow line speeds, such as hand-operated
applications.
 There are five distinct types of bearing options on
normal duty sheaves. Bearings are smaller circular
pieces of metal that fit inside of the pulley to help
it rotate.
 Different bearing styles are designed for various applications.
 Self-lubricating bronze bushings are best for pulleys that are difficult to reach for re-lubrication
and are often best at low speed, intermittent operations.
 Plain bore sheaves are best for infrequent usage and light loads and must be regularly re-oiled.
 Plain bronze bushings require frequent lubrication but are designed for heavier loads and
continuous operations at slow speeds.

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  Straight roller bearings are optimal for medium loads and high-speed operations. Regular
lubrication is required, especially if it is in continuous operation.
 Tapered roller bearings are designed for heavy loads and high-speed, uninterrupted operation.
These do require regular lubrication, particularly if they are in continuous use.
 Normal duty sheaves are made from machined ductile iron, which offers distinct advantages
over other types of metals –, particularly steel. Ductile iron has a higher silicon content, which
offers it more machinability and will often last longer than tools made of steel.
 Normal duty sheaves are commonly used in:
 Sailing equipment
 Farming machinery
 Some construction, but not for heavy load-bearing equipment

Heavy Duty Sheaves

 Heavy-duty sheave blocks are best for heavy-duty applications with thicker ropes and cables and
heavier weight bearings. They are available in 102 mm through 305 mm (4” through 12”), and
are often used in work environments where the sheave block will be operating continuously.
 Heavy-duty sheaves use closed die forging, which means that the hot metal is poured on dies (or
molds) and forged into particular shapes. This helps to strengthen the shape of the tool since it
does not need to be welded together in multiple pieces.
 These are often used for:
 Material handling equipment
 Construction equipment
 Rigging
 Crane slings

Domed Sheaves
 Domed sheaves are reinforced for extreme duty applications. These sheave blocks are welded in
a circular pattern, which reduces additional stresses made by welding ribs. Domed sheaves are
also the largest and are available in 610 mm (24”) and larger sizes.
 Domed sheave blocks have the greatest strength and rigidity of all sheave types and are made
for applications with high working stress, heavy loads, and continuous operation.
 Domed reinforced sheaves are often used in:
 Specialty equipment applications
 Large lifting equipment
 Large cranes and construction equipment

Sheave Inspection and Rejection:

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  Check sheave grooves for wear.
 Check flanges for wear, chips and cracks.
 Check bearings for wobble, lubrication and ease of rotation.
 Check grooves for proper size.
Minimum groove radii for worn sheave tolerances per “Wire Rope User’s Manual” (third edition)
Nominal Wire Rope Size Radii Nominal Wire Rope Size Radii
(in.) (in.) (in.) (in.)
1/4 .128 3/4 .384
5/16 .160 7/8 .448
3/8 .192 1 .513
7/16 .224 1-1/8 .577
1/2 .256 1-1/4 .641
9/16 .266 1-3/8 .705
5/8 .320 1-1/2 .769
 Sheave Fleet Angle*
 Fleet Angle is the entrance and exit angle of the wire rope relative to the sheave
 Fleet angle should be no more then 1-1/2 degrees

Sheaves can often be the cause of poor rope performance. In extreme cases they can rapidly destroy a
new rope to the extent that it lasts far less time than the rope it replaces. This is a real problem because
the most immediately available response to a rope breakdown is a new rope. Sheaves get forgotten, or
are more difficult to address in time.
The first and most important point thing to eliminate are ‘sheaves gone BAD’. Bad sheaves are always
going to be unkind to the rope. They are also going to be difficult (or pointless) to condition monitor by
measurement. A ‘bad sheave’ is going to be one which has any of the bad wear situations we describe in
the following.

Treading
 A common wear presentation is so called ‘rifling’ or ‘treading’. When this occurs, we can see the
negative imprint of the rope onto the sheave.
 This is where we start inspecting any groove. A set of marks much like the treading in the image
might be visible. These could simply be little marks in paint or galvanising – indeed such marks
could be a good thing, since such ‘witness marks’ can confirm to us that a sheave has been load
tested. They could also be simply the imprint of lubricant or a little surface corrosion.
 The first point of inspection therefore is to wipe clean the groove and ensure that it is possible
to get a good look at it. This makes a difference specifically with respect to treading. If we are
looking at a situation where the rope is still in service, then a tiny little treading can be tolerated.
If we are changing the rope, then treading cannot be tolerated because it will never match the
shape of the new rope – even if it is the exact same brand and size – even if it has been cut from
the same reel. This is because one and the other have worn together in sympathy.
 Upon inspecting the sheave, we must establish it to be free from treading otherwise we’ll be
giving a new rope a rough ride – and we’ll also struggle to measure the wear and apply limits.

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Reading the sheave
 Once we have the context, and have eliminated an obvious treading problem, the next step is to
‘read the sheave’. Reading the sheave means feeling for ridges and burrs – and working out if
the shape we’re going to measure really is the right shape to begin with.
 Wear can be apparent right in the middle of the groove. The rope may be cutting a slot at the
base of the groove and we may be able to feel a ridge developing at the transition.
 Wear can also give similar ridges but occur somewhere the rope is working back and forth so
that the groove radius is worn wider than it should be. The groove here is more likely to be
elliptical so it is both too large and not really the right shape. Without the ridges this is a bit like
using a sheave that is too large, but the presence of the ridges makes this somewhat worse than
that.
 Wear can often be biased towards one side.
 In very severe cases we might see a rope spending a great deal of time on the vee flank and
even see wear right out to the sheave rim.
 Or we may have combinations of wear effects, which will make measuring the wear difficult.
 Several other points of inspection must also be attended to and inspectors must be mindful of
other forms of wear, deterioration and defect which they should look out for.
 In cases of severe fleet angle, or bearing spacer collapse the sheave may be worn on the outside
of its rim.
 In severe cases this is accompanied by a sharp burr forming which will rapidly destroy any rope
it touches.

Overhaul Balls
 overhaul balls are used in crane applications to supply downhaul weight required to lower unloaded
fast lines. To meet virtually all field applications, standard overhaul balls are offered in a range of over
two-hundred-forty models, from 3 to 30 tons, and from 35 to 1500 pounds. so that the crane lines are
kept taught. This prevents spooling and twisting issues that would ultimately create permanent damage
the crane. These overhaul balls vary in size and design depending on the crane truck or shop
environment in which it’s being used.
a non-swiveling overhaul balls features can take on the working load limit from 4 to 15 tons, depending
on the model.
Each split overhaul ball is specially designed for tasks where headroom is important. The angular contact
bearings on the overhaul ball ensure the most efficiency and longevity of the swivel and Wireline. Plated
in zinc, these overhaul balls will resist corrosion. This product is further customizable, as our split
overhaul balls are available with wide jaw openings and upper fittings.
Swivel models utilize thrust bearing swivels, with easily accessible lubrication fittings. All models can be
used with multiple sizes of wire rope, utilizing Johnson flexible-size wedge sockets.

Midget Non-Swiveling Overhaul Balls

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Small and economical, these husky units are ideal for low tonnage applications. Both 3 and 5-ton WLL
capacities are available for top performance in lifting and downfall speeds. Weights from only 3 pounds
up to 49 pounds are available.

Midget Swiveling Overhaul Balls

midget swiveling models have an advantage in size, as they are usually short in overall length. The basic
eye-top model is just 13-1/2 inches long, for tight fit applications. A jawtop is also available, utilizing a
pin connection.

Top Swivel Overhaul Balls

this versatile style over forty years ago, providing more easily accessible upper fittings. Top swiveling
models allow the rope and just the top fitting to rotate, facilitating positioning of the hook and load.
This style has become so popular that over 130 models are now offered, from 40 pounds to 1500
pounds, and from 4 tons WLL to 30 tons WLL.

Bottom Swivel Overhaul Balls

The original style overhaul ball, it is known for exceptional compactness. From 25 to 30% shorter than
other styles, it is outstanding in tight lifting applications. The swivel and wedge socket are almost
completely enclosed in the ball assembly to achieve the compact profile frequently needed for close-in
construction work.

Split Ball Assemblies

Split ball assemblies are available to easily and quickly add overhaul weight directly on the wire rope. A
50-pound assembly is available for 1/2”and 5/8” rope, and a 100-pound assembly is available for 5/8”,
3/4”, and 7/8” rope.
Overhaul Balls and Pins
Replacement and substitute assemblies are available. From 40 to 1200 pounds per assembly, the ball
and pin can be changed out to change the existing ball weight or to replace damaged parts

Effects Of Environment
Temperature When Overhaul Balls are to be used at temperatures above 150°F (66°C) or below 0°F
(−18°C), the Overhaul Balls manufacturer or a qualified person should be consulted.

Chemically Active Environments

Chemically active environments, such as caustic or acidic substances or fumes, can affect the strength,
operating characteristics, or both of Overhaul Balls. The Overhaul Balls manufacturer or a qualified
person should be consulted when Overhaul Balls are used in chemically active environments.

Training
Overhaul Balls users shall be trained in the selection, inspection, cautions to personnel, effects of
environment, and rigging practices as covered by this Chapter

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Inspection, Repair, And Removal
General
All inspections shall be performed by a designated person. Any deficiencies identified shall be examined
and a determination made by a qualified person as to whether they constitute a hazard.
Initial Inspection
Prior to use, all new, altered, modified, or repaired Overhaul Balls shall be inspected to verify
compliance with the applicable provisions of this Chapter. Written records are not required.

Frequent Inspection
 A visual inspection shall be performed each shift before the Overhaul Balls is used. Rigging
hardware in semi-permanent and inaccessible locations where frequent inspections are not
feasible shall have periodic inspections performed.
 Conditions such as those listed, or any other condition that may result in a hazard, shall cause
the Overhaul Balls to be removed from service. Overhaul Balls shall not be returned to service
until approved by a qualified person.
 Written records are not required.

Periodic Inspection
A complete inspection of the Overhaul Balls shall be performed. The Overhaul Balls shall be examined
for conditions such as those listed and a determination made as to whether they constitute a hazard.

Periodic Inspection Frequency

 Periodic inspection intervals shall not exceed 1 yr. The frequency of periodic inspections should
be based on
 frequency of use
 severity of service conditions
 nature of lifting or load handling activities
 experience gained on the service life of Overhaul Balls used in similar circumstances (2)
Guidelines for the time intervals are
 normal service — yearly
 severe service — monthly to quarterly
 special service — as recommended by a qualified person
 Written records are not required.

Removal Criteria
 Overhaul Balls
 shall be removed from service if conditions such as the following are present and shall only be
returned to service when approved by a qualified person:
 missing or illegible identification
 misalignment or wobble in sheaves
 excessive sheave groove corrugation or wear

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  loose or missing nuts, bolts, cotter pins, snap rings, or other fasteners and retaining devices
 indications of heat damage, including weld spatter or arc strikes
 excessive pitting or corrosion
 bent, cracked, twisted, distorted, stretched, elongated, or broken load-bearing components
 excessive wear, nicks, or gouges
 a 10% reduction of the original or catalog dimension at any point
 excessive damage to load-bearing threads
 evidence of unauthorized welding or modifications
 for hooks, the removal criteria specified in B30.10
 for shackles, the removal criteria specified in B30.26
 other conditions, including visible damage that cause doubt as to the continued use of the
Overhaul Balls 26-5.8.6 Repairs and Modifications
 Repairs, alterations, or modifications shall be as specified by the Overhaul Balls manufacturer or
a qualified person.
 Replacement parts, such as pins, hooks and sheaves, shall meet or exceed the original
equipment manufacturer’s specifications.

Hooks
hooks are forged carbon or high tensile strength DIN hooks and may be used in a wide variety of lifting
applications. Larger sizes hooks, with capacities of 600t and more may also be produced as a casting.
Fig). Single Hook, Double Hook, Double Hook with shackle hole

Latches:
Latches are used in hooks to prevent the loads from slipping

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Swivels
swivels may be used in applications where wire rope twist
needs to be released. Some of the key features: n Closed
body design n Low weight design n High capacity, low
friction thrust bearings n Wide variety of interfacing
connections n Subsea capabilities optional n Proofloaded
and serialized n Finish depending on specific requirements

Synthetic Web Slings

Web slings are flat belt straps made of webbing material and
most commonly feature fittings, or flat or twisted eyes, on
each end. Web slings are the most versatile and widely-used
multi-purpose sling. They’re strong, easy to rig, and
inexpensive. Compared to chain, they’re more flexible and
lighter and can be used to help reduce scratching and denting
to loads. They can also be fabricated with wide load-bearing
surfaces up to 48” to provide significant surface contact
for heavy and large loads.
Nylon web sling performance isn’t affected by oil and grease, and they’re resistant to alkaline-based
chemicals. However, they should never be used in acidic atmospheres or near chemicals used as
bleaching agents. Polyester web slings can be used in acidic environments or near chemicals used as
bleaching agents, but should never be used in alkaline environments.
They also have a relatively low heat-resistance and are not to be used in environments that exceed
194°F, or environments where temperatures are below -40°F. For loads with sharp edges, corner
protectors or edge guards should be used to protect the sling from cuts and tears. Because there is a
difference between abrasion resistant protection and cut resistant protection, be sure to identify the
type of resistance required for your application.
If used outdoors, they should be stored away in a cool, dark, and dry environment to avoid prolonged
exposure to sunlight and UV rays, which can damage and weaken the strength of the sling. When a lift is
made at the W.L.L., the user can expect approximately 8-10% stretch when using a nylon web sling and
3% stretch when using a polyester web sling at rated capacity.

Inspection
There three types of inspections that occur during the service life of a piece of rigging equipment:
Initial Inspection – Make sure you perform an initial visual inspection when you receive any new rigging
products from a supplier. Double check the tags on slings, and any and all markings on hardware, to
ensure it’s what you ordered and is properly rated for the lift you’re going to perform.

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Frequent Inspection – Best practice is to have your riggers and operators perform a hands-on inspection
of all rigging equipment prior to any change in shift or change in lifting application. For severe or special
service applications, inspect all rigging gear before each use.
Periodic Inspection – Required, at a minimum, once every 12 months. Never use the term “annual”
when referring to a Periodic inspection. The severity of service and operating environment may dictate
more frequent Periodic inspections (monthly to quarterly) than once every 12 months, as recommended
by a Qualified person.
If you’re not confident in your knowledge of the applicable OSHA and ASME standards, or just don’t
have the resources to put a lifting and rigging compliance program into place, you should consider
a third-party inspection provider.

Chapter 4
Putting Slings to Work – Hitch, Capacity, & Hardware Selection

Personal Protective Equipment

Personal protective equipment (PPE) is
protective clothing, helmets, goggles, or other garments or
equipment designed to protect the wearer's body
from injury or infection. The hazards addressed by protective
equipment include physical, electrical, heat, chemicals, biohazards,
and airborne particulate matter. Protective equipment may be worn
for job-related occupational safety and health purposes, as well as
for sports and other recreational activities. Protective clothing is
applied to traditional categories of clothing, and protective
gear applies to items such as pads, guards, shields, or masks, and
others
The purpose of personal protective equipment is to reduce employee
exposure to hazards when engineering controls and administrative
controls are not feasible or effective to reduce these risks to
acceptable levels. PPE is needed when there are hazards present. PPE
has the serious limitation that it does not eliminate the hazard at the source and may result in
employees being exposed to the hazard if
the equipment fails.

Saftey Helmets:
Safety has always been a pain point when it comes to industries,
manufacturing units, construction sites and more. Every day workers suffer
various injuries at the job site. Therefore, it is always advised that the

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workers at job sites should wear protective clothing to ensure minimum injury at the workplace during
the accidents.
One such effective protective gear is Industrial safety helmet. Safety helmets or hard hats are the first
line-of-defense against head injuries. Do you know that the brain is an organ that controls all the
functions of the body? A small injury to your brain can be dangerous, even fatal. Therefore, it is very
important to protect your brain from injuries that can happen in the workplace. Your brain can face
injury due to falling objects, colliding with the low roofs, trips, and falls. A durable and strong safety
helmet protects your brain from such injuries.
How to choose a right Industrial Safety Helmet?
Industrial Helmets: Choosing the right safety helmet is very important, as it safeguards one of the most
important organs of the body. The main function of the hard hat is to help avoid injuries in industrial
settings. Hence, the helmet you choose should be of high quality and strength.
Reflective Helmet: If you are working at the job site with low visibility area, a reflective hard hat can
offer better visibility and help in getting you noticed by other workers.
Apart from that, Industrial Safety Helmets come in different colors that help in differentiating the profile
of the worker and separate the worker from the visitor. The color scheme of different helmets is as
follows:
White – managers, competent operative and vehicle controllers
 Black – Site supervisor
 Yellow – Site workers
 Grey – visitors
 Red – Firefighters
 Green – Safety officers
 Blue – electricians, carpenters and other technical operators

 Eye and Face Protection

What are the potential eye hazards at work?

Workplace eye protection is needed when the following potential eye hazards are present:
 Projectiles (dust, concrete, metal, wood and other particles).
 Chemicals (splashes and fumes).
 Radiation (especially visible light, ultraviolet radiation, heat or infrared radiation, and lasers).
 Bloodborne pathogens (hepatitis or HIV) from blood and body fluids.
Occupations with a high risk for eye injuries include:

 Construction.  Electrical work.

 Manufacturing.  Plumbing.
 Mining.  Welding.
 Carpentry.  Maintenance.
 Auto repair.

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How can I protect my eyes from injury?
There are four things you can do to protect your eyes from injury:
 Know the eye safety dangers at your work.
 Eliminate hazards before starting work by using machine guards, work screens or other
engineering controls.
 Use proper eye protection.
Keep your safety eyewear in good condition and have it replaced if it becomes damaged.
Eye protection is achieved by wearing eyewear specifically designed to reduce the risk of exposure to
chemical splashes, laser radiation and/or flying debris. There are four primary types of eye protection 

Type Use  
 Must have side shields, or a one-piece lens that wraps
around the temple.
 Are the minimum level of eye protection that must be
General worn in the laboratory.
safety  Are not effective in protecting the eyes from splashes,
glasses and are only recommended for use with solutions that are
not likely to damage the eye, such as some buffers and salts.

 Selection is based on the laser wavelength and power.

 Protective properties can be found printed on the
eyewear.
Laser  Are not as effective as laser safety goggles at filtering all
safety light entering the eyes.
glasses  EH&S does not provide laser safety glasses or goggles for
use in the laboratory, but will assist in selecting the correct
laser safety goggles or glasses for your application, which
can be purchased by the PI as needed.
Chemical  Are recommended any time a splash of chemicals or
splash infectious substances could reach the eyes.
goggles  Can act as impact goggles to prevent flying debris from
reaching the eyes.
 May be purchased from the campus bookstore or
obtained from EH&S in accordance with LHAT

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 recommendations.
 Offer protection from flying debris only.
 Often have ventilation holes on the sides that render the
user susceptible to chemical splashes and dust or small
Impact
debris.
goggles
 EH&S does not offer impact goggles, but chemical splash
goggles can often be used in substitution. Feel free to
contact EH&S with any questions regarding this substitution.
 Required when splashes from chemicals that can cause
immediate skin damage are handled (e.g. working with
concentrated acids, dispensing liquid nitrogen, sonicating
tissue samples, etc.).
 Shall be worn in conjunction with chemical splash
Face goggles. Respiratory protective equipment might be
shields required, depending on the task; contact EH&S if you have
any questions regarding face shield use.
 All new PIs receive two complimentary face shields from
EH&S. Existing PIs received two face shields during the 2013
PPE distribution event. Additional and/or replacement face
shields can be purchased by PIs.

 Hand Protection
Appropriate selection of gloves is essential to protecting hands. Chemically protective gloves are one of
the most important tools to minimize dermal exposures to chemicals in research laboratories. Gloves
should only be used under the specific conditions for which they are designed, as no glove is impervious
to all chemicals.
It is also important to note that gloves degrade over time, so they should be replaced as necessary to
ensure adequate protection. Laboratory personnel should use the information below, and manufacturer
compatibility charts (found under useful resources in the above right menu), to choose the type and
style of glove.
Type Use  

Working with biological hazards

Light latex,
Disposable latex (powdered (human blood, body fluids, tissues,
vinyl or nitrile
or unpowdered) bloodborne pathogens, specimens),
gloves
BSL1, BSL2, BSL2+, BSL3

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 Disposable nitrile (puncture
and abrasion resistant, Working with biological hazards
protection from splash and chemical splash hazards
hazards)

Disposable vinyl
Working with biological hazards,
(economical, durable,
BSL1, BSL2, BSL2+, BSL3
similar to latex)

Light chemical Natural rubber latex Working with small volumes of

resistant (chemical resistant, liquid- corrosive liquids, organic solvents,
gloves proof) flammable compounds

Light to heavy
Nitrile (chemical resistant,
chemical Using apparatus under pressure, air
good puncture, cut and
resistant or water reactive chemicals
abrasion resistance)
gloves

Heavy Butyl (high permeation Working with large volumes of

chemical resistance to most organic solvents; small to large
resistant chemicals) volumes of dangerous solvents,
gloves acutely toxic or hazardous
materials

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 Viton® II (high permeation
Same as butyl gloves, plus
resistance to most
hazardous material spills
chemicals)

Same as butyl and Viton® II gloves,

Silver shield (extra chemical
added mechanical protection,
and mechanical protection)
hazardous material spills

Working with hot liquids and

Terrycloth autoclave (heat
equipment, open flames, water
resistant)
bath, oil bath

Insulated
gloves

Cryogen (water resistant or

water proof, protection
Handling cryogenic liquids
against ultra-cold
temperatures)

Wire mesh Working with live animals and

Wire mesh (cut resistant)
gloves exposed to potential cuts

 High-visibility clothing
High-visibility clothing, sometimes shortened to hi vis or hi viz, is
any clothing worn that is highly luminescent in its natural matt
property or a color that is easily discernible from any

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background. It is most commonly worn on the torso and arm area of the body. Health and safety
regulations often require the use of high visibility clothing as it is a form of personal protective
equipment. Many colors of high visibility vests are available, with yellow and orange being the most
common examples. Colors other than yellow or orange may not provide adequate luminescence for
conformity to standards such as ISO 20471.
As a form of personal protective equipment, high-visibility clothing is worn to increase a person's
visibility and therefore prevent accidents caused by persons not being seen. As a result, it is often worn
in occupations where hazardous situations are created by moving vehicles or low lighting conditions.
These occupations include railway and road workers, airport workers and emergency services.
Some reflective tapes used on high-visibility clothing can reflect as much as 82% of the source light,
causing retinal damage. It is therefore recommended[by whom?] that aircraft pilots, professional
truck/bus drivers, and operators of heavy machinery refrain from wearing highly reflective clothing
while conducting their duties.

  Respiratory Protection
Program Procedures
Respiratory protective equipment is only used as a "last line of defense," and as a result, requires
individual assessment and training by EH&S personnel. Proper fitting and use is key to respirator
efficacy, so EH&S requires all individuals who believe one or more of their job tasks require respiratory
protective equipment to contact EH&S. The following steps will be taken:
A workplace hazard assessment will be performed to determine if the task requires respiratory
protective equipment.
If respiratory protective equipment is necessary, the employee will be given a medical evaluation
questionnaire to fill out as well as a supplement to the medical questionnaire that outlines the findings
of the hazard assessment conducted by EH&S. Both forms should be taken to a contract physician or
licensed health care professional (PLHCP) who will perform a confidential medical evaluation to
determine the employee's fitness to wear a respirator.
When the employee is approved to wear a respirator for the job task(s) outlined in the hazard
assessment, the appropriate respirator will be selected and the employee will be fit-tested fit-testing
protocol. Fit-testing assures the selected respirator is worn correctly to allow proper performance.
During fit-testing, the employee receives training on the appropriate method(s) to store, handle and
sanitize the respirator.
Once initial fitting and training is completed, the employee must enroll in and attend yearly training
conducted by EH&S through the UC Learning Center. Employees will be authorized to register for the
"Basic Respiratory Protection" course to fulfill the annual training requirement.

 Type Use

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 Protect against large Working with live animals; working with
Surgical droplets and splashes infectious material in BSL-2+ level labs but
masks (does not require fit- only protects your sample from you, not
testing) the other way around.

Working with live animals or infectious

Protects against dusts,
materials in BSL-2 level labs with known
N-95 fumes, mists,
airborne transmissible disease (e.g.
respirators microorganisms (requires
tuberculosis, also required for influenza
fit-testing)
(flu)); dusty environments

Purifies air: protects

Working with live animals or infectious
against variety of
materials with known airborne
Half-mask particulates, vapors, dust,
transmissible disease; dusty
respirators mists, fumes; depends on
environments; chemical vapors;
filter cartridge
particulates
used (requires fit-testing)

Same as half-mask, with

greater protection factor;
eye, mucus membranes
Full-face
and face protection;
respirators
depends on filter
cartridge used (requires
fit-testing)
For use in half-mask
Respirator
respirators and full-face
cartridges
respirators
Working with live animals or infectious
materials with known airborne
transmissible disease; dusty
environments; chemical vapors;
particulates
 P-100: for dust only
 Organic Vapor (OV): for fumes of organic solvents only
 Acid Gas: vapors of hydrochloric acid, sulfuric acid, etc

  Hearing Protection
All laboratory personnel shall contact EH&S to request noise monitoring in their laboratory settings to
perform noise monitoring and advise on the specific use of hearing protectors.
Laboratory workers whose eight-hour time-weighted average noise exposure exceeds the 85 dBA Action
Level will be enrolled in the UC Merced Hearing Conservation Program. These individuals will receive
annual audiometric testing, will have hearing protectors made available to them by their supervisors,
and will be provided training on the fitting, use and care of these devices.
Monitoring results for individuals whose noise exposure exceed the Action Level will also be notified in
writing using Attachment B — Noise Monitoring — Dosimetry Results.

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 Polyvinyl chloride (PVC) or polyurethane foam, one-time
use design (no cleaning), one size fits all, light weight, low
Disposable
cost, blocks all sound. Useful when working in areas where
earplugs
sound levels average over 85 dBa; EH&S can assist in
assessments

Silicone, tapered fit, reusable (needs cleaning), corded or

Reusable uncorded, light weight, more durable than disposable
earplugs earplugs. Useful when working in areas where sound levels
average over 85 dBa; EH&S can assist in assessments

Earplugs connected to a flexible band that can be worn

Hearing around the neck when not needed. Useful when working in
band areas where sound levels average over 85 dBa; EH&S can
assist in assessments

 
 Safety Lanyards
Lanyards are typically short sections of webbing or cable that are
usually attached to the D-ring of a worker's safety harness
Working at heights has a certain amount of risk attached to it. The
safety procedures that are in place are present so that this risk is
minimized. One such procedure is to ensure that you are wearing
proper fall protection gear before climbing to the required height.
Safety lanyards are an important piece of the fall protection
equipment, these are the ones that connect you to the anchor point
or a lifeline.

Types of Safety Lanyards

At Harness Land, we offer a wide array of safety lanyards to you. You can choose between single or
double leg lanyards as well as shock absorbing and non-shock absorbing ones. What’s more, you can
also choose between the different types of hooks such as aluminum rebar hook, tie back carabiner, or
standard snap hook.
When you choose us for your fall protection gear, you will be choosing a company that strictly adheres
to the rules and regulations of OSHA as well as ANSI. Another benefit of choosing us is that we have a

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wide variety of safety lanyards for you. We guarantee that you will find the lanyard that you are looking
for with us. Some of the most popular safety lanyards at Harness Land include:

Double Leg Tie Off Safety Lanyards

Regarded as one of the most adaptable fall protection equipment, double leg tie off lanyards are also
called as Y-lanyards. These lanyards have become the safety lanyards of choice for safety professionals
in recent times. Some of the perks of choosing this lanyard include two shock absorbers, one for each
leg; a single device that handles easily; you can easily sidestep obstructions even when you are still
attached. Even when you are moving to another anchor point, one of your legs is still attached to the
previous anchor point – so you are secure all the time.

Positioning Lanyards
These safety lanyards do not have any shock absorbing properties. They eliminate the chance of a fall
because they are mainly used for restraint or positioning. It is vital that you remember that these
lanyards must be used for restraint only, they cannot be used in a fall arrest system.

Rescue Shock Absorbing Style Lanyards

If you generally work on a tower or near turbines, the rescue shock absorbing style lanyards is what you
should invest in. They meet ANSI standards and have built-in D-rings on each leg. In the event of a fall,
the rescue shock absorbing lanyards make the entire rescue process easier.
Apart from these lanyards, we also have Kevlar lanyards, pack style lanyards, tie-back lanyards, and
tubular style lanyards.
Important Factors to Consider While Buying Safety Lanyards
Some of the factors you should consider while investing in a lanyard are:
Length – The standard length of a safety lanyard is 6 feet. The ideal length of lanyard for you is the one
that allows you to move without any problem. However, it also needs to be as short as possible because
this will minimize the free fall distance. When you shop with us, there is absolutely no need to worry.
We have short, long, and even adjustable lanyards on offer.
Webbing – The webbing that is used in your safety lanyards must be able to weather extreme conditions
like rough use at work sites as well as the weather elements. We have a variety of lanyards on offer that
are made from different materials such as nylon, Kevlar, and even Nomex. Depending upon your work
conditions, choose one that meets all your requirements.
Shock Absorbers – When you are planning to use a safety lanyard in a fall arrest system, it is vital that
you use one that has shock absorbers. Most of our shock absorbing lanyards are able to limit the fall
arrest force to 900 pounds. These type of lanyards have an external shock pack with a PVC sleeve, this
sleeve tears out during fall arrest. For ease of movement, you can choose our expandable style that
expands and contracts as you move, which in turn helps keep the lanyard shorter.
Impact Indicators – Impact indicators are extremely useful when you are trying to inspect the safety
lanyards. If a particular shock absorbing lanyard has been used in a fall arrest, the shock absorber will
have been deployed. Therefore, it must not be used again and disposed properly.

 Saftey Shoes:

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A pair of safety shoes (also known as safety boots) is personal
protective equipment (PPE) for foot protection at workplaces. It
prevents from getting foot injuries due to slippery surface, heavy
falling or rolling objects, sharp piercing edges, pinch points, rotary
machinery, hot objects, loops of ropes under tension, splinters,
electricity, chemicals or even bad weather etc. Occupational Safety
and Health Administration (OSHA) requires the employers to
ensure that the employees use protective footwear while working
in the areas where there are dangers of foot injuries.
Safety shoes come in many styles both formal or informal.
However, workers require reliable and durable work shoes for their
safety. Traditional safety shoes are steel toed, but it can also be
made of composite materials such as thermoplastics and
aluminum. Following considerations are to be made for selecting right type of safety shoes for the
workers:
Work environment and associated hazards
Material used in safety shoes and their effectiveness to resistant hazards
 Water, heat and cold resistance
 Electric resistance
 Puncture and cut resistance
 Following are the examples of work environments where the safety shoes are mandatory:
 Handling heavy objects or tools that might be dropped (impact resistant)
 Handling pipes, tree trunks, stones, rolls, wheels or round shaped items that might roll over on
feet
 Handling hazardous material (HAZMAT)
 Works involving sharp tools such as knife, axes, nails, scrap metals and glasses etc.
 Working with live or dead electric cables
 Working on a floor which might produce static electricity

Rigging Fundamentals
When it comes to load handling activities which includes lifting, individuals assigned to the various load
handling tasks should at minimum know the basic rigging fundamentals before using rigging hardware
such as shackles, hooks, links, rings, wire rope clips, turnbuckles, snatch blocks and slings. Knowing the
fundamentals is critical to ensuring that those individuals working in and around telecommunication
structures go home safe at the end of the day. This article consists of a series of rigging fundamental
questions to answer before the load handling activity begins, while at the same time imparting some
standard information pertinent to the industry. Note: This article, however, is not intended to be an all-
inclusive list and does not attempt to cover all rigging fundamentals involved with all telecommunication
structure load handling activities that may involve the structures, mounts, antennas, gin poles, winches,
hoists, helicopter and special engineered lifts.
Below are some of the KEY QUESTIONS to answer before the load handling activity begins:

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1. HAS A RIGGING PLAN BEEN DEVELOPED? The rigging plan is a critical first step to insuring proper
procedures, equipment, and rigging are appropriate for the load handling activity to assure personnel
safety, and stability of the structure and the components being lifted. The complexity of the rigging plan
depends on the type of job and type of equipment necessary to complete the tasks. ANSI/TIA-322 states
that rigging plans be prepared in accordance with ANSI/ASSE A10.48 and shall be utilized for all
construction activities. Construction classes II, III & IV rigging plans must also be documented. See
ANSI/TIA-322 & ANSI/ASSE A10.48 for full details.

2. WHO IS RESPONSIBLE FOR THE RIGGING AND LOAD HANDLING ACTIVITIES? Having key designated
personnel assigned to the specific tasks of crane operator, signal person, spotter, competent rigger,
qualified person, and establishing who is responsible for preparing rigging plans is of major importance.
The ANSI/TIA-322 and ANSI/ASSE A10.48 Standards also address the importance of communication and
assignment of responsibilities. It states that the competent rigger must understand the applicable
industry standards, have the knowledge, skill and ability with the procedures and equipment common to
the telecommunication structures industry and trained to identify hazards and authorized to take
corrective measures. ANSI/ASSE A10.48 also requires an on-site competent rigger to be designated for
all classes of construction; however, for Class III and IV construction, a qualified person shall coordinate
the involvement of a qualified engineer as required when establishing rigging plans.

3. HAS COMMUNICATION BEEN ESTABLISHED? Establishing clear communication by use of approved

hand signals or radios is of vital importance. The operator and signal person must be familiar with the
industry standard hand signals and shall use approved radios, or other means of communications, when
direct hand signals would create a hazard or if the ability of the crane operator to clearly see the signal
person is a problem. If radios are used, they must be tested to ensure signal transmission is clear and
reliable. A “qualified” signal person in construction is required and they must have understanding of
ANSI/ASSE A10.48 which requires a designated competent person who meets the qualification criteria
for a signal person in accordance with OSHA 1926.1428.

4. IS THE RIGGING IN ACCEPTABLE CONDITION? Too many accidents happen as a result of companies
not having a designated competent person assigned to inspect the rigging gear and slings before use.
ANSI/ ASSE A10.48 requires a documented daily inspection prior to use on all components of a rigging
system.

5. WHAT IS THE MAXIMUM GROSS LOAD TO BE MOVED OR LIFTED? The weight of the load must be
known, calculated, estimated or measured. However, please remember the maximum gross load not
only includes the weight of the load but all associated rigging equipment. Rigging equipment may
include but is not limited to the overhaul ball (headache ball), load-line, tag line, tag line force, trolley
line, trolley line forces, and any other added weight or force that needs to be taken into consideration to
ensure safety to personnel and structure stability.

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6. WHERE IS THE CENTER OF GRAVITY (C.O.G) OF THE LOAD AND IS IT CORRECTLY CAPTURED BY THE
SLINGS OR MATERIAL HANDLING DEVICE? Too many individuals have a tendency to determine the
weight of the load but bypass the critical next step of knowing where the center of gravity of the load is
located. Estimating the location of the center of gravity helps determine if the C.O.G. is captured
appropriately to ensure good load control during the entire load handling event. Location of C.O.G., also
affects the loading in the sling legs and connection points.

7. IS THE RIGGING APPROPRIATE FOR LIFTING? Make sure that the rigging gear is suitable for overhead
lifting. ANSI/ASSE A10.48 requires rigging hardware and slings used for load handling and lifting to be
specifically certified for such applications in accordance with applicable American Society of Mechanical
Engineers (ASME) B30 standards. The use of rigging hardware not specifically covered by ASME B30
standards is discouraged, and should be avoided. See ANSI/ASSE A10.48 for full information.

8. DOES THE RIGGING HARDWARE & SLINGS HAVE PROPER IDENTIFICATION? At a minimum all new
rigging hardware should be identified with the name or trademark of the manufacturer. Below is an
example of, per ASME B30.26, requirements for new rigging hardware identification.
■ Shackle Body: Name or trademark of the manufacturer, rated load and size.
■ Shackle Pin: Name or trademark of the manufacturer, grade, material type, or load rating.
■ Wire Rope Clip Saddle: Name or trademark of manufacturer and size.
■ Turnbuckle: Name or trademark of manufacturer, size or rated load. ANSI/ASSE A10.48 requires wire
rope slings to have a legible tag specifying its working load limit (WLL). Synthetic slings shall have a
legible tag indicating the manufacturer’s working load limit for the vertical, choked and basket
configurations. Besides the specified (WLL) requirement, chain slings must have the manufacturers mark
indicating the grade of chain. OSHA recommends only alloy grade chain for overhead lifting applications.
For full detailed information regarding minimum identification requirements, see ASME B30.26 (Rigging
Hardware), ASME B30.10 (Hooks), ASME B30.9 (Slings), ANSI/ASSE A10.48 and OSHA 29 CFR. PLANNING
ADVISORY NOTICE (CONTINUED) MARCH
■ APRIL 2017 TOWER TIMES 4 9. IF USING MULTIPLE LEG SLINGS ATTACHED TO THE LOAD, WHAT IS THE
SLING ANGLE? The angle of loading can have a tremendous effect on the loading in the sling legs and
connection points. When slings work at angles opposed to each other, each sling works harder and the
resultant loading in the sling legs can be much greater than their individual vertical share of the load.
ANSI/ASSE A10.48 (see gin pole section) encourages all sling angle of loading be set at 60 degrees or
more. Sling angles less than 45 degrees shall require special attention. The minimum horizontal sling
angle (angle of loading) allowed is 30 degrees unless approved by the sling manufacturer or a qualified
engineer in compliance with an approved rigging plan.

10. WILL THERE BE ANY SIDE OR ANGULAR LOADING ON THE RIGGING GEAR? The WLL of most rigging
hardware is based on in-line loading. If the sling is to pull off at an angle, three more pieces of
information are needed:
■ Does the manufacturer allow it?
■ Is the WLL affected?
■ Are there any special requirements?

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11. DOES THE RIGGING GEAR & SLINGS HAVE KNOWN WORKING LOAD LIMITS? The working load limit
is the maximum mass or force which the product is authorized to support in general service when the
pull is applied in-line, unless noted otherwise, with respect to the centerline of the product. This term is
used interchangeably with the following terms: WLL, rated load value, resultant working load.
competent riggers and qualified persons should know the capacity of all the rigging gear and slings
before use. Other details to consider:
■ Once the WLL of all rigging components are determined, we must ensure that all WLL’s are
appropriate for the load handling activity.
■ ANSI/ASSE A10.48 states that the working load limit (WLL) shall be reduced by 50% when lifting
personnel. In addition the OSHA CPL 02-01-056 must be adhered to when lifting personnel.

12. ARE THE SLINGS PADDED FOR PROTECTION FROM CORNERS, EDGES, PROTRUSIONS AND
ABRASIVE SURFACES? Too many accidents occur because individuals do not adequately protect the
sling(s) from damage. The strength of slings can be reduced dramatically if not adequately protected.
ASME B30.9 (Slings) gives instructions for protecting slings from edges, corners, protrusions and abrasive
surfaces. WSTDA (Web Sling and Tie Down Association) is also an excellent source of information for
synthetic slings.

13. IS THE HITCH APPROPRIATE FOR THE LOAD? If not already pre-determined in the lift plan, the
competent rigger or qualified person must determine the best method to attach the slings to the load. In
rigging, there are three basic hitches. The straight-line hitch (vertical hitch), the choker hitch and the
basket hitch. From these three basic hitches one can derive many possible options such as a two leg
bridle hitch as shown below. Each has its advantages and disadvantages depending on the
characteristics of the load. All loads must be rigged to ensure the load is as secure in the air as it was on
the ground. It is critical to ensure that slings wrapped around the load such as choker and basket hitches
do not slide along the load during the load handling activity.

14. IS A TAG LINE NEEDED TO CONTROL THE LOAD? Proper load control requires the use of a tag line (or
trolley configuration) to control swing, rotation, or position of the load when lifting. They are often
needed to maintain clearance between the load and the structure, gin pole, or other obstructions.
Proper knowledge of type of material, how to properly apply the tag line (or trolley line) to the load and
proper use is essential.

15. HAVE THE WORKERS BEEN PROPERLY TRAINED? OSHA 29 CFR 1926.1400 (construction) requires
that crane operators, competent rigger, signal person and qualified persons be trained regarding
requirements for their respective roles. ANSI/ASSE A10.48 requires the rigger and qualified person(s)
involved in construction or maintenance relating to the communications industry to have documented
training based on the complexity of the scope of work (SOW). The training program is required to ensure
that all employees have the knowledge and understanding of the standard and are able to prepare a
rigging plan and perform the work according to an approved rigging plan.

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16. WILL THE LOAD LIFT LEVEL, BE STABLE AND SECURE? Proper load control means that the load lifts
level, is stable and secure. Ensuring the proper attachment to the structure of the rigging equipment is
the critical first step. Placing the load hook over the center of gravity is an essential step. Placing the
sling(s) so as to capture the center of gravity properly will enable the proper handling of the load.
Selecting best hitch and attachment method to insure the load is secure is next step in the process. The
sling(s) should attach above the C.O.G. to avoid flipping the load. Good rigging practice also includes
making sure that no sudden movements or rough handling of the load can cause the load to disengage
from the slings. The competent person should always be aware of the SOW and ensure that all these
activities occur when lifting a load, as well as verifying other conditions and communicating with all
team members involved in the SOW.

17. ARE THERE ANY UNUSUAL ENVIRONMENTAL OR SPECIAL CONCERNS? Weather related issues such
as wind, ice, rain, snow, or a variety of possible non-weather related concerns may affect the rigging
gear, slings and safe use. Con - sideration for these concerns should be given before starting any load
handling activity. In summary, it is definitely exciting times especially with the new ANSI/TIA -322, and
the ANSI/ASSE A10.48 Standards becoming effective January 1, 2017. In addition, NWSA (National
Wireless Safety Alliance) and NCCCO (National Commission for the Certification of Crane Operators)
have partnered in a very bene - ficial endeavor to develop and provide certifications to enhance safety
while working on towers and other non-standard structures. Current available certifications include:
Rigger Level I, Rigger Level II, Signal Person, Tower Technician 1 and Tower Technician 2. The posi -
tioning requirements as defined by the Telecommuni - cations Industry Registered Apprenticeship
Program (TIRAP) are helping all employers and clients in the telecommunications industry understand
the essential training and education requirements for the industry.
Hardware
SHACKLES
General Information
Shackles are manufactured in two configurations for
use in rigging :
Anchor shackle -- has a rounded eye which makes it
suitable for attaching one or more lifting devices, such
as hooks or slings.
Chain shackle - has a straight eye designed for
connecting to a single lifting device.
NOTE: Both are available with screw pins, round pins, or safety bolts. Screw pins are the type used at
WVNS.
Each shackle body shall be permanently and legibly marked in raised or stamped letters on the side of
the shackle bow with an identifying manufacturer's name or trademark, shackle size, and its SWL.
Shackle size is determined by the diameter of the bow or body.

Frequent (Pre-Use) Inspection

1) Check pin to see if it seats completely.
2) Check to see that pin threads easily by and into and out of the shackle.

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3) The pin shall show no signs of deformation.
4) Check for excessive thread exposure when pin is seated completely.
5) Check for opening of shackle throat.
6) Check for excessive wear, cracks, and corrosion.

Operating Guidelines
1) Never replace the shackle pin with a bolt, only a properly fitted pin shall be used. Bolts are not
intended to take the bending that is normally applied to the pin.
2) Shackles shall not be used if the pin cannot be completely seated. The pin need be only hand tight for
lifting. Use only shackles with screw pin, round pin with cotter should not be used.
3) Screw pin shackles shall not be used if the pin can roll under load and unscrew.
4) Shackles shall never be allowed to be pulled at an angle (eccentric loading) because the capacity will
be tremendously reduced.
Eccentric loading of the shackle may cause the shackle to open up or distort.
5) The shackle pin should go on the hook whenever possible.
Washers may be used to pack the pin to centralize the shackle if necessary.

Different types of shakle

Ideal for use with lifting slings and tow ropes, shackles provide secure fastening and connection for a
diverse range of jobs.
However, it's worth noting that not all lifting shackles are the same. In fact, there are many different
types of shackles to choose from - examples include:
Bow shackles
Recognisable by their 'O' shape, bow shackles are commonly used on multi-leg
slings. Ideal for jobs such as rigging, bow shackles provide an easy way of
fastening chains and straps securely. These shackles come with a variety of
weight limits and in a range of colours, which can be particularly useful for live
event rigging where black shackles (as pictured above) can minimise their
visibility.
Dee shackles
Most commonly used on single-leg slings, dee shackles - as the name suggests
- are shaped like the letter D. They also resemble a loop of a chain, which
explains why they are sometimes referred to as 'chain shackles'. Side or
racking loads may bend a dee shackle, so keep in mind how you plan on using
your shackle before making your final choice.

Green pin shackles

One of the most popular lifting shackle types in our range, our green pin
shackles are essentially alloy bow shackles, providing durable reliability in
eye-catching green for heightened visibility and easy identification.
These dependable fastenings are typically used with wire rope slings. Their
weight limits range from 0.75 tonnes to 85 tonnes.

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Safety pin shackles
Designed for maximum security, safety and reliability, these shackles use a nut
and bolt, with a safety pin providing further stability and assurance.
This particular fastening option is a popular choice for many lifting firms,
including some of the leading lifting rental companies in the UK.
Screw pin shackles
Primarily used for temporary applications, screw pin products are great for
jobs where shackles regularly need to be removed and re-attached. When using
screw pin shackles, it's important to remember to check the pin prior to each lift
and re-tighten if necessary.
For jobs that include notable vibration, wire mousing can help to prevent the pin
from coming unscrewed; however, safety pin shackles are usually preferable for
such jobs.

Stainless steel shackles

Extremely durable and long-lasting, our stainless steel shackles are the ideal
connection for use in tough conditions, making them the perfect fastening
mechanism for sailing and industrial rigging jobs.
Simple to use and extremely reliable, these stainless steel shackles come in 1
tonne or 2 tonne varieties, with varying dimensions to suit your requirements.

Piling shackles
Fully tested and certified, these long-bodied shackles provide a strong and sturdy
solution, making them suitable for a variety of lifting jobs.
With a self-coloured finish, our piling shackles come in a range of durable weight
categories, with weight limits ranging from 1 to 5 tonnes.
In addition to all of the above, these zinc-plated dee shackles cannot be used for
lifting jobs and are unsuitable for carrying weight, they do make perfectly
adequate connectors in situations where no force is being applied.

RINGS
Rings should be forged steel and weldless. Welded rings are not recommended but may be used if
designed by a qualified engineer and subject to NDT testing. Rings shall be visually inspected for
damage, corrosion, wear, cracks, twists, and openings.

EYEBOLTS
There are two types Shouldered - used for vertical and angular lifts; when used for angular lifts the Safe
Working Load (SWL) is to be down rated as shown in Table 1. Angles less than 45 degrees are prohibited.
Shoulder must be flush with the surface and screw.
Unshouldered - for vertical lifts only, angular lifts will bend threaded shaft.

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General Requirements
1) Shouldered eyebolts shall be used for all applications, except where it is not possible due to the
configuration of the item. When unshouldered eyebolts are used, nuts, washers and drilled plates shall
not be used to make shouldered eyebolts. Swivel eyebolts are also available in the tool crib.
2) Eyebolts shall have a minimum thread engagement between the eyebolt and its tapped hold of 1-1/2
times the diameter of thread engagement. Nuts on through-eyebolts shall be self-locking types. The
shoulders shall seat uniformly and snugly against the surface on which they bear.

Inspection
1) Careful visual inspection of each eyebolt immediately before use is mandatory. Eye bolts that are
cracked, bent or have damaged threads shall be discarded.
2) The shank of the de bolt shall not be undercut and shall have a smooth radius into the plane of the
shoulder.

Operation Practices
1) The size of the hole shall be checked for the proper size of eyebolt prior to installation. The condition
of the threads in the hole shall be checked to ensure the eyebolt will secure, and the shoulder can be
brought to a snug and uniformly engaged seat.
2) When installed, the shoulder of the eyebolt must be flush with the surface. When eyebolts cannot be
properly seated and aligned with each other, properly sized washers or shims may be inserted under the
shoulder to facilitate the eyebolts being tightened and aligned (23). However, minimum thread
engagement must be maintained.
3) Angular loading of eyebolts should be avoided. Angular loading occurs in any lift in which the lifting
force is applied at an angle to the centerline of the shank of the eyebolt. Angular loading of the eyebolt
less than 45 degrees shall be prohibited.
4) When more than one eyebolt is used in conjunction with multiple-leg rigging, it is recommended that
spreader bars, lifting yokes, or lifting beams be utilized to eliminate angular loading.
5) To keep bending forces on the eyebolt to a minimum, the load shall always be applied in the plane of
the eye, never in the other direction .
6) If the hook will not go completely into the eyebolt, a shackle will be used to avoid hoot tip loading.
7) Slings shall not be reeved through the eyebolt or reeved through a pair of eyebolts. Only one leg
should be attached to each eyebolt. Reeving slings through eyebolts adds greater load tension in the
eyebolt than normally calculated by using the sling angle.
The following example emphasizes the importance of checking your rigging prior to a lift and also
stresses the importance of using tag lines and staying clear of the load.
On October 15, 1992, a 22-ton concrete shielding block fell while being transported by crane about 25
feet above the floor of a building at the Los Alamos Accelerator Complex. The block bounced about 20
feet laterally from the point of impact and crashed into detector instrumentation causing more than
$100,000 in damage. While the block was being moved, one of the eyebolts pulled out of its insert and
the entire load shifted to the remaining h eyebolt, which supported the block briefly before it also failed,
allowing the block to fall, striking other shield blocks below. Facility personnel determined that, because

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the eyebolts were of unequal length, the shorter eyebolt was backed out (unthreaded) to allow
bothbolts to extend to an equal height above the block surface. The resulting thread engagement of the
shorter bolt was insufficient and led to it pulling free of its insert. There were no injuries to personnel
because the area below the crane lift path was evacuated prior to lifting and transporting the block.

HOOKS
1) The safe working load (SWL) for a rigging hook shall be equal to or exceed the rated load of the chain
wire rope, or other suspension member to which it is attached. The designed SWL applies only when the
load is applied in the saddle of the hook.
2) It is a good practice to use a shackle when two or more sling eyes are used on a hook. This allows the
load to be centralized on the hook for full capacity. Never tip load a hook.
3) The manufacturer's identification shall be forged or die-stamped on a low-stress and nonwearing area
of the hook.
4) The load hook should be the weakest member of the lifting equipment, so it will bend if overloaded
before any other piece of equipment fails.
5) Hooks shall be provided with a safety latch to bridge the throat opening to prevent the release of
load lines. Remote "in cell" cranes may not have a safety latch, or other applications that make the latch
impractical.
6) Hook tips should point out and away from the load to assure when slack is taken up the hook will not
tip load.
7) Hands, fingers, and body shall be kept from between the hook and load.

Frequent (Pre-Use) Inspection

1) Look for distortions such as bending, or twisting exceeding 10 degrees from the plane of the unbent
hook.
2) Check for an increase in throat opening exceeding 15% of original throat opening. On most hooks
there will be punch marks as reference points to bo by.
3) Check for wear in the saddle area of the hook. Wear exceeding 10% of the original dimension is
sufficient enough to take the hook out of service.
4) Check for cracks, severe nicks, and gouges. Transverse cracks are more critical to a hook's
performance than longitudinal cracks.
5) Check the hook attachment and securing means for defects.
6) Rigging hooks shall be inspected as a part of the slings to which they are attached.

WIRE ROPE CLIPS

General Information
1) They are used in the field to make an eye on wire rope. Will be only 80 percent of the wire rope's
strength. They shall not be used to fabricate wire rope slings except where the application of slings
prevents the use of prefabricated slings, and must be proof tested to 200 percent of safe working load.
2) Clips (clamps) shall be legibly and permanently marked with size and the manufacturer's identifying
mark.
4) Clips should not be reused as they may not torque properly on the second application.

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Frequent (Pre-Use) Inspection
Before use, clips shall be visually inspected for damage, corrosion, wear, and cracks. Verify that the clip
components are marked as stated under "general information." Clips shall be inspected to ensure that
the assembled clip contains the same size, type, and class parts.
Different types of clips are as follows:
1) U-Bolt clip
2) Fist grip clip
3) Collet connection clip

Operation Practices
1) Assure clips are orientated correctly
2) When using single grip clips, be sure to put the saddle on the live end of the rope.
3) Be sure to torque clips to proper specification.
4) Check torque after use and retorque after use if necessary.
5) Follow the proper procedure when installing clips.
Apply first clip one base width from dad end of wire rope. Tighten nuts evenly to recommended torque.
Apply second clip nearest the loop. Turn evenly but do not tighten.
Apply all other clips spaced equally in between the first two. Apply tension and tighten all nuts to
recommended torque.
Recheck torque after use.

TURNBUCKLES
General Information
1) Turnbuckles should be avoided; however if they are used in a rigging system, that system must be
designed, analyzed, and approved by a qualified engineer.
2) Turnbuckles used in hoisting and rigging operations shall be fabricated from forged alloy steel.
3) If a turnbuckle is used in an application where vibration is present, the end fittings should be secured
to the frame with lock pins or wires to prevent them from turning and loosening. Locknuts (jam nuts)
shall not be used. Locknuts can significantly increase the stresses imposed upon the threads.
4) Before placing turnbuckles in lifting service, a permanent identification tag shall be affixed.

The Different Types of Turnbuckles

As you know, turnbuckles control the tension between cables or wire ropes. Additionally, a turnbuckle
helps rigging and hoisting crews reduce excess slack in the cables. There are several different types of
turnbuckles to help crews work safely and efficiently. If you’d like to learn about your options when
choosing a turnbuckle, we’ve got you covered in our guide below.

Eye/eye
One of the most common types of turnbuckles is eye-to-eye. This turnbuckle features a ring-like end on
both sides that easily attaches to other components such as a shackle. The main advantage of eye/eye

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turnbuckles is their security. If you’re performing a lift where you’re concerned the anchor may slip, you
should use an eye/eye turnbuckle because it eradicates the possibility of slippage.

Hook/eye
As you might suspect, the hook/eye turnbuckle has an eye on one end and a hook on the other. The
benefit of a hook/eye turnbuckle is the fact that you can easily attach and detach the turnbuckle by
merely reducing the tension on the cables. You should never use a hook/eye turnbuckle in scenarios
where the tension could suddenly loosen because the hook could come out of place.

Hook/hook
When you have guaranteed control, a hook/hook turnbuckle is acceptable. However, you shouldn’t use
this turnbuckle for lifting because there is a risk the hardware may slip out of the hook. Hook/hook
turnbuckles are most common for support or to adjust the length of a cable or rope. Because a
hook/hook turnbuckle is so versatile, every company should have one in their collection.
Jaw/eye
A jaw-to-eye turnbuckle is common because of the jaw’s versatility. A jaw is a u-shaped end with a nut
and bolt so you can easily attach it to other components you can’t open, like an eye. The jaw/eye
turnbuckle is common because the jaw end provides added security with the nut and bolt on one side
and the reliability of an eye on the other.
Jaw/jaw
Unsurprisingly, the jaw/jaw turnbuckle has a jaw on each end, which allows you to attach your
turnbuckle to the most unusual items. Moreover, the jaw/jaw can provide equal tension easily because
the nut and bolt allow the turnbuckle to pivot as needed. Both a jaw-to-eye and jaw-to-jaw turnbuckle
should be in your arsenal.
While these five different types of turnbuckles are the most common, we offer a variety of others,
including deck toggle hand swage and a toggle swage turnbuckle. The most important aspect of cable
rigging hardware is quality. When you’re lifting extremely heavy materials, you need to ensure your
hardware can handle it. That’s where we come in.
As a family-owned and operated business, American Cable & Rigging supplies the best rigging hardware
available. We refuse to skimp on quality because our family is made up of industry experts. In other
words, we know the type of durability and strength your job site requires. Please contact us with any
questions, or stop by our retail location if you’re in the Mills River, NC, area. We’d be happy to see you.

Inspection
Tumbuckles shall be inspected for damage before each use. Inspect turnbuckles for the following:
1) Cracks and bends in the frame.
2) Thread damage and bent rods.
Damaged threads or bent frame members shall disqualify the unit for use.
NOTE Turnbuckles nd in lift service do not have to meet testing criteria.

Load-Measuring Devices
Requirements for Their Use

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1) Load-indicating devices shall be used with lifts where the binding or friction of the load could result in
a greater stress in the hoist or tackle than would result from the apparent hook load.
2) The use of load-indicating devices shall be specified for loads which could be over 90% of the rated
capacity of the equipment being used, if the load cannot be weighed and verified before the lift.
3) Load-indicating devices are not required in the course of routine operations where loads of known
and essentially consistent weight are to be handled or if the equipment includes a functional load
limiter.

Identification Requirements
Labels shall be conspicuously placed on the indicating system readout, at the operator's location, or
both, giving the following:
1) Units of measure.
2) Maximum capacity of the indicating system.
3) Operating range of the indicating system for which the accuracy criteria are met.
4) Basic operating instructions and precautions, including the recommended interval for performance
testing.
5) Device manufacturer's name, address, and device model number.
6) Date when calibration expires.

Operation of Load-Measuring Devices

Operation and maintenance of the load-indicating device shall be in accordance with the appropriate
manufacturer's recommendations to attain system accuracy. Manuals containing installation, operation,
test, and service information shall be provided by the manufacturer, and a copy shall be available to the
operator and/or other responsible person at all times.

Range
The Load-indicating system should be selected to ensure the expected load is between 10% to 70% of
full scale indication.
Example: You would not select a dynamometer with 2000 lbs. Capacity to pick a 1700 lb load. (1700 lbs.
Is 85% of the dyno's capacity)

Operation Checks
The load-indicating system shall include a means for the operator or another responsible person to
determine that it operative before crane use. And the readout device shall be located so the operator,
and/or other signal person, can obtain readings from the normal working position.

Chain Slings:
Chain slings must be made of alloy steel Chain has the advantage of being better suited for lifting rough
loads and withstanding high temperatures. When possible use a wire rope sling instead of a chain sling.
The failure of a single link of a chain can result in an accident. When overloaded it will stretch a bit and
fail suddenly without warning. Another difficulty of chain is that inspection is difficult due to the
necessity to inspect each link.

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Frequent (Pre-Use) Inspection
As required for all slings, Alloy Steel Chain slings shall be visually inspected by the person using the sling
each day of its use. This visual observation should be concerned with discovering damage that may be
an immediate hazard and a check of the equipment tag to verify the inspection due date.
Defects to look for on chain slings are as follows:

Length
Check overall length to see it matches up with the length on the tag. If a sling is shorter or longer
(considering allowable tolerances) than the length on the tag. The sling must be taken out of service.

Master Link
Check the master link for elongation and wear on its bearing points.

Identification Tag
Be sure that the identification tag is legible with the proper information on it.

Connecting Link
Check the connecting link to see if it's bent, twisted, or deformed in any way.

Links
Chain links must be checked for cracks, nicks, and gouges.
Elongation
 Bends or twists
 Heat damage
 Excessive wear

Hooks
Hooks will be covered under rigging hardware.
Rigging Hooks
DESIGN
Hook design shall meet generally accepted hook design standards and shall comply with the
requirements of ASME B30.10
Types
There are numerous types of hooks available in the market. It is important to select the correct hook for
the job, as they all have different applications. Some of the different types of hooks include eye, clevis,
swivel, foundry and grab hooks
Safety Latch Hook or Sling Hook – these types of hooks always
stay closed and require manual opening of the latch to take the load off.
Self-locking Hook – these types of hooks have a trigger that needs to be manually operated to open and
close the latch mechanism.

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 Grip Latch Hook – these types of hooks are probably the most robust and could be the safest one. These
types of hooks tend to last longer thanks to the engineering design.
Eye Type Connection – An eye hook requires a coupler in most cases to be able to connect to a sling or
shackle. It allows easy connection to couplers which gives more flexibility to the chain or sling
movement.
Clevis Type Connection – A clevis hook connects directly to the chain and may be more affordable as
there are less components required with this type of connection. However, there is less flexibility in the
movement where the hook is connected to the chain.

Swivel Hooks
On the other hand, swivel hooks are designed with a ball bearing that allows the hook to swivel freely
under load.

Foundry Hooks
Foundry hooks are usually designed without a latch. These types of hooks are usually used in
applications where there could be a risk if humans connect or remove the load from the hook.

Grab Hooks
A grab hook provides flexibility to shorten chain slings and can be used for back-hooking. They have
supporting lugs that allow no reduction of the working load limit.
MARKING
The manufacturer’s identification shall be forged, cast, or die-stamped on a low-stress and nonwearing
area of the hook.
CONSTRUCTION
 The hook material shall have sufficient ductility to permanently deform before failure at the
temperature at which the hook will be used.
 Rated capacities for hooks shall equal or exceed the rated capacity of the chain, wire rope, or
other suspension members to which they are attached.
LOAD LIMITS
A hook shall not be loaded beyond its rated capacity, except as is necessary to conform to the
requirements for load testing of the sling or hardware to which it is attached.
INSPECTIONS
Initial Inspection
 A designated inspector shall inspect all new and repaired hooks prior to initial use. Dimensional
data on the hooks shall be recorded to facilitate subsequent inspections for wear and throat
openings. Dated and signed inspection records shall be kept on file and shall be readily available
 Inspection procedure and record keeping requirements for hooks in regular service shall be
determined by the kind of equipment in which they are used. When such requirements for
hooks are stated in standards for the specific equipment, they shall take precedence over the
requirements of this section.

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Daily Inspection
 The operator or other designated person shall visually inspect hooks daily or prior to first use, if
the hook is not in regular service, for the following (records are not required):
 Cracks, nicks, gouges.
 Deformation.
 Damage from chemicals.
 Damage, engagement, or malfunction of latch (if provided).
 Evidence of heat damage.
 A designated person shall examine deficiencies and determine whether they constitute a safety
hazard and whether a more detailed inspection is required

Frequent Inspection
 The operator or other designated personnel shall visually inspect the hook at the following
intervals (records are not required):
 Normal service – monthly.
 Heavy service – weekly to monthly.
 Severe service – daily to weekly.
 Hook service is defined as follows:
 Normal service – operation at less than 85 percent of rated capacity except for isolated
instances.
 Heavy service – operation at 85 to 100 percent of rated capacity as a regular specified
procedure.
 Severe service – operation at heavy service coupled with abnormal operating conditions.
 These inspections shall, in addition to the requirements of Daily Inspection include the
following:
 Wear.
 Hook attachment and securing means.
 A designated person shall examine deficiencies and determine whether a more detailed
inspection is required

Periodic Inspection
 A designated inspector shall perform a complete inspection at the following intervals:
 Normal service – yearly.
 Heavy service – semiannually.
 Severe service – quarterly.
 A designated inspector shall examine deficiencies and determine whether they constitute a
safety hazard.
 The inspection shall include the requirements of Section Frequent Inspection
 Hooks having any of the following conditions shall be removed from service until repaired or
replaced:
 Any visibly apparent bend or twist from the plane of the unbent hook.

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  Any distortion causing an increase in throat opening exceeding 5 percent not to exceed ¼ inch,
(or as recommended by the manufacturer).
 Any wear exceeding 10 percent (or as recommended by the manufacturer) of the original
section dimension of the hook.
 Cracks.
 If a latch is provided and it becomes inoperative or fails to fully bridge the throat opening, the
hook shall be removed from service until the device has been repaired or replaced.
Testing
 Performance testing of hooks shall not be required except where necessary to conform to the
requirements for the equipment of which they are part. When tests are specified,
documentation shall be uniquely identified to the hook by serial number or other identifier.
 If detailed inspections are performed
 the results shall be evaluated by a designated person to determine the need for subsequent
nondestructive testing (NDT). If NDT is deemed necessary, it shall be performed in accordance

Maintenance
A designated person shall repair cracks, nicks, and gouges by grinding longitudinally, following the
contour of the hook, provided that no dimension is reduced more than 10 percent of its original value
(or as recommended by the manufacturer).
All other repairs shall be performed by the manufacturer.

Operation
The following shall apply to rigging hook users:
 Determine that the load does not exceed the lesser of the rated capacity of the hook or the load
rating of the equipment of which it is a part.,
 Avoid shock loading.
 Keep hands, fingers, and body from getting between the hook and the load.
 Load shall be centered in the base of the hook to prevent point loading of the hook.
 Hooks shall not be used in such a manner as to place a side load or back load on the hook.
When using a device to close the throat opening of the hook, care shall be taken that the load is not
carried by the closing device
 The use of a hook with a latch does not preclude the inadvertent detachment of a slack sling or
a load from the hook. Visual verification of proper hook engagement is required in all cases.
 Self-locking hooks shall be locked during use.
 When a lock is equipped with a latch, the latch shall not be constrained from closing during use

LATCHES

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The use of latches on hooks is a topic that is constantly up for debate in the lifting and rigging industries.
While some people argue that hook latches are always required and should always be utilized, others
argue that latches are not required.
Unfortunately, there are limited explanations or interpretations of when a latch on a hook must be
utilized. With no clear industry-wide rules on whether a hook latch is required on a crane hook or a sling
hook, the decision is ultimately left up to the owner or end-user. When deciding on whether to use a
latch or not, careful consideration must be given to the specific lifting application.
regarding the use of hook latches, as well as some interpretations that Occupational Safety and Health
Administration (OSHA) has provided in response to questions that have been asked of them.
Below are four such interpretations pertaining to the use of latches on hooks. For clarity’s sake when
reading the OSHA interpretations below, OSHA provides definitions for the terms “shall” and “should” as
follows:
 “Shall” means mandatory
 “Should” means recommended
Please Note: As a company, we use the terms “hook latch” or “hooks with latches.” OSHA uses the term
“safety latches,” so for the purpose of this article, we may use that term to summarize OSHA’s
interpretations or standards. However, the term “safety” implies that the user will always be safe when
lifting a load using a hook with a latch.
It is always the responsibility of the end user or other designated or qualified person to inspect their
rigging equipment and make sure that it is in proper working condition and rated for the specific task,
prior to performing a lift.

OSHA Interpretation 1
 Question: Is it mandatory for large crane hooks to
have safety latches on them? If so, are older hooks
without them “grandfathered”?
 OSHA Response: OSHA requirements for a safety
latch on hooks do not depend on the size of the
hook but rather the activity for which the hook is
being used. Safety latches on hooks are required in
two instances:

Personnel Platforms
 Section 1926.550(g)(4)(iv)(B) states: Hooks on overhaul ball assemblies, lower load blocks, or
other attachment assemblies shall be of a type that can be closed and locked, eliminating the
hook throat opening. Alternatively, an alloy anchor type shackle with a bolt, nut and retaining
pin may be used.
 This provision is intended to prevent personnel platforms from falling as a result of becoming
accidentally unfastened from the hook.
Working Under the Load

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  Section 1926.753(d) prohibits: Workers engaged in steel erection activities from being directly
under a suspended load, with some exceptions. Where those exceptions apply (i.e., where
workers are engaged in the initial connection of steel or employees are unhooking the load),
specific criteria apply. One such criterion is the requirement for safety latches.
 Section 1926.753(d)(2)(ii) states:
 Hooks with self-closing safety latches or their equivalent shall be used to prevent components
from slipping out of the hook
 This provision was intended to prevent the components from becoming accidentally unfastened
from the hook and falling on the worker below. The preamble to the proposed rule explained
that an “equivalent” device would include:
 A hook with another type of closing device, i.e., a hook with a spring-loaded gate or another
type of safety hook that would provide the same level of safety as a safety hook with a self-
closing latch.
 Neither the personnel platform nor the steel erection/working under load requirement has an
exception for large hooks – the requirements apply irrespective of the size of the hook. Also,
there is no “grandfather” exception for older hooks without safety latches.
Summary
 OSHA 1926.550(g)(4)(iv)(B) states that requirements for latches on hooks are not mitigated by
the size of the hook or “grandfathered” for older hooks without safety latches
 Hooks with latches are required when used in conjunction with a personnel platform, overhaul
ball assembly, lower load block, or other attachment assemblies
 OSHA 1926.753(d) prohibits steel erectors from working directly underneath a suspended load
unless self-closing latches or their equivalent are used to prevent components from becoming
accidentally unfastened from the hook and falling on workers below.
 Exceptions may apply to employees engaged in the initial connection of steel or employees who
may be unhooking the load
 Equivalent device would be a hook with a spring-loaded gate or another type of hook that would
provide the same level of safety as a hook with a closing latch

OSHA Interpretation 2
 Question: Does OSHA require the use of latches on hooks on slings?
 OSHA Response: Whether OSHA requires a safety latch on a sling hook depends on the activity
for which the sling is being used.
 You are correct that although the standard for slings provides that “slings shall be securely
attached to their loads,” the section does not
explicitly require that the hook is equipped with
a safety latch (29 CFR §1910.184(c)(6)).
 Use of a hook with a safety latch would, of
course, be one way of securely attaching a sling
to its load. As you also noted, OSHA’s standard
for derricks does include an explicit

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 requirement for latch type hooks: “Hooks shall meet the manufacturer’s recommendations…and
safety latch type hooks shall be used wherever possible.” (29 CFR §1910.181(j)(2)
(i) and 1910.181(j)(2)(ii)).
 The standard defines “safety hook” as “a hook with a latch to prevent slings or load from
accidentally slipping off the hook.” (29 CFR §1910.181(a)(29)).
 We would also call your attention to the following provisions in OSHA’s maritime and
construction standards: 29 CFR Part 1917, Marine Terminals, at 29 CFR §1917.45(e)(2) (“Crane
hooks shall be latched or otherwise secured to prevent accidental load disengagement.”); 29
CFR Part 1918, Safety and Health Regulations for Longshoring, at 29 CFR §1918.66(e)(2) (“Crane
hooks shall be latched or otherwise secured to prevent accidental load disengagement.”), and
at §1918.81(b) (“Cargo handling bridles, such as pallet bridles, which are to remain attached to
the hoisting gear while hoisting successive drafts, shall be attached by shackles, or other positive
means shall be taken to prevent them from being accidentally disengaged from the cargo
hook.”); and 29 CFR Part 1926, Safety and Health Regulations for Construction, at 29 CFR
§1926.753(d)(2)(ii) (in specified situations, “Hooks with self-closing safety latches or their
equivalent shall be used to prevent components from slipping out of the hook…”).
 The Occupational Safety and Health Act of 1970 also contemplates that, in the absence of a
specific OSHA standard addressing a hazard, employers are required, by the statute’s “General
Duty Clause” (Section 5(a)(1)), to protect employees from serious recognized hazards. OSHA
often considers the provisions of industry consensus standards, such as those published by the
American National Standards Institute (ANSI) or the American Society of Mechanical Engineers
(ASME), when evaluating whether a hazard is “recognized” and whether there is a feasible
means of abating that hazard. One such provision that OSHA would consider is Section 2-1.14.5,
Hooks, of ASME 30.2-2001, Overhead and Gantry Cranes: “Latch-equipped hooks shall be used
unless the application makes the use of the latch impractical or unnecessary.”

Summary
 OSHA states that “slings shall be securely attached to their loads.” They go on to explain that
this does not explicitly say that the hook needs to be equipped with a latch, however, they do
note that the use of a hook with a latch is one way to securely attach a sling to its load.
 OSHA’s standards for derricks does include an explicit requirement for latch-type hooks:
“Hooks shall meet the manufacturer’s recommendations…and safety latch type hooks shall be
used wherever possible.
 A “safety hook” is defined as “a hook with a latch to prevent slings or loads from accidentally
slipping off of the hook.”
 OSHA has provisions requiring the use of hook latches for maritime and construction
applications:
 Crane hooks shall be latched or otherwise secured to prevent accidental load
disengagement. [Marine Terminals]
 Crane hooks shall be latched or otherwise secured to prevent accidental load
disengagement. [Longshoring]

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  Cargo handling bridles, such as pallet bridles, which are to remain attached to the hoisting gear
while hoisting successive drafts, shall be attached by shackles, or other positive means shall be
taken to prevent them from being accidentally disengaged from the cargo hook.  Hooks with
self-closing safety latches or their equivalent shall be used to prevent components from slipping
out of the hook.
 OSHA states that in the absence of a specific OSHA standard addressing a hazard, employers are
required, by the statute’s “General Duty Clause”, to protect employees from serious recognized
hazards.
 OSHA often considers the provisions of other industry standards, such as those
by ANSI or ASME, when evaluations whether a hazard is “recognized” and whether there are
feasible means of reducing that hazard.
 ASME 30.2-2011 Overhead and Gantry Cranes states: “Latch-equipped hooks shall be used
unless the applications makes the use of the latch impractical or unnecessary.”

OSHA Interpretation 3
 Question: …requesting clarification of the OSHA requirement for safety latches on lifting hooks.
In March 1976, OSHA responded to a letter
requesting clarification regarding latches.
 OSHA Response: The requirement for safety
latches (AKA throat latches) is only specified
in OSHA 1910.181(j)(2)(ii), which states that
“Safety latch type hooks shall be used wherever
possible.”
 OSHA compliance officers may use the OSHA
general duty clause identified as paragraph 5(a)
(1) of the Williams-Steger Act whenever a hazard is created by a hoisting operation where the
hoist hook is not provided with a throat latch. The compliance officer may then support the 5(a)
(1) citation by calling attention to 1910.181.(j)(2)(ii).
 A second alternative would be to cite the “General Duty Clause” 5(a)(1) and support it with the
industry practice where the use of safety or throat latches is fairly common.

Summary
 OSHA 1910.181(j)(2)(ii) states that “safety latch type hooks shall be used wherever possible.”
OSHA may refer to the “General Duty Clause” whenever a hazard is created by a hoisting operation
where a hook without a latch is used.

OSHA Interpretation 4
 Question: …requesting an interpretation of the
term “closed hook” in OSHA Instruction STD 1-
11.2B, paragraph F.2.c.

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  OSHA Response: The Lifting Bridle Requirements in the above-referenced instruction refer to
working platforms suspended from cranes used to hoist and suspend employees in unique work
situations, when such action would result in the least hazardous exposure to employees. In
order to permit employers to use crane-suspended work platforms, OSHA has determined that
certain conditions must be met to ensure a greater degree of protection for employees. The
lifting bridle on working platforms suspended from cranes for employee access or egress must
be secured by a shackle or attached by a closed hook which cannot open due to the load
position in the hook. Experience has shown that spring loaded safety latches can open with
certain changes in the load position in the hook. Therefore, spring loaded safety latched hooks
are not considered “closed hooks” for hoisting and suspending employees on a work platform.
 There are available and in use hooks that can be closed and locked which will not allow the load
to escape should the load position shift in the hook. Use of this type of hook or of a shackle will
ensure controlled conditions to permit employee hoisting.
 The requirements set forth in OSHA Instruction STD 1-11.2B are designed to further the
protection of employees working on platforms suspended from cranes, and the proposed
standard 29 CFR 1926.550(g) will reflect these attachment requirements.

Summary
 The lifting bridle on working platforms suspended from cranes for employee access must be
secured by a shackle or attached by a closed hook which cannot open due to the load position in
the hook.
 Spring-loaded latches can open with certain changes in the load position in the hook, and are
not considered “closed hooks” for hoisting and suspending employees on a work platform.
 A hook that can be closed and locked will not allow the load to escape should the load position
shift in the hook. Use of this type of hook or of a shackle will ensure controlled conditions to
permit employee hoisting.

Application
 Any hook that is designed to have a latch, should have the latch installed
 New slings are sold with the latch installed unless the customer requests no latch
 If customers make an inquiry about the use of a latch on a hook, we may recommend for them to

consider several OSHA standard interpretations, among them the following:

 The Occupational Safety and Health Act of 1970 also contemplates that, in the absence of a
specific OSHA standard addressing a hazard, employers are required, by the statute’s “General

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 Duty Clause” (Section 5(a)(1)), to protect employees from serious recognized hazards. OSHA
often considers the provisions of industry consensus standards, such as those published by the
American National Standards Institute (ANSI) or the American Society of Mechanical Engineers
(ASME), when evaluating whether a hazard is “recognized” and whether there is a feasible
means of abating that hazard.
 One such provision that OSHA would consider is Section 2-1.14.5, Hooks, of ASME 30.2- 2001,
Overhead and Gantry Cranes: “Latch-equipped hooks shall be used unless the application makes
the use of the latch impractical or unnecessary.”
 Or the following OSHA standard interpretation may be referenced: The requirement for safety
latches (AKA throat latches) is only specified in OSHA 1910.181(j)(2)(ii), which states that “Safety
latch type hooks shall be used wherever possible.”
 Or the following OSHA standard interpretation may be referenced: Whether OSHA requires a
safety latch on a sling hook depends on the activity for which the sling is being used.Inspection
and Rejection
 The operator or other designated person shall visually inspect hooks latches daily or prior to first
use, if the latch is not in regular service, for the following (records are not required):
 Cracks, nicks, gouges.
 Deformation.
 Damage from chemicals.
 Damage, engagement, or malfunction of latch (if provided).
 Evidence of heat damage.

Hitch Types
 Basic Hitches:
 Straight, or vertical, attachment is simply using a sling to connect a lifting hook to a
 load. Full rated lifting capacity of the sling may be utilized, but must not be exceeded. Whenever
a single sling is used in this manner, a tagline should be used to prevent load rotation which may
cause damage to
 the sling. When two or more slings are attached to the same lifting hook in straight, or vertical,
manner, the total hitch becomes, in effect, a lifting bridle, and the load is distributed among the
individual slings.
 CHOKER hitches reduce lifting capability of a sling, since this method of rigging affects ability of
the wire rope components to adjust during the lift. A choker is used when the load will not be
seriously damaged by the sling body-or the sling damaged by the load, and when the lift
requires the sling to snug up against the load.
 The diameter of the bend where the sling contacts the load should keep the point of
 choke against the sling body – never against a splice or the base of the eye.
 When a choke is used at an angle of less than 135 degrees, the sling rated capacity
 must be adjusted downward to compensate for further loss of capability.

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  A choker hitch should be pulled tight before a lift is made - not pulled down during the lift. It is
also dangerous to use only one choker hitch to lift a load which might shift or slide out of the
choke.

 BASKET hitches distribute a load equally between the two legs of a sling-within below. Capacity
of a sling used in a basket is affected by the bend, or curvature,where the sling body comes in
contact with the load-just as any wire rope is affected and limited by bending action, as over a
sheave

 Bridle HitchesTwo, three or four single hitches can be used together to form a bridle hitch for
hoisting an object that has the necessary lifting lugs or attachments. They can be used with as
many different types of end fittings. They provide excellent load stability when the load is
distributed equally among the legs, when the hook is directly over the center of gravity of the
load and the load is raised level. In order to distribute the load equally, it may be necessary to
adjust the leg lengths with turnbuckles or chain lever hoists. The use of a bridle sling requires
that the sling angles be carefully determined to ensure that the individual legs are not
overloaded.
 Unless the load is flexible, it is wrong to assume that a 3- or 4-leg hitch will safely lift
 a load equal to the safe load on one leg multiplied by the number of legs because there is no
way of knowing that each leg is carrying its share of the load. With slings
 having more than 2 legs and a rigid load, it is possible for two of the legs to take
 practically the full load while the others only balance it.

 Estimating Load Weights

 The most important step in any rigging operation is the determination of the weight
 of the load to be hoisted. If this information cannot be obtained from shipping papers, design
plans catalogue data or from other dependable sources, it may be necessary to calculate the
weight..

Synthetic web slings

Synthetic web slings have a number of advantages which include:
 Pliable, flexible, and tend to mold themselves to the shape.
 Minimize twisting and spinning.
 Do not rust and are non-sparking. Won't mar or crush the load.
 Are elastic and stretch.
There are two type of synthetic web slings: nylon and polyester.
Nylon is the most common type used on site. It has an elastic stretch of 6% at noted capacity.
Polyester has less stretch, approximately 3 percent. The stretching of slings allows a cushion against
sudden shock.

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Both types are sensitive to heat and certain chemicals. Neither should be exposed to temperatures
above 180 degrees F, and will soften on prolonged sunlight exposure. Therefore, the slings should be
stored inside or under cover.
The size of the sling is determined by the width of the web. Each sling has a tag sewn to it with the type,
size and rated capacities. Note the capacity for the vertical, choker and basket hitch are different.
The use of synthetic web slings in radiation areas should be avoided if possible. If it is necessary to use a
nylon sling in a radiation area, the responsible person shall ensure radiation exposure to the sling does
not exceed 100,000 rad during the life of the sling. Polyester fiber slings shall never be used in a
radiation area.

Frequent (Pre-Use) Inspections

Slings shall be visually inspected for defects by the person using it before actual use.
Red colored yarns are woven into the inner layer of most slings and, when exposed, indicate the sling
should be removed from service.

Causes of wear or damage to synthetic web slings include :

Acid or Caustic Attack

Acid or caustic attack is normally evident by discoloration of the fabric. It can also cause the fabric to
appear to be rotten.

Melting or Charring
Melting or charring on any part of the sling is sufficient enough reason to take a sling out of service.
Damaged areas will be blackened, hard and melted like plastic, or speckled as when damaged from weld
splatter.

Holes, Tears, Cuts or Snags

When holes, tears, cuts or snags appear on synthetic web slings, it is a judgement call on whether or not
the sling is to be taken out of service. It must be determined how much of the inner thread damage
there is to the sling, for they compose 80% of the sling's strength. This type of damage can be found on
any port of the sling. When red guard warning yarn is exposed (red thread that is sewn in by the
manufacturer) the sling must be taken out of service.

Excessive Abrasive Wear

Abrasive wear is characterized by frayed fibers on the surface webbing of the sling that hold in place the
load-bearing (longitudinal) fibers. This type of abrasive wear is caused when a load slips in a sling or
when slings are allowed to be pulled from under a load.

Broken or Worn Stitching

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Slings must be inspected for broken or worn stitching in the load bearing splices of the sling. Broken or
worn stitching in any other part of the sling is not of a critical nature. However, broken or worn stitching
in load bearing splices can cause significant reduction of sling capacity.

Knots
Slings with knots in any part of them shall not be used. A knot in a sling can reduce the sling capacity up
to 50% in the area of the knot.

End Fittings
Be sure to check for excessive pitting or corrosion, cracked distorted or broken end fittings.
Check for any other visible damage that causes doubt as to the strength of the sling.

Determining Factor
Heavy cranes and hoist structures are used in shipping, factories, construction and virtually every other
sectors of industry. Improper rigging methods, use of wrong equipment or other factors affecting the
operations can cause serious injuries to the workers using the equipment as well as those in close
proximity. Serious injuries, burns, cuts, physical impairments and fatalities can be caused due to
improper use of rigging equipment (Lifting Tackle). The process of rigging and lifting uses cranes and
other large pieces of lifting equipment to lift and move loads.
Though this practice is regulated by OHS Act, each year many workers are killed in rigging operations
and crane accidents and others are left seriously injured. It is important that the operators involved in
rigging operations are sufficiently trained and when lifting operations become critical as a result of risk
factors the skills of qualified Riggers becomes essential. Qualified Riggers are competent to understand
how to apply rigging equipment to lifting and rigging operations. Following are six major factors that can
compromise the safety of the lifting and rigging equipment:

Work Load Limit

Don’t assume. It is important that you determine the actual work load limit of the equipment. You can
determine the weight of the load by checking the shipping papers, catalogue, manufacturer’s
specifications and other reliable sources. The size and weight of all the equipment used in the hoisting
operation should be determined including the beams, slings, wire ropes, load and the crane boom. If the
ideal work load weight is not provided, you have to calculate the weight using the standard weight and
apply appropriate formulas using area and volume. Generally, hoisting and rigging applications will
require you to calculate the resistive forces applied. Skates and rollers on ground will also add some
resistance and that must be included in the calculation considering friction coefficient and angle. It is
important to remember never to exceed the given manufactures working load limit.

Weather Condition
Weather conditions are also important elements that affect rigging safety. These need to be considered
while planning and executing lifting or hoisting operations. Poor visibility, darkness, dust etc. should be
considered while planning a lift. In extreme cold conditions avoid shock-loading or applying sudden jerk

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to rigging equipment and hardware, which can break the already brittle parts. Also keep in mind that at
freezing temperatures, loads are likely to be frozen to the ground or the structures they might be resting
on. In windy conditions, a great deal of judgment is required to carry out lifting operations. Most cranes
have some specifications concerning the maximum wind speed they can tolerate. While no such
specification is generally available in the load charts, it is important that the crane manufacturer should
be consulted to know the maximum permissible wind speed.

Proper Rigging Method

Every rigging operation has a definite rigging method that should be followed in order to ensure safe
working conditions. Using improper rigging methods can reduce the efficiency of the load to be lifted
and can also cause fatal injuries if the load security loosens up and the (COG) centre of gravity moves
out of control. You need to ensure that all rigging equipment are placed and rigged properly to the load
as well as to the lifting machine. It is important to determine proper sling methods in order to increase
the efficiency of the lift and reduce the amount of excessive forces applied. It is also important to secure
or remove all unused slings before lifting the load. Determine the (COG) centre of gravity of the load as
well as the crane in order to prevent the load swing. Avoid dragging slings from under the load. Also
make sure the sling angles are properly maintained to reduce risks of load imbalance. Avoid sudden
snatching, swinging, and stopping of suspended loads. Rapid acceleration and deceleration also
increases these dynamic forces. Failure to maintain the load capacity is one of the main reasons of
rigging failure.

Proper Rigging Equipment

Choosing the right equipment for your rigging operation is the first step to ensuring safety. It is
important that a competent person with the necessary knowledge and/or qualifications (qualified Rigger
for critical lifts) is consulted while choosing the right rigging equipment. That’s because you must know
the purpose of the equipment and also the load weight which is to be rigged to the equipment. You
need to understand the characteristics of various rigging equipment and their nature. Also while
predetermining their use try and understand what should be kept in mind while storing or inspecting
such equipment. For example, there are various kinds of lifting tackle like synthetic polyester webbing
slings, chain and wire rope slings, shackles, etc. that can used for various purposes. Choosing the right
rigging equipment/lifting tackle will protect the workers and property from any harm and the operation
can be carried out easily. An experienced qualified rigger will have the best knowledge about selecting
the appropriate equipment for a specific lift. Some of the main aspects to consider are strength,
diameter, grade, and the type of construction.

Inspection and Maintenance of Rigging equipment (Lifting Tackle)

All machinery and rigging hardware should undergo regular inspection. Understanding the nature of the
material and its properties will allow you to identify the types of wear and abrasion it can face.
Inspection and maintenance are generally equipment specific. There are generally three types of
inspection that every piece of lifting tackle (Rigging Equipment) should go through: • pre-use visual
Inspection • OHS Act Periodic examination • Post visual Inspection Proper storage and appropriate
lubrication will help increase the service life of the lifting tackle. Another aspect of maintenance is that

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you must store lifting tackle in a cool dry room away from dust and chemicals. Avoid leaving these lying
on the open ground, use a pallet.

Responsible Lifting and Rigging Operator

Responsible competent lifting and rigging operators are a necessity in every industry. Operators must be
competent enough to carry out rigging operations safely and must be trained and/or qualified (qualified
Rigger for critical lifts) and licenced to operate certain machines like cranes, forklifts, and certain
technical devices. Being an operator also means they should be able to supervise the workforce that is
under their control. Proper knowledge and understanding in their field will allow them to take accurate
decisions when required. When on duty they should be alert enough to report any type of foreseen and
unforeseen danger. Also, the management must give rigging operators the authority to stop an
operation if he finds it risky. As a competent lifting and rigging operator they should understand the
importance of conducting a safe hoist operation. They should understand how to lift and when to lower
the load safely. An operator who leaves a load suspended and unattended should be subject to strict
action, which may include suspending his or her appointment to operate the crane pending possible
further training and supervision. Keeping these six elements in mind while performing a lifting or rigging
operations will ensure safety at the work on site and reduce the risks of injury to yourself and your
fellow workers.

Compression Hardware Types, Materials, And Assembly

Types
 Wire rope clip types covered are U-bolt and double saddle
 Wedge sockets
 Compression hardware other than those detailed in this Chapter shall be used only in
accordance with recommendations of the manufacturer or a qualified person.

Materials
 Wire rope clip materials shall be of sufficient strength such that failure of the wire rope will
occur before failure of the wire rope clip at the temperatures the manufacturer has specified for
use. Saddles shall be forged steel.
 Wedge socket materials shall be of sufficient strength such that failure of the wire rope will
occur before failure of the wedge socket at the temperatures the manufacturer has specified for
use.

Assembly — Wire Rope Clips

 Before installing a wire rope clip on plastic coated or plastic impregnated wire rope, consult the
wire rope clip manufacturer, wire rope manufacturer, or a qualified person.
 For U-bolt clips used to create end terminations, the saddle shall be placed on the live end of
the wire rope, with the U-bolt on the dead-end side.

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  At least the minimum number of clips as recommended by the manufacturer or a qualified
person shall be used.
 The spacing and turn-back should be as recommended by the manufacturer or a qualified
person.
 The wire rope clip shall be tightened to the torque recommended by the manufacturer or a
qualified person.
 After assembly, the connection shall be loaded to at least the expected working load. After
unloading, wire rope clips shall then be retightened to the torque 14 recommended by the
manufacturer or a qualified person.

Assembly — Wedge Sockets

 The wedge socket shall be assembled as recommended by the manufacturer or a qualified
person.
 Before installing a wedge socket on plastic coated or plastic impregnated wire rope, consult the
wedge socket manufacturer, wire rope manufacturer, or a qualified person.
 The live end of the wire rope in the wedge socket cavity shall be in alignment with the socket’s
pin.
 The assembler shall match the proper wedge with the socket for the wire rope to be installed.
NOTE: Wedges shall not be interchanged between different manufacturers’ sockets or models.
 The length of the dead-end tail of the wire rope shall be as required by the manufacturer or a
qualified person.
 The dead-end tail of the wire rope extending beyond the wedge socket shall be secured in a
manner recommended by the wedge socket manufacturer or a qualified person.
 The dead end of the wire rope shall not be secured to the live end of the wire rope such that it
restricts the movement of the live end.
 After assembly, the connection shall be loaded to fully seat the wedge before use.

DESIGN FACTOR
 Due to the nature of the design and use, wire rope clips and wedge sockets do not have a
conventional design factor. Wire rope clips and wedge sockets shall be designed to have an 80%
minimum termination efficiency based on the wire rope published minimum breaking force with
which they are used.

RATED LOADS
 The rated load for wire rope assemblies using compression hardware is based on the following
factors:
 wire rope minimum breaking force
 80% minimum termination efficiency
 design factor of the wire rope application

Proof Test Requirements

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  Compression hardware is not required to be proof tested unless specified by the purchaser.
 If required, the proof test shall be applied to the wedge socket or the connection made by the
wire rope clips after the assembly is complete.
 After proof testing, wire rope clips on a finished assembly shall be retightened to the torque
recommended by the wire rope clip manufacturer or a qualified person.
 Proof tested compression hardware shall be inspected after the test for the conditions

Proof Load Requirements

 The proof load shall be a minimum of 40%, but not exceed 50%, of the wire rope minimum
breaking force, unless approved by the compression hardware manufacturer or a qualified
person.

Identification
 Wire Rope Clip Saddle Identification Each wire rope clip saddle shall have durable markings by
the manufacturer to show
 name or trademark of manufacturer
 size

Wedge Socket Identification

 Each wedge socket body and wedge shall have durable markings by the manufacturer to show
 name or trademark of manufacturer
 size
 model, if required to match wedge to body

Maintenance of Identification
 Compression hardware identification should be maintained by the user so as to be legible
throughout the life of the hardware.

Effects Of Environment
Temperature
 When wire rope clips are to be used at temperatures above 400°F (204°C) or below −40°F
(−4°C), the wire rope clip manufacturer or a qualified person should be consulted. (b) When
wedge sockets are to be used at temperatures above 400°F (204°C) or below −4°F (−20°C), the
wedge socket manufacturer or a qualified person should be consulted.

Chemically Active Environments

 The strength of compression hardware can be affected by chemically active environments, such
as caustic or acidic substances or fumes. The compression hardware manufacturer or a qualified
person should be consulted before compression hardware is used in chemically active
environments.

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Training
 Compression hardware users shall be trained in the selection, inspection, cautions to personnel,
effects of environment, and rigging practices as covered by this Chapter.

Inspection, Repair, And Removal

General
 All inspections shall be performed by a designated person. Any deficiencies identified shall be
examined and a determination made by a qualified person as to whether they constitute a
hazard.

Initial Inspection
 Prior to use, all new, altered, modified, or repaired compression hardware shall be inspected to
verify compliance with the applicable provisions of this Chapter. Written records are not
required.

Frequent Inspection
 A visual inspection shall be performed each shift before the compression hardware is used.
Rigging hardware in semi-permanent and inaccessible locations where frequent inspections are
not feasible shall have periodic inspections performed.
 Conditions such as those listed , or any other condition that may result in a hazard, shall cause
the compression hardware to be removed from service. Compression hardware shall not be
returned to service until approved by a qualified person.
 Written records are not required.

Periodic Inspection
 A complete inspection of the compression hardware shall be performed. The compression
hardware shall be examined for conditions such as those listed above and a determination made
as to whether they constitute a hazard.
 Periodic Inspection Frequency: Periodic inspection intervals shall not exceed 1 yr. The frequency
of periodic inspections should be based on
 frequency of use
 severity of service conditions
 nature of lifting or load handling activities
 experience gained on the service life of compression hardware used in similar circumstances
Guidelines for the time intervals are:
 normal service — yearly
 severe service — monthly to quarterly
 special service — as recommended by a qualified person

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  Written records are not required

Removal Criteria
Compression hardware shall be removed from service if conditions such as the following are present and
shall only be returned to service when approved by a qualified person:
 missing or illegible identification
 indications of heat damage, including weld spatter or arc strikes
 excessive pitting or corrosion
 bent, twisted, distorted, stretched, elongated, cracked, or broken components
 excessive nicks or gouges (f)
 a 10% reduction of the original or catalog dimension at any point
 evidence of unauthorized welding or modification
 unauthorized replacement components
 insufficient number of wire rope clips
 improperly tightened wire rope clips
 indications of damaged wire rope
 indications of wire rope slippage
 improper assembly or other conditions, including visible damage, that cause doubt as to
continued use

Repairs and Modifications

 Repairs, alterations, or modifications shall be as specified by the compression hardware
manufacturer or a qualified person.
 Replacement parts shall meet or exceed the original compression hardware manufacturer ’s
specifications.

Storage and Work Environments

 Compression hardware should be stored in an area where it will not be subjected to damage,
corrosive action, or extreme heat.
 If extreme temperatures or chemically active environments are involved, the guidance provided
in above paragraph

Safe Operating Practices and Procedures

 Hoisting of the personnel man-basket shall be performed in a slow, controlled, cautious manner
with no sudden movements of the crane or the platform.
 Load lines shall be capable of supporting, without failure, at least seven times the maximum
intended load, except that where rotation resistant rope is used, the lines shall be capable of
supporting without failure, at least ten times the maximum intended load. The required design
factor is achieved by taking the current safety factor of 3.5 and applying the 50 per cent de-
rating of the crane capacity.

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  Load and boom hoist drum brakes, swing brakes, and locking devices such as pawls or dogs shall
be engaged when the occupied personnel man-basket is in a stationary working position.
 The crane shall be uniformly level within one percent of level grade and located on firm footing.
Cranes equipped with outriggers shall have them all fully deployed following manufacture’s
specifications, insofar as applicable, when hoisting employees.
 The total weight of the loaded personnel man-basket and related rigging shall not exceed 50
percent of the rated capacity for the radius and configuration of the crane.
 The crane operator shall remain at the controls at all times when the crane engine is running
and the man-basket is occupied.
 Hoisting of employees shall be promptly discontinued upon indication of any dangerous weather
conditions or other impending danger.
 No lift shall be made on another of the crane or derrick’s load lines while personnel are
suspended in a man-basket.

When moving a load from one place to another, it is always a priority to ensure safety and efficiency,
and using the correct below-the-hook lifting device is the best way to do it.

Below-the-Hook

What is a below-the-hook lifting device?

A below-the-hook lifting device is a mechanical lifting tool that attaches to a lifting apparatus and used
to hold the load firmly and securely. It then moves the weight from one place to another.
Most below-the-hook lifting equipment operate mechanically, but can also perform pneumatically,
electronically or hydraulically when unique controls are made.

Components of a below-the-hook lifting device

The components that make up below-the-hook lifting gear are a latch, bail, a lifting lug, rigging
hardware, a hook, and a gusset. A latch holds the lifter in either an open or closed position. The rigging
hardware connects with a lifting lug, which acts as the point of attachment for the rigging equipment
through the hook.
The bail is the opening where the hook of the crane holds. Bails can be pin or plate in style. A gusset on
these lifting equipment adds sturdiness to the area of extreme stress and usage. The gusset is a well-
reinforced welded plate that is solidly built for its purpose.
Below-the-hook lifting gear have many applications depending on which type of device you are using.
Their most basic use is the transportation of different kinds of loads from one place to another and
other lifting tasks. Other applications include:

Types of below-the-hook lifting devices

There are many different types of lifting devices costumed to serve different purposes in the logistics
industry.

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Gripping lifters
As their name suggests, gripping lifters are used to grip loads. They use indentation or friction, which
brings pressure to grip a load and they possess tong grabs that imitate a scissor in how they get hold of a
load. Finally, they can be used to either lift or turn a charge after gripping it.

Sheet lifters
They are used for loads made of sheets of wood. With its two claws, they hold a load by wrapping
around the edges. The claws have a lip on its lower part to prevent the sheets from falling out of the
filter

Beams
A beam is used to provide sufficient protection for the load and also controls the movement of the
cargo. Beams are made from fabricated metal and have multiple load-lifting points. But first, let’s look at
the various types of beams. They include lifting beams, spreader beams, and spreader bars. Lifting
beams are long beams that are heavier than spreader bars. Their advantage is that they have well-
reduced headroom for lifting tasks. The spreader beams aid in load balancing and control. Spreader bars
are lighter and affordable than lifting beams. Their function is to hold a sling apart to the lifting distance.

Die turners
Die turners are generally used to turn large dies securely instead of flipping the dies.

Magnet lifts
This type of below-the-hook hook lifting gear carries and releases flat or round ferrous objects. They can
work with or without electrical connections.

Vacuum lifters
They make a vacuum space to attach the lever to an object using an electric-powered extraction
pump and sealed pads.

Pallet lifters
Pallet lifters lift pallets from surfaces using forks.

Mechanical lifters
This lifting equipment is composed of two or more big parts that move in tandem. These parts are used
to attach a load to an elevator.

Coil hook
A coil hook allows the coil lifting using its inner diameter. It may be in a horizontal or vertical position.
A hook rotator attaches to the lower part of an elevator and powers the rotation of the hook for
additional load control.

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Drum Turners
Used to rotate drums for filling and emptying.
It is critical that your below-the-hook lifting gears to be OSHA compliant. Many companies take their
time to prove all their devices but ignore the compliance of below-the-hook lifting equipment. Below are
the OSHA compliance standards for below-the-hook lifting devices.

ASME B30.20
Deals with vacuum lifting gear operated with close proximity lifting magnets; magnetic devices operated
remotely, grapples, structural and mechanical lifting equipment, and scrap and material handling. It
offers a well laid out solution relating to maintenance, operation of hardware used to hoist loads,
installation, inspection, marking construction, and inspection.

ASME BTH-1
ASME BTH-1 gives the least structural and mechanical design and electrical component selection criteria
for ASME B30.20.
Applications of Below-the-Hook Devices
Although you can get customized solutions, these devices are also used for a few common applications.
These include:
 Lifting and moving pipes, metal bars, concrete blocks, and metal girders
 Stacking and retrieving metal coils and wire rope coils
 Stacking and retrieving metal sheets, plates, and similar items
 Lifting and moving pallets and drums
 Lifting and moving loose items like sand and grains using big bags and spreader beams

Inspection Requirements
Failure to inspect your below-the-hook lifting device, and failure to maintain proper inspection records,
are two of the most common reasons that your lifting or rigging program may not be fully compliant
with OSHA and ASME standards.
Below-the-Hook lifting devices need three regular inspection frequencies per ASME B30.20:
 Before and during each lift made by the lifter
 Frequent inspection
 Periodic inspection
 Prior to and during use – Your operator should inspect the below-the hook device before and
during each lift made by the lifter.

Frequent Inspection – Visual examinations by the operator or other designated person(s) with records
not required:
 Normal Service – Monthly
 Heavy Service – Weekly to Monthly
 Severe Service – Daily to Weekly

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  Special or Infrequent Service – As recommended by a qualified person before and after each
occurrence

Periodic Inspection – Visual inspection by a qualified person making records of apparent external

conditions to provide the basis for a continuing evaluation. An external code mark on the lifter is an
acceptable identification in lieu of records.
 Normal Service – Yearly
 Heavy Service – Semi-Annually
 Severe Service – Quarterly
 Special or Infrequent Service – As recommended by a qualified person before the first such
occurrence and as directed by the qualified person for any subsequent occurrences.

Rejection:
Homemade or Unmarked Below-the-Hook Devices
 Does your homemade lifting device meet the design requirements of ASME B30.20 / ASME BTH-
1? Was all welding performed in accordance with ANSI/AWS D14.1 welding specifications?
 One of the most common issues found during a rigging inspection, are custom below-the-hook
lifting devices that are either homemade or unmarked. In the below-the-hook lifting world there
are two main standards that you should familiarize yourself with if you’re purchasing or
designing an engineered below-the-hook lifting device:
 ASME B30.20 Below-the-Hook Lifting Devices – addresses structural and mechanical lifting
devices, vacuum lifting devices, operated close proximity lifting magnets, remotely operated
lifting magnets, and scrap and material handling grapples. It offers comprehensive solutions
applying to the marking, construction, installation, inspection, testing, maintenance, and
operation of equipment used for attaching loads to a hoist.
 ASME BTH-1 Design of Below-the-Hook Lifting Devices – provides minimum structural and
mechanical design and electrical component selection criteria for ASME B30.20 below-the-hook
lifting devices.
 Make sure that the below-the-hook lifting device is properly marked and tagged in accordance
with the industry guidelines, and you’ve gone a long way towards making sure your below-the-
hook devices are OSHA and ASME compliant.
 Too often we find that below-the-hook lifters have been made in-house and lack a tag or plate
that provides the following information on the specific device:
 Manufacturer’s name and contact information
 Serial number (unique to that specific lifter)
 Lifter weight
 Rated load
 Cold current amps (when applicable)
 Rated voltage (when applicable)
 ASME BTH-1 Design Category
 ASME BTH-1 Service Class

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 This information can be critical for any rigger, as it provides the weight of the device itself—which
must be considered when calculating if the load is within the capacity of the crane being used for
the lift. It also provides the manufacturer’s name, contact information, and unique serial number. If
you were to have issues with the device down the road, you would need that information for
traceability purposes.
 ASME tag requirements also provide the end-user with information regarding how and why the
product was designed. Design Category tells whether the lifter was designed for a specific
application or designed to be a general purpose lifter. Service Class provides a service
classification for the device by factoring in load cycles per day, as well as the desired service life
(in years) of the device.
 Always make sure that your below-the-hook lifter has the capacity visible, as well as a plate or
tag that is welded or stamped into the device. Lifting beams and other devices can get smashed
and abused during the course of their lifetime and a rickety plate can get knocked loose, or a
painted marking can get marred or scuffed and become illegible.
 If an inspector finds a below-the-hook lifter that’s missing any or all of this information, they’ll
have to fail the device for meeting compliance requirements—and you could be looking at an
expensive and time-consuming process to get your device reverse engineered and re-tagged.

Wrapping it Up
 ASME B30.20 and ASME BTH-1 are the two most important standards when it comes to the
design and markings of a below-the-hook device. If you partner with a reputable manufacturer,
they’ll take care of most of these requirements—it will just be your responsibility to make sure
that all markings and tags remain legible and that your below-the-hook devices are inspected
and you retain the inspection records.

Hoist Hooks
A lifting hook is a device for grabbing and lifting loads by means of a device such as a hoist or crane. A
lifting hook is usually equipped with a safety latch to prevent the disengagement of the lifting wire rope
sling, chain or rope to which the load is attached.
A hook may have one or more built-in pulley sheaves as a block and tackle to multiply the lifting force.
Hoist can be electric-powered, ai-powered or hand-powered and are not permanently mounted..

Electric-Powered Hoist - pendant operated, controls will return to off position when released and
motion stops.
Air-Powered Hoist - pendant operated, controls will return to off position when released and motion
stops.
Hand Chain Operated - manual, designed to automatically stop and hold load when lifting force is
removed. Chain hoists should be rigged so that there is a straight line between the upper and lower
hooks. They are intended for use in a vertical or near vertical position only. If rigged at an angle, the
upper hook can be damaged at the shank and the throat may open up. If the gear housing is resting

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against an object while under load it can be damaged or broken. Always make sure that the hoist is
hanging freely

Hoist Terminology Bottom Block

The assembly of hook or shackle, swivel, bearings, sheaves, pins and frame suspended from the hoisting
ropes or chains.
Limit Switch - Device which restricts the raising and lowering capabilities of the hoist through altering
the electrical circuit associated with that hoist
Upper limit switch - contact device which restricts the upward travel of the hoist based on counting
revolutions on drum or when the block contacts a device below the hoist drum
Lower limit switch - contact device restricting the downward travel of the hoist based on counting
revolutions on drum, in which case the LLS ensures one full wrap* of rope shall remain on the hoist
drum when the hook is in its fully extended position.
Pendant Station - Controls suspended from the hoist for operating the unit from the floor. DRUM -A
Cylindrical-flanged barrel on which the wire rope is wound for operation or storage. It may be smooth or
grooved.

Spreader and Equalizer Beams

Spreader beams are usually used to support long loads during lifts. They eliminate the hazard of the load
tipping, sliding, or bending as well as the possibility of low sling angles and the tendency of the slings to
crush the load. Equalizer beams are used to equalize the load in sling legs and to keep equal loads on
dual hoist lines when making tandem lifts. Spreader and equalizer beams are both normally fabricated
to suit a specific application. If a beam is to be used which has not been designed for the application,
make sure that it has adequate width, depth, length, and material. The capacity of beams with multiple
attachment points depends on the distance between the points. For example, if the distance between
attachment points is doubled, the capacity of the beam is cut in half.

Manufactures
Typical shipyards will require spread lifting capabilities matching the lifting capacity of their largest
crane, or a rough average of about 300 tons. This capacity is larger than most commercially available bar
manufactures produce and can require a custom order or design. Readily, available commercial spreader
bars have primarily smaller lifting capabilities than but larger working loads can be obtained. Spreader
beam manufactures include, Bushman Cadwell, Modulift, Tandemloc Inc, and Vestil. NASSCO has
roughly 24 spreader bars in regular use, ranging form 2.5 to 295 short tons lifting capability and form 4 ft
to 42 ft in spreadable length. The largest spreader bar matches the lifting capability of the largest crane .
Many of the spreader bars have a unique geometry and lifting attachments to accommodate a large
range of lifts. All spreader beams have been custom designed in house.

End Connections
Spreader beams are used to spread the load of an object being lifted and they achieve this by different
forms of attachments. Typical attachments points are hooks, permanently secured master links, or pin

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connections for shackles or endless slings. Most critical lifts are secured with either padeyes and
shackles or pins and endless synthetic slings .

Standards and Regulations

The best standards for spreader beams are the American Society for Mechanical Engineers Below the
Hook Lifting Devices Design Guide and associated standard B30.2. Special considerations need to be
made during the design of spreader beams as the long life cycle can have significant effect on the
design. It is possible that during this life cycle they will perform tens of thousands of lifts potentially of
unknown loads and variable conditions. A respectable design factor should be chosen as bearing wear,
fatigue, corrosion, and other effects of ageing that will set in.

Allowable Loads
As large spreader beams are typically unique they will have specific allowable loads associated with
them. It is recommended that for any given spreader beam documentation be created that explains
what these allowable loads are

Sizes and Standard Types

Box Spreader Beam

NASSCO spreader bars include, four adjustable box beams, two with 295 ton lift capability and two with
170 ton capability. The 295 ton spreader bars have top and bottom lifting attachment which always
travel together and span 14 feet to 50 feet with 5 configurations in between. These beams, however,
cannot be used as equalizers and are not deigned to withstand much internal moment.

Round Spreader Beam

Round bar has a lift capability of 210 tons and span of 14 ft, with effectively two padeyes on top and two
on bottom, located on each end. This spreader is similar to the adjustable box beam spreader for use
but cannot be adjusted with regards to spread distance.

Telescoping Spreader Beam

Other spreader bars in existence include modular, and telescoping spreader bars. These have the
advantage of relatively easily breaking down or reducing in size such that can be transported or stored
easily. An example of a telescopic bar can be seen in Figure 31Figure 31: Telescoping Spreader Beam
which has a 50 ton lifting capability, up to 65 ft in length with 6 in adjustment increments. With
significant adjustment possible vertical slings can be used minimizing internal moments and compressive
forces will be imparted into the ships block during the lift. These spreader beams typically cannot be
used as an equalizer because they are not designed for internal moment. A similar concept to the
telescoping spreader beam is modular spreader beams which have bolt together sections that can be
added or removed to vary the length of the beam.

Equalizer Plate Clamp Spreader Beam

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Three Equalizer Type bars with 30, 35 and 64 ton ratings, spreading 17, 35 and 42 ft. These bars have
two top attachments and permanent chain attachments with plate clamps underneath located on
average every 3 ft. The ones at NASSCO are designed to be used with plate clamps to equally spread the
load out over a large area. This is particularly useful if lifting large plates that are not well stiffened and
required multiple pick points.

Roller Spreader Beams

NASSCO has four beams that are referred to as roller beam bars, with lifting capabilities of
99,124,141,173 short tons and respectively 12ft, 8ft, 20ft and 12 feet in length. These beams are
essentially an I-beam with padeyes attached on both top and bottom, located on roughly every 5 ft.

Single Web Girder Spreader Beams

NASSCO has three Single Web Girder Bars with lift capabilities of 40, 70 and 80 ton and lengths of 45
feet. These spreader bars are capable of many different lift arrangements and can be used as equalizers.
Figure 28 shows a load rating for many different typical lifting arrangements.

Spreader Periodic Inspection and Inspection

Spreaders, which are in the group of lifting and conveying machines, are most commonly used in ports.
However, spreader is also used in large factories, warehouses and silos. Spreaders are generally used
wherever containers are used. It is an important apparatus of cranes that lift containers and its task is to
provide the connection between the container and the crane. They can be from two to three meters in
length up to five or six meters. Their width can be more than one meter. There are four locks
(twistlocks) on the feet of the spreaders. These are fixed in the slots on the container and lifting is done
in this way. When the container reaches the place where it will be transported, the locks are released
and the spreader is separated in the container.
Different types of spreaders are used depending on the weight of the load they will lift. Usually a single
spreader is used to lift 20-ton containers. A twin spreader is used to lift 40 ton containers. To lift larger
weights, the spreaders generally used in ports are tandem type spreaders. In short, spreaders are
designed and manufactured to be used in cranes of various sizes and capacities.
Spreader literally means disperser. By distributing the weight of the lifted load to four corners, a more
comfortable transportation opportunity is provided.
Since the spreaders work under load, it is important to ensure the safety of life and property in
enterprises. In the relevant standards, there are principles for equipment safety, work safety, working
environment safety, locking and placing safety and verification systems of cranes and lifting equipment.
If there is no basis for control criteria and control intervals in the relevant standards, generally the
conditions stipulated by the manufacturer company are adhered to. The following are a few standards
taken into account in the testing and inspection of spreader studies carried out by authorized inspection
bodies:
 TS EN 15056 Cranes - Specifications for container carrier distributors
 TS EN ISO 12100 Safety in machines - General principles for design - Risk assessment and risk
reduction

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Our organization takes into account the legal regulations in force and the standards published by
domestic and foreign organizations while providing testing and inspection services. Likewise, periodic
control and inspection services of spreader are provided within the scope of periodic controls of lifting
conveying machines. The latest technological devices and methods are used in all these studies.

Equalizer Beam
The main purpose of an equalizer beam is to ensure that the percentage of the load shared by each
crane will not change during the erection of the piece of equipment. This is accomplished by designing
the beam so that the pin holes are all on the centerline of the beam. This way, when the beam gets out
of level, the distances between the holes are still proportionately the same. If all the pin holes are not on
the centerline of the beam, then the beam is not a true equalizer beam. To quote a fellow RE, "this
means that some equalizer beams are more equal than others". Usually, there are two pin holes at each
end and two at the center of the beam. This enables the Rigging Engineer to rig up the beam so that the
cranes will share the load in a 50-50, 40-60 or a 30-70 percent ratio.
MONITORING THE LEVEL OF THE EQUALIZER BEAM: Determining the amount that the hooks can be out
of level with each other during the lift is the easy part. Monitoring the actual out of levelness during the
lift is more difficult. The level of the equalizer beam can be determined in one of two ways, using tapes
or a transit. Using an inclinometer is probably the best way, but it is rather expensive to purchase. The
transit method is probably the second best way due to the fact that only one person is involved and the
tapes tend to whip around a bit due to the wind. 1. An inclinometer usually has a magnetic base that will
clamp directly to the top of the equalizer beam. It has a scale marked off in increments of degrees in two
directions and a built in potentiometer. A hand held receiver that can either be connected to the
inclinometer by a cord or by remote also has a potentiometer in it so that the degees the equalizer
beam is out of level is displayed. The person monitoring the inclinometer can read the amount of
degrees the equalizer beam is out of level. 2. A transit can be used to monitor the out of levelness of the
equalizer beam. Before the lift, attach a vertical scale to each end of the equalizer beam at the lift pins.
The scales should be free to hang like plumb bobs from the pins. The scales should be marked off in
inches or centimeters with zero at the center of the pins. The length of the scales should be the
maximum out of levelness value plus 12” (30 cm). The transit should be located perpendicular to the
equalizer beam and far enough away to maintain a 2:1 slope. During the lift, the surveyor would keep his
horizontal stadia cross hair centered on the lowest lift pin. He could then determine the amount the
beam is out of level by reading the scale on the high lift pin. 3. The tape method involves hooking a long
tape to each end of the equalizer beam. The tapes are then run down vertically and around pins located
at ground level. They are then run horizontally out from under the lift a safe distance to a monitoring
station. When the cranes are hooked up to the vessel in the IPP and the hoist lines are snugged up with
the beam level, a reading for each tape would be taken at the monitoring stations. The distance to the
monitoring stations would be adjusted as required to ensure that both tapes are reading the same.
During the lift, the difference in the readings should never be more

Safe Rigging Practices

All personnel involved with the use of rigging gear should be thoroughly instructed and trained to
comply with the following practices:

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  Wire rope slings must not be used with loads that exceed the rated capacities outlined in
enclosure (2) of the COMSECOND/COMTHIRDNCBINST 11200.11. Slings not included in the
enclosure must be used only according to the manufacturer's recommendation.
 Determine the weight of a load before attempting any lift.
 Select a sling with sufficient capacity rating.
 Examine all hardware, equipment, tackle, and slings before using them and destroy all
defective components.
 Use the proper hitch.
 Guide loads with a tag line when practical.
 When using multiple-leg slings, select the longest sling practical to reduce the stress on the
individual sling legs.
 Attach the sling securely to the load.
 Pad or protect any sharp comers or edges the sling can come in contact with to prevent
chaffing.
 Keep slings free of kinks, loops, or twists.
 Keep hands and fingers from between the sling and the load.
 Start the lift slowly to avoid shock loading slings.
 Keep slings well lubricated to prevent corrosion.
 Do not pull slings from under a load when the load is resting on the slings; block the load up to
remove slings.
 Do not shorten a sling by knotting or using wire rope clips.
 Do not inspect wire rope slings by passing bare hands over the rope. Broken wires, if present,
can cause serious injuries. When practical, leather palm gloves should be worn when working
with wire rope slings.
 Center of Balance. It is very important that in the rigging process that the load is stable. A
stable load is a load in which the center of balance of the load is directly below the hook. When
a load is suspended, it will always shift to that position below the hook. To rig a stable load,
establish the center of balance (C/B). Once you have done this, simply swing the hook over the
C/B and select the length of slings needed from the hook to the lifting point of the load.
 When using a multi-legged bridle sling, do not forget it is wrong to assume that a three- or
four-leg hitch will safely lift a load equal to the safe load on one leg multiplied by the number of
legs. With a four-legged bridle sling lifting a rigid load, it is possible for two of the legs to
support practically the full load while the other two only balance it
NOTE: If all the legs of a multi-legged sling are not required, secure the remaining legs out of the way

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Job Site Considerations The handling, setting and erection of
materials and equipment is a hazardous occupation. Each operation presents its own peculiar problems
and no two jobs are alike. With proper consideration taken, each job can be performed free of bodily
harm to the employee and without damage to the equipment.
The person authorized and qualified to do rigging must always pay close attention to details. One
careless moment or act can result in serious injury or death and tremendous property damage. Proper
rigging is an art and should never be left to the inexperienced. If you don’t know how to do it properly,
then don’t attempt it.
Persons performing rigging tasks usually already have two strikes against them when they start!
1. Unfavorable Job conditions.
2. Job Schedule to meet

Rigging Selection Very rarely does the average worker on a construction site get the opportunity to
actually pick the rigging. It is normally purchased by a supervisor, the Company Purchasing Department
or it is sent out from another project. This in itself can create serious problems.
The rigging capacity and the material to be lifted must match. Using too small capacity rigging or
components is just asking for an accident to happen.
1. Who is responsible (competent/qualified) for the rigging? a. Communications Established?
2. Is the Equipment in Acceptable Condition?
a. Appropriate Type?
b. Proper Identification?
C.Properly Inspected?
3. Are the Working Load Limits Adequate? a. What is the weight of the load? b. Where is the center of
gravity? c. What is the sling angle? d. Will there be side loading? e. Capacity of the gear?
4. Will the Load be Under Control?
a. Tag Line available?
b. Is there any possibility of fouling?
c. Clear of Personnel?
5. Are there any Unusual Loading or Environmental Conditions?

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a. Wind?
b. Temperature?
c. Surfaces?(Ice, Suction, Water)
d. Unstable Object(s)?
The Users Responsibilities Utilize Appropriate Rigging Gear Suitable For Overhead Lifting. Utilize The
Rigging Gear Within Industry Standards And The Manufacturers Recommendations. Conduct Regular
Inspection And Maintenance Of The Rigging Gear. Basic Sling Operating Practices (ANSI B30.9)
Whenever any sling is used, the following practices shall be observed!

Basic Sling Operating Practices (ANSI B30.9)

1. Slings that are damaged or defective shall not be used.
2. Slings shall not be shortened with knots or bolts or other makeshift devices.
3. Sling legs shall not be kinked.
4. Slings shall not be loaded in excess of their rated capacity.
5. Slings used in a Basket Hitch shall have the load balanced to prevent slippage.
6. Slings shall be securely attached to the load.
7. Slings shall be padded or protected from the sharp edges of their loads.
8. Suspended loads shall be kept free of obstructions.
9. All employees shall be kept clear of loads about to be lifted and of suspended loads.
10. Hands or fingers shall not be placed between the sling and it’s load while the sling is being tightened
around the load.
11. Shock loading is prohibited.
12. A sling shall not be pulled from under a load when the load is resting on the sling.
INSPECTION Each day before being used, the sling and all fastenings and attachments shall be inspected
for damage and defects by a competent person designated by the employer. Additional inspections shall
be performed during sling use as often as necessary to assure the safety of the operation.
REPLACEMENT Severe localized Abrasion or Scraping. Ten Randomly Distributed Broken Wires in one
Rope Lay, or Five Broken Wires in One Rope Strand in One Rope Lay, Evidence of Heat Damage. (Cut
with a Torch) , Kinking, Crushing, Birdcaging, or Any Damage Resulting in Distortion of the Rope
Structure. Damaged, Distorted or Field Welded Hooks. Damaged
or Worn End Attachment

Center of Gravity
Introduction
There are some pretty complicated explanations of the center of
gravity of a load. Complex mathematical ways are available to
determine the center of gravity of any load. As riggers, all we care
about is where the load's center of gravity is located.

Why Is The Center of Gravity Important? 

Balanced lifts are inherently more stable in flight. Knowing the
location of the center of gravity of a load is important in order to make a balanced lift.

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Simple Definitions 
The center gravity of a load is the single point on the load at which
it can be hoisted perfectly balanced. Some riggers like to think of
it somewhat in reverse: it is the point at which all of a load's
weight is concentrated. When performing a lift, they see it as
counteracting this concentrated weight at exactly the right spot.

It Is Not Rocket Science 

Sometimes finding the correct pick point for a load, or in other
words, the center of gravity, is pretty simple. A load that is
uniformly consistent in cross section along its length will have its center of gravity located exactly half
the length of the load. This is because uniform cross sections
result in uniformly distributed weight.

How to Find the Center of Gravity by Trial and Error

Lifting problems can arise when loads have unevenly
distributed weight. When it is obvious that the load does not
have uniformly distributed weight, the following step by step
method can be used to locate the center of gravity by trial and
error:
Make attachment(s) to the load based an estimate of the location of the center of gravity
Slowly remove hoist slack and lift the load just enough to
observe for any rotation
If the load is stable, continue with the lift ◦ If the load is
unstable, move the attachment point toward the load's low
point and make another trial lift
Continue this method until the load remains stable.

Loads Rotate Around Their Center of Gravity 

It is a known fact that loads, given the opportunity, will rotate
around their center of gravity. This leads to some simple, but important, hoisting rules.

Have you ever heard someone say that one of the advantages of being short and stocky is that you're
less likely to get knocked over? They might have even mentioned that it's because the short and stocky
person has a lower center of gravity. The center of gravity (CG) of an object is the point at which weight
is evenly dispersed and all sides are in balance. A human's center of gravity can change as he takes on
different positions, but in many other objects, it's a fixed location.
Follow me through a quick experiment. You'll need the following:
 A #2 pencil
 A fine edge like a ruler or a credit card

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  A permanent marker
 A ruler (if you don't have one, you may be able to eyeball it)
Step 1: Attempt to balance the pencil on the edge you have selected.
Balancing the pencil may take some trial and error. The point at which the pencil balances may not be
where you first thought. If it begins to tip in one direction, move the pencil back slowly in the opposite
direction until it will stay there on its own.
Step 2: Once the pencil is balanced, mark the location of the balancing point with a permanent marker.
Step 3: Measure the distance between the ends of the pencil and the balancing point you have
marked. Are the two lengths equal? On my pencil, the length from the eraser to the balancing point was
actually 1.25 inches less than the length from the pencil tip to the balancing point. Why would this be
the case?
In our experiment, the balancing point was another word for the center of gravity of this pencil. In other
words, if we cut the pencil in two at the mark we made in the experiment, the two parts would be equal
in weight. However, they are not equal in length. As you may have already figured out, the metal piece
that houses the eraser contributes more to the weight of the pencil, so the CG is closer to that side of
the pencil.
Keeping Up with that Center
The center of gravity is an important concept
in determining the stability of a structure. It's
the reason why a good homeowner will keep
the top branches of his trees trimmed. It's
also the reason why a pick-up truck might
not be the best vehicle choice for a first time driver. Stability is maximized in objects with a lower center
of gravity and a wide base. The taller and more top-heavy an object, the more likely it is to tip over when
it is tilted by a force. This figure demonstrates a bus driving on two different grades; the second one is
steep enough to cause the center of gravity to fall outside of the base of the vehicle, which will cause it
to topple over.
Centre of Gravity Equation

Practice Problems
1. A long rod of length 20 meters has a mass of 100 kg. There is a 25 kg mass at the left end. Where is
the center of gravity relative to the left end?
2. Where would you place a 50 kg mass on a 75 kg, 14-meter rod so that its center of mass is 1 meter to
the left of the physical center of the rod?
Solutions
1. We will use the center of gravity equation to determine the location of the center of mass. Weight is
the mass times the acceleration due to gravity, 9.8 m/s2.
Weight 1 is the weight of the rod and weight 2 is the mass of the extra mass.

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Notice that the accelerations due to gravity cancel.
The center of mass of this system is 8 meters from
the left end.

2. We will not use the acceleration due to gravity in this solution.

Mass 1 is the mass of the rod and mass 2 is the extra mass.

The 50 kg mass would have to be 4.5 meters from the left end.

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 Chapter 5
Safe Rigging Practices & Procedures for the Offshore Oil & Gas Industry
Cargo
 the word cargo refers in particular to goods or produce being
conveyed—generally for commercial gain—by water, air or
land. Freight is the price paid to carry cargo. Cargo was originally
a shipload. Cargo now covers all types of freight, including that
carried by rail, van, truck, or intermodal container. The term
cargo is also used in case of goods in the cold-chain, because the
perishable inventory is always in transit towards a final end-use,
even when it is held in cold storage or other similar climate-
controlled facility. The term freight is commonly used to describe the movements of flows of goods
being transported by any mode of transportation.
Multi-modal container units, designed as reusable carriers to facilitate unit load handling of the goods
contained, are also referred to as cargo, specially by shipping lines and logistics operators. Similarly,
aircraft ULD boxes are also documented as cargo, with associated packing list of the items contained
within. When empty containers are shipped each unit is documented as a cargo
and when goods are stored within, the contents are termed as containerised
cargo
Bulk cargo is a cargo type which is classified as liquid or dry. Oil Containers,
Pipes, Rig parts, Drilling fluid, equipment and materials, Water, sand and
chemicals

Securing a load:
Load securing, also known as cargo securing, is the securing
of cargo for transportation. According to the European
Commission Transportation Department “it has been estimated that up to 25%
of accidents involving trucks can be attributable to inadequate cargo securing”. Cargo that is improperly
secured can cause severe accidents and lead to the loss of cargo, lives, and vehicles, or cause
environmental hazards.
Because of globalization, the subsequent flow of goods that are transported over greater
distances, containerization and new regulatory measures”.  will lead to a greater demand for efficient,
cost effective and environmentally friendly cargo restraint products.
Many types of cargo such as corrugated fiberboard boxes are often formed into a unit load. This often
consists of items on a pallet unitized by stretch wrap, shrink wrap, pressure-sensitive tape, or strapping.
Larger shipping containers such as crates are often on skids and are ready for loading. These unit loads
are placed in intermodal containers, trucks, or railroad cars for shipment. Some large bundled items or
large machinery are placed directly into or onto the transport vehicle for shipment.
Load securing functions to hold the unit pallet loads, crates, or other items immobile and secure. An
unsecured load can shift in transit and create dangerous dynamics, damaging the cargo and the
structure of the vehicle or intermodal container.
Methods

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There are many different ways and materials available to stabilize and secure cargo in vehicles and
intermodal containers. Often combinations of load securing methods are use. For example a load can be
blocked against the headboard of the truck and have webbing restraints tying it down.

Blocking and bracing

Blocking and bracing is a load securement method using lumber and metal bars to reduce or inhibit
front to rear shifting of freight/cargo. Plastic forms are also used.

Blocking and Bracing with timber

Fasteners
Depending on the type of load and the particular vehicle, large bolts and nails may be used. These may
be on the load itself or on wood blocks used to brace the load. Fasteners rely on the constructional
strength of the Cargo Transport Unit (CTU).

Dunnage
Dunnage for securing cargo includes scrap wood to fill voids in cargo, wooden boards forming "cribs",
blocking and bracing, and modern mechanical, spring-loaded post-and-socket systems, Dunnage
segregates cargo in the hold and prevents shifting of the cargo in response to ship or vehicle motions.
Dunnage stresses the constructional strength of the Cargo Transport Unit (CTU).

Strapping

Polyester strapping and dunnage bag application

Strapping is used to create a transportable unit. Types of strapping
include steel, polyester, polypropylene, nylon, paper, and composites. The type of strap used depends

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on the requirements, for example, strength, elasticity, ability to withstand various environments, ease of
use, safety, and cost. Strapping methods and limits should be according to valid standard, for example
EN12195.
All types of tensioned strapping, particularly steel, need to be handled carefully because of potential
injury.

Lashing

Polyester Lashing application

Lashing is the securing of cargo for transportation with the goal of minimizing shifting. Items used for
lashing include ropes, cables, wires, chains, strapping, and nets. These items are anchored to the Cargo
Transport Unit (CTU) and tensioned against the cargo. Another form of lashing used four devices
attached to the top of each corner of a container. Lashing products and methods are governed by
various authorities such as the Association of American Railroads (AAR) for rail transportation in North
America, the international Maritime Organization (IMO) for ocean transportation, and the National
Motor Freight Traffic Association (NMFTA) and European Union standard EN12195.

Dunnage bags

Dunnage bag application in container

Whereas strapping and lashing is often used to secure odd-shaped cargo such as machinery, structures,
and vehicles. Dunnage bags are mostly used for homogeneous shaped cargo such as food & beverage
products, electronics and appliances and roll paper. Often, strapping/lashing and dunnage bags are used
in combination to secure chemical products. Dunnage Bags are not approved for rail transportation of
hazardous materials in the United States.
Dunnage bags, also known as air bags, were introduced some 40 years ago as a convenient, fast and cost
effective alternative to secure and stabilize cargo in ISO sea containers, closed rail cars, trucks and
(ocean-going) vessels. The purpose of dunnage bags is often misunderstood when they are considered

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as a void filler only to prevent lateral movement of cargo. When properly applied however, dunnage
bags form a 3-dimensional bulkhead of the cargo itself preventing both lateral and longitudinal
movement. Dunnage bags rely on the Cargo Transport Unit (CTU) construction, which is to be noted
when planning. All cargo movements will therefore stress the construction.
Tie downs

Chains used on logging truck

Heavy loads are sometimes secured to vehicles with tie down straps, heavy duty strapping, or
tensioned chains. Heavy objects with round shape like paper rolls can be difficult to secure. Strong
woven tarpaulins manufactured to this purpose can then be used. They work in several ways: first of all
the ends of the tarpaulin can be used to block the horizontal movement in longitudinal direction as
direct spring lashing, secondly the mid part of the tarpaulin work as a top over lashing where the surface
pressure caused by tensioning the strapping is evenly distributed over the entire load and thirdly the
tarpaulin forms itself according to the cargo form and prohibits horizontal movements of single cargo
items.

Dynamic Loading: 
Loading introduced into rigging or equipment by forces of motion. The small amounts of speeding up or
slowing down of the load result in dynamic loads.
Dynamic Loading Voids Working Load Limits:Sudden changes in load, up or down, in excess of 10% of
the line's rated working load, constitutes a hazardous shock load, and would void normal working load
recommendations.  Whenever a load is picked up, stopped, or swung, there is an increased force due to
dynamic loading. The more rapidly or suddenly such actions occur, the greater the increase in force. in
extreme cases, the force-out on the rope may be several times the normal load involved.  Therefore, in
all such applications such as towing lines, lifelines, safety lines, climbing rope, etc., working loads as
published do not apply.

Hazardous Material:
Hazardous materials are substances that could harm human health or the environment. Hazardous
means dangerous, so these materials must be handled the right way.
Hazard communication, or HAZCOM is teaching people how to work with hazardous materials and
waste.

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There are many different kinds of hazardous materials, including:
 Chemicals, like some that are used for cleaning
 Drugs, like chemotherapy to treat cancer
 Radioactive material that is used for x-rays or radiation treatments
 Human or animal tissue, blood, or other substances from the body that may carry harmful
germs
 Gases that are used to make people sleep during surgery
 Hazardous materials can harm you if they:
 Touch your skin
 Splash into your eyes
 Get into your airways or lungs when you breathe
 Cause fires or explosions
 Your hospital or workplace has policies about how to deal with these materials. You will receive
special training if you work with these materials.

Watch out for Hazardous Materials

 Know where hazardous materials are used and stored. Some common areas are where:
 X-rays and other imaging tests are done
 Radiation treatments are performed
 Medicines are handled, prepared, or given to people -- especially cancer treatment drugs
 Chemicals or supplies are delivered, packed for shipping, or thrown away
 Always treat any container that does not have a label like it is hazardous. Treat any spilled
substance the same way.
 If you do not know if something you use or find is harmful, be sure to ask.

Labels and Signs

 Look for signs before you enter a person's room, a lab or x-ray area, a storage closet, or any area
you do not know well.
You may see warning labels on boxes, containers, bottles, or tanks. Look for words like:
 Acid
 Alkali
 Carcinogenic
 Caution
 Corrosive
 Danger
 Explosive
 Flammable
 Irritant
 Radioactive
 Unstable
 Warning

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  A label called the Material Safety Data Sheet (MSDS) will tell you if a material is hazardous. This
label tells you:

 Names of the hazardous chemicals or substances in the container.

 Facts about the substance, such as the odor or when it will boil or melt.
 How it could harm you.
 What your symptoms could be if you are exposed to the material.
 How to safely handle the material and what PPE to wear when you handle it.
 What steps to take before more skilled or trained professionals come to help.
 If the material could cause a fire or explosion, and what to do if this happens.
 What to do if a spill or leak occurs.
 What to do if there is danger from the material mixing with other substances.
 How to safely store the material, including what temperature to keep it at, if moisture is safe,
and whether it should be in a room with good airflow.

Work Safely
 If you find a spill, treat it like it is hazardous until you know what it is. This means:
 Put on PPE, such as a respirator or mask and gloves that will protect you from chemicals.
 Use disinfectant wipes to clean up the spill and put the wipes in double plastic bags.
 Contact waste management to clean the area and to throw away the supplies you used to clean
up the spill.
 Always treat any unlabeled container as if it contains hazardous materials. This means:
 Put the container in a bag and take it to waste management to be thrown away.
 DO NOT pour the material down the drain.
 DO NOT put the material in the normal trash.
 DO NOT let it get into the air.

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  If you work with hazardous materials:
 Read the MSDS for all materials you use.
 Know what type of PPE to wear.
 Learn about exposure risks, such as whether the material can cause cancer.
 Know how to use the material and how to store it or throw it away when you are done.
 Other tips include:
 Never enter an area where radiation therapy is taking place.
 Always use the safest container to move materials from one area to another.
 Check bottles, containers, or tanks for leaks.

Personnel Transfer:
The transfer of personnel is one of the specific activities for offshore operations. Purpose, scope and
responsibilities shall be clearly defined, to avoid any damage and loss of life. Such transfers include here
in this specific guideline only personnel mainly in the offshore industry. It covers risk assessment,
training and competence, responsibility, equipment and communications.

INSPECTION
All equipment used in the lifting of personnel shall be inspected, tested, and maintained to protect
against failure during lifting operations. Inspections shall be performed by a designated person.
Deficiencies identified shall be examined and a determination made by a qualified person as to whether
they constitute a hazard.

Personnel Lifting Platform

General.
The platform manufacturer shall furnish complete inspection criteria for platform users. The criteria
shall address all inspection frequency classifications listed in this volume and shall cover the platform
rigging components fasteners all safety features and attachments
Frequency

Initial Inspection.
Prior to initial use and at each new job site, all platforms shall be inspected to verify compliance with the
provisions of this volume.

Regular Inspection
Frequent. The platform, suspension system, attachment points, and any platform motion controls shall
be inspected at least once each day before use. The inspection is to identify conditions that have been
specifically indicated by the platform manufacturer, or a qualified person, as potentially creating a
hazardous operating condition. The inspection shall address at least those items listed in Appendix III.
Any conditions found that constitute a hazard shall be corrected prior to lifting personnel.
Periodic. At least once every 12 months, or as required by the platform manufacturer, a periodic
inspection of the platform shall be performed in accordance with the instructions provided by the

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manufacturer. Platforms that have been out of service for 12 or more consecutive months shall receive a
periodic inspection prior to use.
Records
For frequent inspections, dated records for the hoisting equipment and personnel platform shall be
made and kept by the platform user for the duration of the personnel lift operation.
For periodic inspections, dated records for the platform shall be made by the platform owner. The last
periodic inspection shall be kept with the platform and available for review.

Testing
Platform Manufacturer Tests
Personnel platforms shall be tested by the manufacturer to the extent necessary to verify compliance
with the requirements of this volume, including items such as the following:
 load suspension mechanisms or attachment components
 occupant safety features
 platform rating
 Where the complete production platform is not supplied by one manufacturer, such tests shall
be conducted at final assembly by the platform assembler or a designated person.
 Rope sling, chain sling, or other leg suspension systems shall be tested, prior to installation, by
applying a test load to each individual leg equal to twice the rated load of the leg. If a master
link is used in the suspension system, it shall be tested to at least twice the sum of the weight of
the platform and the platform rating. All tested components shall be visually inspected after
testing. Any component showing damage shall be replaced and the test procedure repeated.
 The suspension system attaching points on suspended platforms shall be subjected to
nondestructive testing by the platform manufacturer.

Proof Testing
 At each new job site, prior to hoisting people in the personnel platform, the platform and rigging
shall be proof tested to 125% of the platform’s rating. With the proof test load evenly
distributed in the platform, the platform shall be hoisted and held in a suspended position for
not less than 5 min. After the proof testing, the platform shall be inspected. Any damage
revealed by the inspection shall be corrected and another proof test conducted.
 When feasible, the hoisting equipment to be used for lifting personnel should be the equipment
used to perform the proof tests at the job site as defined in previous section
 After any structural repair or modification, a platform shall be proof tested to 150% of the
platform’s rating. Boom attached platforms shall use the test procedure described in
 Suspended platforms shall be tested by raising the loaded platform to a height, then lowering it
at a speed of not less than 100 ft/min (30.5 m/min). Once a lowering speed of 100 ft/min (30.5
m/min) or more is reached, the platform descent shall be halted by applying the hoisting
equipment brakes and then the platform allowed to hang for a period of not less than 5 min.
After this test and hanging period, the platform shall be inspected previous section
 Any damage revealed by the inspection shall be corrected and another proof test conducted.

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  Records. The record of the most recent proof testing shall be maintained at the job site.

Hoisting Equipment
 Hoisting equipment shall be tested in accordance with the defined “Operational Tests” and
“Load Test” requirements of the applicable ASME B30 volume.
 The hoisting equipment used for lifting personnel shall be tested during the trial lift, as defined
in previous section

Maintenance
 Maintenance instructions in this volume are intended as the minimum guidance for
general applications. The personnel platform and hoisting equipment manufacturer’s
information shall be consulted for specific or more stringent maintenance instructions
 Personnel Lifting Platform
 Preventive Maintenance
 A preventive maintenance program based on the platform manufacturer’s
recommendations shall be established.
 Replacement parts used shall be equal to or exceed the original equipment
specifications.
 Adjustments and Repairs
 Any hazardous condition disclosed by any inspection shall be corrected before use of
the platform is resumed. Adjustments and repairs shall be accomplished by designated
personnel.
 Adjustments shall provide for correct functioning of components.
 Replacement parts used or repairs made shall be equal to or exceed the original
equipment specification.
 All welding repairs shall be done by a certified welder.
 Any adjustment or repair to the platform suspension system shall be done by a qualified
person.
 Rope slings or chain slings showing indications described in ASME B30.9 shall be taken
out of service.
 Modifications. Only modifications approved in writing by the manufacturer or a qualified
person shall be accomplished.
 Records. The platform owner shall maintain records on any repairs to, or replacements
of, the structural components of the platform.

Hoisting Equipment
Hoisting equipment shall be maintained in accordance with the requirements of the applicable ASME
B30 volume and be capable of operating in accordance with the manufacturer’s manuals.

Type of Possible Transfers

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- ship to ship including small boats
- ship to offshore structures and vice versa
- nets, baskets
- special accessories like FROG and TORO
- swinging ropes
- gangways, bridges, accommodation ladders, pilot ladders
- mating “surfer” structures
- automatic devices like robot arm or equivalent
- helicopter
Design Requirements for Personnel Transfer Units

Net – people outside (System Billy Pugh)

The bottom structure, inside of the ring, to be closed with a net, covered by
plastic or canvas. The bottom ring outside made of PU-foam, strong enough
for the designed capability of people and equipped with an adequate
fender system. An upper ring will stabilize the netting. The net-material has
to be UV-stabilized. Tag line to be fitted in the bottom area. Hoisting facility
corresponding to the SWL. Depending on the capacity a shock absorbing
system will be preferably

Net – people inside (System Esvagt)

Bottom deck plate with vertical rigid parts is made of stainless steel with a
non-slip pattern on the top side surface. Between these vertical parts UV-
stabilized netting material is mounted. The 4 entrances fitted with non-skid
flooring and can be closed by webbing strips with fast click-buckle system.
Underneath of the bottom plate big collars are mounted and provide shock-
absorbs functions with an outside large collar. The capacity is limited up to 4
persons. Strap-tightener are used for tightening the stretcher.
Basket – Type A
This type of basket has a base and top and plurality of concentric sets of
laces extended between the base and top. An expander post is coupled
between the base and top for placing tension on the laces extending
between the base and top. A hoist connection for attachment of the
personnel transfer device to a hoist is mounted. This type should be
preferably used as a transport unit and not for personnel transfers.

Basket – Type B
The typical basket is made of mild steel or solid wood as a design with rail
and roof without buoyancy device. Sometimes the roof is missing. This
type of basket is normally applied as a working basket. It is not allowed to
be used as a personnel transfer carrier for example for the transfer from
ship to ship or other similar duties. The size of such a basket depends on

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the maximum capacity of persons. The handrail shall be inside for protection of external contact and a
minimum height of 1.1m. The basket has an access gate that does not swing outwards equipped with a
safe locking device. Working baskets shall be provided with means for attaching safety harness and
adequate space for tools, which has to be locked in a safe way. A static calculation is required for the
basket itself and for lifting accessories like master link and hoisting facilities.
The hoisting unit is like a bridle and depending on the size of the basket the relevant type is applicable
The corrosion protection shall meet the requirements, which material is applicable (mild steel or solid
wood) and shall be painted in a bright colour. All personnel involved shall assess the need for a prejob
talk, SJA or use of other analysis method is mandatory.

Special Personnel Carriers

This type of transfer carrier has a stainless steel frame with fixed
buoyancy bodies incorporated in the body structure. Therefore both
systems, which are today available, have adequate buoyancy capacity and
are self-righting afloat in a stable condition. The safe transport is
guaranteed by mounted seats with safety belts on a sprung suspension
including a shock absorbed feet protection. Also stretcher mode is
possible for both carriers. These two types have typical shapes and
different systems of buoyancy. One has a tetrahedral configuration with
fixed buoyancy bodies and the other one has rotationally moulded MDPE
shell with PU-foam fill and central column lifting equipment.

Personnel Carrier Rigging Configuration

The following rigging configurations are recommended for all crane assisted personnel carrier devices:

Double Safety Loadline

All personnel carriers can be equipped with a double safety loadline assembly composed of a main
support line constructed of a galvanized steel wire rope sling, it has a minimum breaking strength of
34,000 Ibs. (15422 kgs) and a secondary shock absorbing safety line rated at a minimum breaking
strength of 27,700 Ibs. The designation for a double safety load line on a Billy Pugh Co. personnel net is
“DC”. Example: X-871 D/C *Billy Pugh personnel nets also have a backup fiber rope safety line contained
within the stabilizer unit.

Snag Resistant Tag Line

A semi-rigid, snag resistant tag line consisting of a poly-dacron rope coated with a slip resistant polyester
resin specifically manufactured for this purpose, should be affixed to all personnel carriers. Tag lines
should have a minimum length of 10'(3.05 m). Tag line should be attached to either the center deck
lashing point, or the outside bottom platform ring in such a manner that minimizes tag line damage
when carrier is resting on a surface and attached with a minimum 5/8" (190 mm) bolt type anchor
shackle. Personnel transfer device tag lines should be identified by a high visibility color or reflective

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external coating. These tag lines can be obtained by specifying “Billy Pugh tag line followed by the
length. A normal length for these units is 15 ft.

Safety Sling or Lanyard

A safety sling or lanyard designed to provide emergency fall containment, should be affixed between the
crane hoisting line and the carrier upper master link. This will add a measure of safety in the event the
personnel net upper lifting ring becomes detached from the crane hook. The safety lanyard should be
composed of a galvanized steel wire rope sling, with a minimum breaking strength of 34,000 Ibs. (15422
kgs).

Inspection Procedures
All inspections should be performed by a qualified person and should always incorporate an operator's
pre-use inspection which should include the following minimum components:

• Visually inspect safety load line when attaching to crane. Inspect crane hook positive locking device
for function and physical condition.
• Check sidewall rigging, top & bottom platforms, and cushion ring for wear or damage.
• Ensure snag resistant tag line is properly affixed. The following quarterly inspection procedures are
recommended for all offshore personnel carriers.
• Inspect top and bottom lifting ring for excessive wear, cracks, or corrosion following manufacturer’s
recommendation and relevant API spec. Visually inspect safety load line when attaching to crane.
Inspect crane hook positive locking device for function and physical condition.
• Check sidewall rigging line splices (top & bottom) for wear, UV degradation (blistering, discoloration,
or cracking), and unraveling. All synthetic rope splices should have a 3 tuck minimum.
• Visually inspect stabilizer and safety load line unit for visual damage including external protective
cover. Damage of external cover may require additional internal examination by a qualified
inspector.
• Inspect bottom platform ring for deterioration, cracks, or angular distortion.
• Check cover on bottom platform ring for tears or cuts. Damage of bottom platform cover may
require additional examination by a qualified inspector.
• Check top and bottom flotation batts for deterioration or damaged closed cell foam. Damage of
flotation may require additional examination by a qualified inspector.
• Visually inspect bottom and top pneumatic cushion hoses (if so equipped) for deterioration or
damage.
• Inspect for modifications or non-OEM supplied components. Non OEM components or modifications
should be removed.
• As a general rule, we recommend that all Billy Pugh Co. personnel nets be replaced annually when
used on a daily basis (such as a jack-up drilling rig). On production platforms and other applications
where the personnel net is used less frequently, we recommend that it be changed out every other
year. This is a guideline only and will vary depending on how the net is cared for and stored.

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Loads, Load Conditions and Emergency Use

Loads Following loads to be considered

Accidental loads Are loads not normally occurring during installation and operating phases e.g. failing
crane operations or falling dropped objects Dead load This is the self-weight of any component of the
lifting appliance which is not included in any other load Design loads Load or load condition which forms
basis for design and design verification Functional loads Loads due to normal operations including
dynamic amplification Environmental loads Following influences and load effects have to be taken into
consideration: Wind, waves (sea state, mainly significant wave height), temperature influences
Permanent loads To be clearly documented and accounted for the design documents and calculations
Static load For design of transfer units a calculation of all relevant forces shall apply including of load
distribution of the equipment Test loads Required load for testing the lifting appliance and/or loose gear
and/or lifting equipment. Safety factor is generally 2.2 × SWL.

Load Conditions
Operating Loads Operating loads include all loads occurring during normal operations, i.e. - permanent
loads - defined limited environmental loads - functional loads, here especially crane loads
Limitation of Operations Especially for cranes the change over to personnel lifting mode shall apply and
extreme environmental loads, i.e. wind and sea state have to take into account. Furthermore any range
limitation to be observed, if applicable.

Emergency
Use In case of emergency the actual limitations for personnel transfers by crane will be ignored. Entirely
the OIM has to decide, which environmental loads on site are acceptable or not. But the crane driver
must have the right to object.

Cargo container unit

 Types of Container Units. As such, depending on the type of products to be shipped or the special
services needed from them, container units may vary in dimension, structure, materials, construction
etc. various types of shipping containers are being used today to meet requirements of all kinds of cargo
shipping. Some of the most common types of shipping containers in use today are mentioned below
 Dry storage container
The most commonly used shipping containers; they come in various dimensions standardized by ISO.
They are used for shipping of dry materials and come in size of 20ft, 40 ft and 10ft. 
 Flat rack container
With collapsible sides, these are like simple storage shipping containers where the sides can be folded so
as to make a flat rack for shipping of wide variety of goods.
Open top container
With a convertible top that can be completely removed to make an open top so that materials of any
height can be shipped easily
Tunnel container

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Container storage units provided with doors on both ends of the container, they are extremely helpful in
quick loading and unloading of materials.
Open side storage container These storage units are provided with doors that can change into
completely open sides providing a much wider room for loading of materials.
Double door container They are kind of storage units that are provided with double doors, making a
wider room for loading and unloading of materials. Construction materials include steel, iron etc in
standardized sizes of 20ft and 40ft.
Refrigerated ISO containers These are temperature regulated shipping containers that always have a
carefully controlled low temperature. They are exclusively used for shipment of perishable substances
like fruits and vegetables over long distances.
Insulated or thermal containers These are the shipping storage containers that come with a regulated
temperature control allowing them to maintain a higher temperature. The choice of material is so done
to allow them long life without being damaged by constant exposure to high temperature. They are
most suitable for long distance transportation of products. 
 Tanks Container storage units used mostly for transportation of liquid materials, they are used by a
huge proportion of entire shipping industry. They are mostly made of strong steel or other anti corrosive
materials providing them with long life and protection to the materials.
Cargo storage roll container A foldable container, this is one of the specialized container units made for
purpose of transporting sets or stacks of materials. They are made of thick and strong wire mesh along
with rollers that allows their easy movement. Availability in a range of colored wire meshes make these
shipping container units a little more cheerful.
 Half height containers Another kind of shipping containers includes half height containers. Made mostly
of steel, these containers are half the height of full sized containers. Used especially for good like coal,
stones etc which need easy loading and unloading.
Car carriers Car carriers are container storage units made especially for shipment of cars over long
distances. They come with collapsible sides that help a car fit snugly inside the containers without the
risk of being damaged or moving from the spot.
Intermediate bulk shift containers These are specialized storage shipping containers made solely for the
purpose of intermediate shipping of goods. They are designed to handle large amounts of materials and
made for purpose of shipping materials to a destination where they can be further packed and sent off
to final spot.
Drums As the name suggests, circular shipping containers, made from a choice of materials like steel,
light weight metals, fiber, hard plastic etc. they are most suitable for bulk transport of liquid materials.
They are smaller in size but due to their shape, may need extra space. 
Special purpose containers Not the ordinary containers, these are the container units, custom made for
specialized purposes. Mostly, they are used for high profile services like shipment of weapons and arson.
As such, their construction and material composition depends on the special purpose they need to cater
to. But in most cases, security remains the top priority.
 Swap bodies They are a special kind of containers used mostly in Europe. Not made according to the ISO
standards, they are not standardized shipping container units but extremely useful all the same. They
are provided with a strong bottom and a convertible top making them suitable for shipping of many
types of products.

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Inspection and Rejection criteria:
A shipping container in bad condition can cause unforeseen losses. Damaged cargo and expensive
repairs occur when you neglect your containers, which can suffer all kinds of damage during rough
crossings and handling.
Your containers should be regularly inspected, cleaned, and repaired to ensure the contents are
properly protected.
Here are some examples of defects found during the container inspection procedure and how to resolve
these defects:

Bad odors
Problem:
Odors present in the container before cargo is loaded (stuffed) can transfer to the products. The cause
of the odor may be from products previously transported in the container, or from lingering pungent
chemical cleaning agents.
Solution:
Use biodegradable cleaning products that will not leave lingering odors. Thoroughly rinse the container
after using cleaning agents. Air out the container after washing until it’s dry and free of any odors.
Stains
Problem:
Textiles can be easily stained by grease and dirt left from other products such as machinery previously
transported in the container.
Solution:
Don’t repurpose containers that have been used to transport greasy or oily products. Use tough cleaning
agents to get rid of the stains.

Holes in container sides

Problem:
Holes in container ceilings, floors, and walls can let in water and dust. Holes can occur as a result of
dents and damage to surfaces caused during shipping and handling of the container.
Solution:
Regularly check the interior of containers for light leaks indicating holes.
Check the exterior of the containers for erosion and dents or damage to the paintwork. Spotting defects
early on reduces repair costs. Erosion can be prevented by applying a new coat of weather-proof paint
to the affected area. Large holes need to be patched up with welding equipment.

Damaged floorboards
Problem:
Wooden floorboards degrade over time, becoming uneven and loose. Floorboards also splinter and
eventually break apart from repeated stuffing and unstuffing of cargo.
Solution:

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Regularly inspect the condition of the floorboards and make necessary repairs. Sand down splintered
floorboards. A durable weather-proof coating can be applied as a preventative measure. Replace loose
or broken floorboards.

Mold
Problem:
Dampness and humidity promote mold growth, especially on the floorboards, which can contaminate
cargo and produce a bad odor.
Solution:
Regularly spray container interiors with industrial anti-bacterial disinfectants and air out the containers
to eliminate dampness and prevent mold growth

Inspection before packing

Outside of container:

1. No holes or cracks in walls or roof.

2. Doors operate properly.
3. Closing devices operate properly.
4. No adhesive labels from the previous cargo, e.g. IMO placards.
5. For flatracks: stanchions (if ordered) are complete and correctly fitted. For 40′ flatracks: all
lashing belts are present.
6. For open-top containers: roof bows are complete and correctly fitted.
7. For open-top containers: tarpaulins are undamaged and fit properly; ends of tarpaulin ropes are
undamaged; all roof eyes are present.
8. For hard-top containers: roof is undamaged, roof locking mechanism fits and operates properly.

Inside of container:

9. Container is watertight. Test method: enter container, close both doors tightly and look for
incoming light (e.g. through cracks, holes, door gaskets etc.).
10. Container interior is absolutely dry. (Wipe up any condensation or white frost in order to avoid
corrosion and moisture damage of the cargo.)
11. Container is clean, free of cargo residues and neutral in odor.
12. No nails or other protrusions which could damage the cargo.

Inspection after packing

1. The container is packed appropriately for the cargo, anticipated transit stresses and the
container.

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 2. A copy of the packing list is placed in a highly visible location inside the container (for Customs
inspections and the like).
3. When lumber is used as a packaging material etc., it may, under certain circumstances, be
necessary to comply with the quarantine regulations of the country of destination and a
phytosanitary certificate or proof that the lumber has been treated may have to be placed
conspicuously in the container. Information may be obtained from the phytosanitary authorities
of the countries concerned.
4. The doors and, if applicable, roof covering have been carefully closed. (Strong steel wire cables,
padlocks or high security seals provide protection from cargo theft.)
5. Closures are secured with metal and other seals in order to reduce the risk of theft (record the
seal number).
6. For open-top containers: tarpaulins are correctly fitted and tarpaulin ropes correctly threaded
(Customs-approved closure).
7. If the cargo is covered with tarpaulins in special containers: the tarpaulins are securely fastened.
8. Old adhesive labels have been removed.
9. For refrigerated containers with refrigeration unit and heatable tank containers: the correct
temperature has been set. For refrigerated containers, the temperature recorder is running and
the temperature is displayed.
Handling
The handling system is completely mechanized so that all handling is done with cranes and special
forklift trucks. All containers are numbered and tracked using computerized systems. Container System
Developed. For some years the use of unit containers for shipping various classes of merchandise by
motor truck, railroad, and steamer has received considerable attention in the shipping world. A large
pro- portion of the container shipped by rail- road and steamers must be handled by motor trucks at the
terminals. With the existing methods, this not only involves considerable loading and unloading, which is
a waste of labour, but the transportation equipment must be kept idle while this unloading and loading
are taking place. This is an economic waste. With the unit container system—the containers are
comparatively large metal boxes—the containers are loaded and sealed by the shipper, are transported
to the railroad terminal or wharf on motor trucks, and finally delivered to the consignee on motor
trucks. The containers are never opened from the time they leave the shipper's plant to the time they
arrive -at their destination. It is necessary to provide equipment to handle these containers at the
shipping point and the destination, as well as at the various transfer stations, such as the railroad
container yard and the dock. Prom reports it appears that these containers were first used successfully
between London and Paris for handling mails and baggage. For someyears past the New York Central
Railroad has been experimenting with container cars, and has operated .several of them between New
York, Chicago, and intermediate cities. The containers are loaded on at the station platform, and hoisted
on motor trucks, which run to the station, yard. There the containers are placed on a special car. At the
destination the transfer operation is reversed, and the container is unloaded at the consignee's door. It
is stated that two problems arise with the container system. The first consists in designing the
containers, which, while comparatively light, will be strong and durable; and the second, in developing
the necessary mechanism for rapid handling and transferring the containers at the transfer stations.
These problems have been taken up by the Inter-national Motor Company, the manufacturers of the

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Mack truck, and an aluminium alloy container has been evolved. The material in the container is such
that the weight is only very slightly over 15 per cent, of the maximum weight of the merchandise it is
designed to carry. In order to realise all the advantages of the system it is necessary to standardise all
the equipment. The Mack container is 12 feet long, 7ft. 4in. wide, and 6ft. 3in. high, internal dimensions.
One of these containers constitutes a load for a 74-ton flat truck. It has been found that many of these
containers are too large for some shippers, and a smaller size — one half that of the large — is being
used. These smaller containers are mounted on pivoted wheels, and can therefore, be manoeuvred into
the corners of a box car. The container is loaded while on a ramp, track. The horizontal portion of the
track is higher than the truck platform, and the truck can be backed into the ramp snd under the
container. A pair of guard rails are mounted on sleepers inside the ramp to facilitate the backing of the
track into the ramp. Mack trucks fitted for use with containers have a coupler fitted at the centre of the
platform near the cab ordriver's scat, and a locking device at each of the four corners. This equipment
does not interfere with the use of the truck for other purposes. The container has hinged double doors
at both ends for loading -purposes. Four bails arc provided at the top corners for the easy attachment of
crane hooks. Designs have been worked out for the provision of ramps over the rails at railroad stations,
so that the container may be slipped off the truck and the railway flat car run underneath it, and the
container lifted. The chief advantage of the system of unit containers is the improvement in the
utilization of the transportation equipment which it makes possible. Trading and unloading of the truck
consumes a minimum of time and time loss at terminals due to congestion is also eliminated. Moreover,
the container can be loaded by the ramp track directly on to the warehouse floor, and can, he moved
about or around on its roller bearing wheels. Material advantage Fix this text also accrues to the railroad
through using the container system. It is unnecessary to have a loading platform blocked by waiting
trucks, and to have the platform loaded, with merchandise and general container awaiting segregation.

Risk Assessment, Lift Plan, JSA Process, and Communication

when workers prepare equipment to be lifted by cranes, hoists or other material-handling machinery –
is a common work process on shipyard and construction sites, among others. Performing rigging
operations safely is critical

What are the hazards of working around machinery?

Hazards associated with working near or on machinery vary depending on the exact machine used but
can include exposure to:
 moving parts (e.g., risk of injuries from entanglement, friction, abrasion, cutting, severing,
shearing, stabbing, puncturing, impact, crushing, drawing-in or trapping, etc.)
 energy (e.g., electrical, electromagnetic, magnetic, etc.)
 heat or cold
 noise
 vibration
 radiation
 gas or liquid under pressure (e.g., injuries from injection or ejection by hydraulic systems,
pneumatic systems, compressed air, paint sprayers, etc.)

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  psychosocial hazards (e.g., stress, job content, work organization, cognitive factors, etc.)
 Because there are many different types of machines and processes, a risk assessment should be
conducted for each machine or situation, and in some cases, before each use. It may be
necessary to involve individuals with specialized or technical expertise (i.e., engineer, safety
professional, manufacturer, etc).

What are some hazards that are associated with machinery and powered equipment?
The following checklist will help identify hazards in your workplace. It is important to tailor the
information to your workplace and add any additional items as necessary.
Possible Hazard Check One Notes
OK Needs
Investigation
Machine
Identify the use and limits of the machine by      
considering:

production rates and cycle times

intended use of the machine
types of materials being used
forces generated
range of motion of moving parts
Identify how much space the machine needs      
to safely operate for all tasks being
performed by and on the machine, including
access for maintenance and repairs.
Identify the life expectancy of parts and fluids      
as a result of wear and tear
Identify the environmental limits of the      
machine (e.g., operating temperatures,
humidity, noise, etc…)
Consider how the machine interfaces with      
other machines, equipment, and energy
sources
Consider all tasks the machine performs, and      
is performed on the machine during its use

trial runs
regular operation
tool changes
scheduled maintenance
un-jamming and recovery from crashes
unscheduled maintenance

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Consider tasks associated with different      
phases of the machine’s life

start-up and programming

loading, packing, transporting, unpacking
decommissioning and disposal
Mechanical Components
At the point of operation, identify the      
following:

what parts move

the range of motion of moving parts
the type of motion (e.g., rotation, shearing,
bending, cutting, punching)
Note – the point of operation refers to the
area of the machine where useful work is
performed. Typically this point is where an
operator has contact with the machine.
Identify how power is transmitted to the      
machine

hydraulic
pneumatic
mechanical
If present, identify if the machine has a brake      
or clutch, and how it operates
Identify all the “in-running nip points” on the      
machine
Identify all the pinch points on the machine      
Identify entanglement hazards of the      
machine as a result of contact with:

rotating and moving parts

materials in motion
projections or gaps
Identify where a worker could come in      
contact with parts moving at a high velocity
(e.g., abrasion or friction hazards)
Identify cutting or severing hazards where a      
worker could come in contact with cutting
tools, saws, routers, knives, or sharp
materials

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Identify shearing hazards where a worker      
could be severely cut by being between two
machine parts or between a machine part
and a workpiece or stationary object
Identify crush hazards where a worker could      
be caught between parts of a machine
moving against one another
Identify if it is possible to be struck or      
punctured by flying objects
Review the machine’s operation to      
determine if a worker could come into
contact with pressurized liquids or gases
Identify any sharp edges and angular parts      
that protrude (stick out) from the machine
Identify situations where harm may occur if      
there was a fault or break in the machine or
material (breakage point)
Identify situations where harm may occur if      
the machine’s operating software (if
applicable) fails.
Worker specific considerations
Identify all work that a worker must perform      
while operating the machine, including:

how stock is fed into the machine

how final products are removed from the
machine
removal of scrap
periodic cleaning of the point of entry and
other parts of the machine
pre-shift safety checks
Identify all work that must be done when      
performing maintenance
Identify all work that must be done to change      
a tool or die
Identify any potential slip or fall hazards in      
and around the machine as a result of the
floor surface, or due to material spills (e.g.,
lubricating oils, grease, water, saw dust,
plastic pellets)
Identify other possible hazards, for example      
vibration or noise
Identify potential ergonomic issues in the

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 operation of the machine. Make sure that
the:

worker does not have to reach excessively

worker does not have to use excessive force
worker does not have to perform high
frequency movements
machine cycle is based upon worker capacity,
not visa versa
worker can perform work in several positions
that promote a neutral body position
work surface is adjustable
worker has sufficient room to move without
striking anything

Environmental Conditions affects lifting/Rigging

Cranes are a common sight at various construction sites and harbors. Although they vary in size and load
capacity, they all have to be operated with care and caution to protect workers and the public. And
before any work can take place, it’s important to ensure proper ground and environmental conditions.

Power lines
 In the planning stages, and before any work can begin, those in charge need to request that
utility owners and/or operators provide them with voltage information of power lines in the
vicinity. They must also consult with utility companies before performing work in close proximity
to power lines.
 When identifying the work zone (either marking the boundaries or allowing the work zone to be
a 360-degree area around the equipment), it needs to be determined if any part of the
equipment, load line or load (if operated up to the equipment’s maximum working radius) could
get closer than 20 feet to a power line of less than 350 KV. If so, the company has
three electrical compliance options:
 Deenergize and ground the powerlines in question.
 Ensure a 20-foot clearance.
 Ask the utility company for the line voltage in order to figure out the minimum clearance
distance.
 If the first option is not possible, those in charge of crane setup and operation will need to
design encroachment prevention measures by using the following steps:
 Conduct a planning meeting with the operator and other workers who will be in the area to
agree on the steps needed to prevent electrocution.
 If tag lines are going to be used, they must be non-conductive.

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  Erect and maintain elevated warning lines, barricades, or line of signs for the crane operator to
clearly see. These need to be set up 20 feet from the power line or at the minimum distance
allowed.
 If the operator is unable to see the elevated warning line, a dedicated spotter must be used.
 In addition to the encroachment prevention precautions, a proximity alarm, a warning device, a
range limiter, a dedicated spotter or an insulating link should also be used.
 If it’s impossible to work in a zone permitted by regulations, the company must show that it’s
infeasible to perform work without breaching the minimum approach distance and then
deenergize and ground or relocate the power line. If that’s the case then the power line owner
(or a registered professional engineer) will set a minimum approach distance.
 In addition, a planning meeting between the employer and the power line owner (or registered
professional engineer who is a qualified person with respect to electrical power transmission
and distribution) will have to determine procedures required to prevent electrocution. These
could include:
 elevated warning line or barricade;
 barricades 10 feet from equipment;
 range limiter;
 insulating link;
 nonconductive rigging and tag line;
 limiting access to essential workers;
 grounding the equipment;
 deactivating automatic re-energizer; and
 installing an insulating line cover-up.

Ground conditions
 Given the size and weight of the majority of cranes, it’s vital to monitor ground conditions on
the worksite. The controlling entity (usually the contractor or employer) is responsible for
ensuring that the conditions are sufficient for crane assembly.
 The ground needs to be firm, drained and graded, and able to support the crane (in conjunction
with blocking, mats, etc.). In addition, the controlling entity must inform the crane operator of
known underground hazards such as utilities, and provide them with all other information
known about ground conditions.  

Weather
 The importance of weather when performing crane assembly and operations cannot be
overstated. Various weather conditions can affect ground stability, visibility, workers’
performance and grip and, in extreme circumstances, even lead to a crane overturning.
 This is why it’s so important to include weather in the employer’s work plans. Additionally,
weather should also be one of the topics discussed at each safety meeting. Although people
working with cranes are regularly exposed to the elements and working in the rain or scorching

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 heat is nothing new, sometimes it might be wise to consider if certain conditions are worth the
risk.
 Due to the nature of their job, cranes need to be assembled and disassembled at various
different locations and environments. This is why considering all the conditions that could have
an impact on the crane’s performance and safety need to be considered. Ground conditions,
electrical safety and the weather are the usual suspects, but it’s worth considering anything and
everything that could affect the stability and performance of the crane and the performance of
the crew, including human factors and work processes that may inadvertently increase the risk
of a crane-related incident.

Challenges associated with Rigging and Lifting Safety

 Rigging and lifting are very important ingredients of overall comprehensive subject of “Material
Handling” which comprises securing the load, arranging for its movement like pushing, pulling,
lifting, carrying and shifting from destination A to say B. Binding, securing and preparing it for
movement is Rigging, while opposing gravity which pulls the load down is lifting and that is
accomplished manually as well as mostly by mechanical means, with or without external power.
  Rigging (material handling) because of heavy weight and large dimension, is a very important,
responsible but risky job in any industrial activity, in its different phases of production,
construction, maintenance and even general working. Hydra/Mobile cranes mounted on wheels
or crawler, with easy maneuverability even in congested areas, are largely used in projected
area, storage places and loading/unloading/carrying work. Other adopted methods include
manual handling and with powered industrial trucks and forklifts. EOT cranes in permanent
bays, storage/gantry cranes for storage yards, tower cranes for construction sites serve useful
purposes.
 Manual handling of loads at work contributes significantly to the number of workplace injuries
such as disc injuries, ligament/tendon injuries, muscular/nerve injuries, hernia, fractures,
abrasion and cuts etc.
 Many of the injuries are of cumulative nature rather than being attributable to any single
handling incidents. Mechanical handling techniques have improved efficiency and safety but
have introduced other sources of potential injury into the workplace.
 But, because of lack of awareness and knowledge of safe working methods and practices,
material handlers, crane operators and slingers commit mistakes and unsafe acts, or unsafe
conditions and situations are created at workplace due to haphazard and unsystematic working.
As a result, large number of accidents occurs causing serious injuries and loss of property.
 In all circumstances, the safety of the equipment can be affected by operating conditions,
workplace hazards and the operator which essentially needs comprehensive training and
grooving.
 These occurrences are largely preventable if, correct, safe and systematic practices are adopted.
 This write up emphasizes on the basic hazards associated with rigging and lifting and measures
to eliminate / minimize these hazards and control associated risks.

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Importance of Rigging
 The most important job of any crane operation is rigging of the load. Poor rigging may result in
personal injury, property damage, or other serious hazards. Rigging is the most time consuming
of any crane operation and represents the single most hazardous potential of crane operation.
In a multi sling operation, each leg must be of same length and must contribute equally to the
load distribution. Nylon slings are susceptible to damage by sharp corners or by excessive
loading. Rigging requires years of practice to be perfect. If in doubt about the security of your
rigging, ask for help.
 Rigging should be checked by lifting the load a few inches off the ground to ensure that no swing
develops and that the load is completely secure. Remember it is important to take time to
accomplish this task correctly.
 Not doing so may result in catastrophic consequences. One of the most important things to
check before lifting a load is to look for loose items, such as screws or tools which may have
been used to secure the load. Such items can become projectiles during a lift. This is the reason
why crane operators or especially tag line operators should wear hard hats when operating the
crane and why it is essential to make sure the path of the crane does not pass over the head of
the individual.

Causes of Crane Failure
 Overturning
 Overloading
 Collision
 Structural Failure
 Foundation Failure
 Loss of Load
 Operator Error
 Lack of Maintenance

Crane & Rigging Safety Rules
 Make sure the load does not exceed rated capacity
 Know the center of gravity of the load
 Attach load above the center of gravity for stability
 Select hitch that will control the load
 Know the rated capacities of rigging and slinging
 Inspect all rigging before use
 Protect the sling from sharp corner
 Allow for increases tension due to sling angle
 Equalize loading on multiple leg slings
 Attach tag line prior to lift
 Keep personnel clear of lift area
 Wear hard hats when making overhead lifts

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  Know limitations of hoisting device
 Verify hook completely closes
 Maintain load control at all times
 Never leave load unattended

Crane Safety after Use
 Spot crane in the approved location
 Lower the load to the ground
 Disconnect the load and slings
 Raise all the hooks to upper limit switch
 Place all controls to off position
 Visually check for dangerous conditions
 Never leave a load unattended

ILO recommendations on the use of lifting equipment
 ILO recommends that employers should have a well-planned safety program so that all the
lifting appliances and lifting gear are selected, installed, examined, tested, maintained, operated
and dismantled.
 With a view to preventing the occurrence of any accident,
 In accordance with the requirements laid down in the national laws, regulations and standards.
 Every lifting appliance including its constituent elements, attachments, anchorages and supports
should be of good design and construction, sound material and adequate strength for the
purpose for which it is used.
 Every lifting appliance and every item of lifting gear should be accompanied at the time of
purchase with instructions for use and with a test certificate from a competent person or a
guarantee of conformity with national laws and regulations concerning:
 The maximum safe working load
 Safe working loads at different radii if the lifting appliance has a variable radius
 The conditions of use under which the maximum or variable safe working loads can be lifted or
lowered.
 Every lifting appliance and every item of lifting gear having a single safe working load should be
clearly marked at a conspicuous place with the maximum safe working load in accordance with
national laws and regulations.
 Every lifting appliance having a variable safe working load should be fitted with a load indicator
or other effective means to indicate clearly to the driver each maximum safe working load and
the conditions under which it is applicable.
 All lifting appliances should be adequately and securely supported, the weight bearing
characteristics of the ground on which the lifting appliance is to operate should be surveyed in
advance of use.
 Now let’s have a glance at OSHA’s Regulations intended to prevent rigging accidents.
 Proper & periodic inspection of rigging equipment before use and ensuring that it is safe.

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  Remove rigging equipment from work when they are not in use
 Before beginning properly inspect the ground where rigging equipment are to be used
 Keep precise load, never overload rigging equipment
 Thoroughly examine steel chain slings which are in use
 Riggers should be well trained for rigging materials, their proper usage and their resulting
hazards
 Ensure proper use of PPE
 Maintain and ensure proper signaling procedures
 With above discussion we can analyze that awareness, knowledge & training, plays a major role
in rigging and lifting.

Site control / access

 There must be a nominated Rigging Supervisor on all rigging jobs. Where there are two or more
rigging companies present (e.g. venue and tour riggers), one person should be appointed in overall
charge of production rigging operations
 The Rigging Supervisor must ‘sign-off’ / approve all lifting plans / plots; any subsequent alterations
required to these (by Lighting Supervisors or others) must first be approved by the Rigging
Supervisor. The Rigging Supervisor should also be able to provide load calculations which
demonstrate the factor of safety being applied to supporting structures and lifting components
(slings, chain hoists, trussing, etc.)
 All work at height must be adequately planned and organised to ensure those who work at height
are suitably protected from injury, with adequate means of rescue available, and measures taken to
prevent persons below from being injured from falling objects (see our Work at Height Safety
Guidelines in Related Topics)
 Where the rigging requires access to studio grid spaces, suitable safe working procedures and access
control measures must be applied (see Studio Grid Access in Useful Documents)
 Where MEWPs are used for access and lifting production equipment, these must be of a type
suitable for the workspace and only operated by suitably trained/ qualified people (see Mobile
Elevating Work Platforms in Related Topics).

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