Crane rigging training manual

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Ronald G. This spiral bound soft-cover manual addresses all aspects of rigging, EOTs Electrical Overhead Traveling Cranes , mobile cranes, and tower cranes in detail. This handbook can be used for training programs by riggers, crane operators, in-house maintenance personnel and engineers or as a tool box reference. Tariq Speed added it Aug 09, There are no discussion topics on this book yet. No trivia or quizzes yet. Mazhar is currently reading it Dec 15, Zubair Alam marked it as to-read Sep 24, Frank Meadows marked it as to-read Jul 09, Desiree Aukema-Walker marked it as to-read Nov 13, To see what your friends thought of this book, please sign up.

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It addresses wire rope and inspection, rigging hardware, slings, safe working loads, chain data, mobile cran pages, 3. The coil of rope should be to the left of the top block for lifting tackle, i. The first man should reeve the standing end of the rope through the lowest sheave of the top block, then pass it to the second man who will reeve it through the lowest sheave of the second block.

The rope should be passed successively through the sheaves of both blocks from left to right and finally made fast to the becket of the second block by two half hitches. The running end should be secured to prevent it from slipping.

Lifting RopeTackle When calculating the capabilities of a lifting tackle it must first be realised that only the returns between the blocks are assisting to lift the weight and that the running end is not helping in the lifting. The power is exerted directly on it and in the opposite direction to that in which the weight is moving.

One-third reduction allowed. Example using a 3 and a 2 tackle reeved with a 24 mm rope. Hauling Tackle When calculating the strength of a hauling tackle it must be remembered that the hauling part of the fall is pulled in the same direction as the weight to be moved and assists the returns to move the weight.

The hauling part must therefore be included in the calculation assessing the number of returns at the moving block. All other considerations in assessing the strength of a hauling tackle are exactly the same as for a lifting tackle.

Example using a 3 and a 2 tackle reeved with a 24 mm fibre rope. SWL of rope x Returns at moving block plus hauling part x. They should have at least three full tucks against the lay. After the three full tucks the ends of the strands can be reduced and tapered and the splice served. However when a load is applied to the rope and the splice stretches, the serving will become loose.

It is better, stronger, and safer to dog knot half the strands with a neat seizing after completing the splice. Thimbles A thimble should be spliced into the eye of the standing or becket eye of a tackle.

Thimbles are solid round, split round or pear shaped split. They are split to enable them to be opened and fitted to the anchorage and then closed before splicing. There should be no points on the throat of the thimble that could bite into the rope.

Thimbles should be large enough to allow the rope to seat well into the score with the rope supported for half of its circumference without the groove edges biting into the rope. A small thimble can cut the rope and do more damage than ordinary wear and abrasion. Fibre rope slings 34 Blocks and tackles A tackle is the term used when fibre rope is reeved around sheaves to gain a mechanical advantage. Blocks Blocks are made of wood clump , wood and steel internal iron bound 1IB , and steel.

The wooden clump blocks are fitted with a FSWR or fibre rope strop fitting in a score at right angles to the sheave and steel pin. The sheaves are usually bronze or gunmetal.

Some older sheaves were made from the very hard wood, called lignum vitae. Double sheave block The wooden llB block has beech cheeks and partitions, with a forged eyebolt and forked steel plates morticed into the cheeks and drilled to take a steel pin. The sheaves are usually bronze or gunmetal and the pin is secured by a steel keeper plate over a square head. Steel blocks are made of mild steel cheek plates secured to a yoke drilled for an eyebolt or a forged hook.

Reinforcing plates often run down outside the cheek plates to the bottom, where they are drilled to take becket, spreader bolts and ferrules. The sheave pin fits into holes drilled through straps, cheeks and partitions and is usually of mild steel with a flanged end and a spigot with a cotter retainer at the other end.

Lifting hooks or eyes are the swivel type not upset or riveted type. Care must be taken when maintaining and inspecting to look for worn pins, sheave bushes, insecure fastening of the hook yoke to cheeks and yoke crosshead, securing of sheave pin, becket and pin and general soundness of the whole frame.

Types of tackles: Gantline - A single fixed block. Single whip - Two single blocks. Whip upon whip - Two moveable and one fixed single block. Luff tackle - Single and double block. Gun tackle - Two double blocks. Light gin tackle - or Handy billy - Double and treble blocks. Heavy gin tackle - Two treble blocks. Note: The above masses must not exceed those marked on the blocks as being the safe mass that may be lifted.

Most blocks are limited by the size of hooks and other components and not the number of fails of rope.

A factor for friction has been added. If welded they should be to an engineered design and strongly made. A drop nose pin used as a hinge pin is recommended and the locking device must be strongly made and suitable for the intended use of the block. When reducing the number of parts to give a faster hook ensure that the falls are not reduced from one side of the boom head sheaves and the main hoist block.

Otherwise rotational torque can develop on the boom head exerting side pull on the main hoist block. When reducing parts the rope must be reeved again to ensure that there are an equal number of parts either side of the boom head and the main hoist block. The number of parts must be capable of supporting the load to be lifted. A fast hook must still be a safe hook. The greatest load on any rope in a purchase is the load in the lead rope to the winch.

This is due to the friction between the rope in the groove of the sheave and the sheave pin. Note: The total load on the lower block includes the load to be lifted plus packing, slings, shackles, blocks. Total Load includes the weight of the lower block, the suspended load, slings or any other lifting attachment. Load in Lead Line to the winch is equal to the becket load plus the progressive load increase in the rope due to friction.

This is calculated by allowing a percentage increase in load for each sheave in the system. Allow for one lead sheave to the winch. All sheaves are fitted with bronze bearings. The lifting tackle weights 70 kilograms. The lifting slings and shackels for the load weighs.

The Reeved Tackle Weighs 0. The load in the head block sling. The tackle required to lift and sling the load weighs. The lifting tackle and slings for the load weighs. Pay particular attention to the sheave groove and flange. Any cracks or chips on the flange can cut the rope as it lays into the groove. The groove should be checked for wear which will result in the reduction of the groove diameter and give an uneven bearing surface for the rope.

All sheaves should be checked for lubrication. Badly lubricated sheaves cause extra friction in the system and wear on the sheave pin and bearing. The pin should be prevented from rotating with the sheave. Some sheave pins only have a small cotter pin, which fits into a recess on the cheek plate. The cotter pin sometimes shears and allows the pin to turn with the sheave. Rotating pins are dangerous as they turn and can cut through the cheek plate. A 'jockey sheave' is sometimes used as the first diverting sheave to reduce the fleet angle.

It is important to keep an eye on the lubrication of a jockey sheave 42 The braking mechanism is connected to either the drum or the gearing, which is joined to the drive mechanism. Drums are measured from the centre to the Inside of the flange. A drum, which measures 1 m from flange to flange, is therefore a 0.

The rope should lie neatly on the drum and not be bunched up. There should be a minimum of two full turns on the drum at all times. The rope must be anchored to the drum with a fixed mechanical anchorage. Be aware of the danger of not properly tightening an anchorage. Do not rely on the frictional grip relayed by the two turns on the drum. Comply with the crane manufacturer's recommendation about whether drums are overwound or under wound. If a drum is wound up incorrectly it can affect the anchorage, brake and drive mechanism to the drum, resulting in mechanical failure.

The lay of the rope and whether the drum is overwind or under wind determine where the rope is to be anchored. Be especially careful when raising very heavy loads to a great height such as with long boom mobile cranes. The amount of turns on the drum determines the drum diameter. As the diameter increases the torque to the drive mechanism and brake increases. As a result the higher the load is raised the faster it is raised, and the more difficult the load is to control.

Operators should ensure that the hoist brake is adjusted to take the extra torque when the load is raised to its maximum height. A brake, which holds the load near the ground, may fail when the load is high. The top layer on a multi-layered drum must not be closer than two rope diameters to the top of the flange when the drum is full.

The width of the winch drum is 3. The winch drum is grooved. Using the width and type of drum given, calculate the minimum distance between the lead block and the winch drum. Winch holding down bolts and anchorage generally. Rule of thumb for counterweight is 4 times SWL Sliding gears, if any, and dog-clutches to be in full engagement.

See that there are no broken gear teeth, or cracked bearing caps, gears loose on shafts, and similar defects. The yearly service date has been stamped on service plate. No matter which drum, when under strain, crossed turns will damage bottom layers of rope, and pull it between the turns of bottom layers, where the bottom layer is not spooled neatly, with consequent damage to the rope.

This will help to guard against sudden stalling which would damage rope, winch, or anchorage and cause a hazard to the operator or other persons. The same could happen if the rope is spooled badly on the drum. For this reason, and for reasons of general safety on the winch See that guards covering gears, couplings, belts and other moving parts are always maintained in good order, and replaced after being removed for any reason.

The part of the rope used for back- hooking naturally receives most wear, and therefore should be inspected frequently, This may be due to bad nips, either around the hook or sharp parts of the load causing local wear or internal wear on the rope.

The hook and other type of termination, together with any thimbles, swivels, or other devices in use should be frequently checked i No brakes should ever be interfered with at any time. The attachment of the counterweighted brakes should also be frequently checked and never tied back to render it in effective. A friction driven winch should not be used for hoisting loads a positive drive is required for prevention of slip-back, etc. A winch by such means as spragging gear teeth, etc.

Objects placed between teeth or spokes. Where a winch is fitted with a warping drum nigger-head this may be used for hoisting loads, with approved operator only. When using a nigger head do not use synthetic fibre rope, such as nylon as the friction causes heat, which melts the rope fibres. They also have great elasticity and stretch which is an advantage for shock load absorption, but which may cause dangerous recoil if the rope breaks. The requirement for a winch used to hoist or lower personnel, is an automatically applied, or fail-safe brake system.

Use particular care to ensure that the load does not gain speed, which would make it difficult to stop, or which may damage the winch due to over speeding. Warning signs or barricades or both to keep persons out of the rope path or path of the load, and in some cases an audible warning device, such as a whistle, bell or horn.

Again the operator's view may be obstructed, so that due warning may be given to worn the public. The name aptly describes the function, which is to give a rope a fair lead on to a winding drum, for correct spooling. Usually consists of one or more rollers, sometimes on a swivel, a fixed guide is sometimes used.

A snatch block or other leading block may be fixed to a suitable anchorage to guide the rope but remember snatch blocks should not be used for lifting purposes. They are designed for easy Insertion of the rope, when hauling loads mainly in a horizontal plane, and for the sole purpose of guiding the rope.

Particular attention should be paid to their means of anchoring. When leaving a winch un-attended you should move to prevent un-authorized use, particularly at the close of work? If it is a hand winch it may be possible to remove the handles. With an electric winch the isolating switch should be locked in the "Off" position. With an air, hydraulic or other type, including internal or external combustion, means should also be provided for locking off the source of power.

Can FSWR be safely used in a fibre rope tackle block? A 3 x 3 sheave system with one lead sheave is to be to assist winching. Calculate: a The slope length. The minimum winch capacity. High strength structural bolts are used rather than commercial bolts where higher induced tension in the joint is the main design consideration. The Design Engineer is responsible for all connections being in accordance with the relevant Codes and Specifications of the Engineer The rigger.

Fitter or other allied tradesman on the job is responsible for the assembly and correct tightening of the bolted connection. The Supervising Engineer or his representative is responsible for procedure and inspection. The three radial lines on the top of the bolt head indicating quality and type of thread -Metric easily identify these high strength structural bolts.

The nut is heavier than a standard nut and is identified by three lines arranged circumferentially on the face. The load that a bolted joint can carry before the mating faces of the bolted members move is determined by the amount of preload on all bolts comprising the joint. Induced tension in the joint is controlled by nut rotation. Regardless of the nature of the load or type of bolts used, the bolts should be tightened correctly that is to there recommend preload.

There are no exceptions. The Joins depends on the clamping force developed by the bolts and the transmission of load by friction between the mating surfaces of the bolted members.

It Is Important to properly control the tightening of the nuts and the preparation of the contact surfaces. Therefore the assembly surfaces in contact must be free of oil, dirt, loose rust, loose scale, burrs and other defects, which would prevent solid seating of the parts or would interfere with the development of friction between them. The surfaces are often abrasive blasted and coated with an inorganic zinc silicate paint that has the same resistance to slipping as blast cleaned metal.

Site personnel must avoid damage to the treated surfaces during erection, i. Each bolt shall be assembled with at least one high strength washer and where only one washer is used it shall be placed under the rotating component nut or bolt.

When the bolt is snug all components must be drawn into close contact and at least one full thread should protrude through the nut. Increased bolt length is required when using load indicator washers. The tightening of nuts with a calibrated power or hand torque wrench is difficult to ensure the minimum bolt tension has been achieved without constant checking and inspection. Therefore this method is not recommended.

It is important to note that the Code specifies bolt tension not torque. This can be achieved by tighten the nut and bolt to what they call snug tight a person with a podger pulling to hand tight which is about a kg force. Always tighten the bolt from the stiffest part of the joint and move towards the free edge. When the snug tight condition has been reached, location marks are established on the bolt and nut usually by using a centre punch or texta.

The bolts are finally tightened by a half or three quarter turn of the nut. If bolts are driven into the holes they will prevent the joint compacting and restrict the bolt preload. Always check that the joint is fully compacted. Check the match marks and the degree of turn from the snug tight position. And when using Direct Tension Indicator Washers check the indicator washer has been closed to the correct gap.

Normally a 0. All Columns and trusses to be plumbed and braced. Guys are not to pass over thoroughfares. Packs of purlins to be spaced so overloading of trusses does not occur. Fully bolt and tighten purlins as they are placed. When bolting up bolts to be placed diagonally to prevent roll. Drifts, podger and bolts to be secure in riggers belt before going aloft. Never leave tools where they can be knocked off beams. Safe access to be provided to and from the work face.

Do not work on wet steelwork. Do not work of ladders they are access only. Complete fall protection must be in place. How are the first-placed structural members levelled and plumbed? Explain your answer. During erection of steel framed building what should be continually installed in case of high winds? Synthetic ropes can be much thinner and yet have a 7 Each type of synthetic fibre rope is subject to different deteriorating and condemning factors. Acids affect some while others are affected by alkalis and most are difficult to tell apart after some use.

All types have different strengths and so the WLL is not constant. Synthetic fibre ropes have a smooth slippery surface, which can cause slip, and failure of most bends and hitches and is not suitable for hand haulage.

Prevent this with additional half hitches or seize the tail with yarn, twine or marline. Where splices are made, two additional five tucks with all of the strands are made and the protruding strands halved and fused together to prevent the splice from drawing or pulling out. All plain ends of rope should be whipped, to hold the strands together until the rope is fused. Under some conditions synthetic fibre rope can conduct electricity and therefore should not be used as taglines near powerlines.

Nylon Polyamide filament Nylon has a breaking strength 2. It is not resistant to all chemicals and can be affected by linseed oil and mineral acids such as sulphuric and muriatic acid. Alkalis have little effect. Although nylon melts or fuses with excessive heat it stops smouldering when the heat source is removed. It can melt with the heat build up when turns are surged around warping drums. Nylon has about four times more stretch than natural fibre ropes, which is good for shock loads but has little value for lifting gear.

It is resistant to rot and mildew. Dacron -terylene Polyester filament Dacron-terylene has twice the breaking strength of natural fibre rope and is not as elastic as nylon. Resistance to mild acid conditions, rot, mildew, heat or flame are the same as nylon. Exposure to alkaline conditions eg. Polypropylene Laid shattered film type Polypropylene has about 1. It is unaffected by water and will float. It is also unaffected by acids or alkalis except in a very concentrated form.

Lighter weight size for size. Greater elasticity or stretch Greater shock absorption because of greater elasticity. Greater resistance to rot and mildew. Better resistance to abrasion Some are resistant to acids, others to alkalis. Greater flexibility, ease of handling Less water absorption. Manufacturers' information and advice on inspection should be followed.

A mm length of rope for comparison that was cut from the end of the line at the time of purchase. Enough room to handle the whole length of the line systematically.

A good light. A magnifying glass may be of assistance. The entire length of the rope must be inspected at intervals of not more than mm. The rope strands should be unlaid slightly to inspect the inside. Care should be taken to return them to their normal position after inspection. Local abrasion as distinct from general wears. It may be caused by the passage of the rope over sharp edges while under tension and may cause serious loss of strength and damage. Local rupturing or loosening of the yarns or strands may indicate them.

Internal wear caused by repeated flexing of the rope particularly when wet, and by particles of grit picked up. It is indicated by excessive looseness in the strands and yarns.

Heavy loading may result in permanent stretching so that the extension available in an emergency is reduced. If the original length of the line is known.