Symmetrical Group

Policies and Procedures

OHS&E\SAFETY PROCEDURES

SG-PR-33-22_Rigging and Slinging

• PURPOSE

The purpose of this document is to provide guidelines for the correct storage, use and maintenance of all lifting equipment and to ensure that only trained and appropriately certificated Symmetrical Group employees, contractors or visitors carry out all rigging and slinging work.

• SCOPE

Covers all Symmetrical Group divisions, workshops and worksites.

• DEFINITIONS

• RESPONSIBILITIES
• The S&E Coordinator is responsible for implementing systems to ensure:
• that approved lifting equipment is purchased, hired and used by Symmetrical Group employees and subcontractors;
• a register of all lifting equipment is maintained at workshops and sites;
• training is carried out for all personnel who are to work with lifting equipment.
• Workshop/Site Supervisors are responsible for ensuring that:
• only approved and inspected lifting equipment is used;
• only appropriately certificated personnel work with the relevant equipment;
• a JSA is provided for any task for which it is required;
• any training provided for trainees is fully supervised;
• keep all registers fully maintained.
• Riggers and dogmen are responsible for:
• safety carrying out their work covered by their certificate without direct supervision;
• carry out any regular inspections of lifting equipment, identify unserviceable items and assist in maintaining a register.
• to assist Symmetrical Group management in the training of new dogmen or riggers.

• PROCEDURE

5.1 Lifting Equipment

Symmetrical Group management shall ensure that all lifting gear and associated equipment complies with regulatory requirements and maintained in a serviceable condition.

• There shall be a system in place for the purchase, storage, maintenance, inspection and safe usage.
• There shall be a system in place whereby all personnel to report and remove damaged, unsafe lifting equipment from the workplace. This will allow assessment for either repair or disposal (to allow replacement).

Lifting equipment that is faulty, damaged or used incorrectly has the potential to cause serious injury or even death and result in significant property and equipment damage. Prior to any task involving the use of lifting equipment it is required that:

• A JSA will be provided if relevant;
• Full knowledge of how the equipment should be used;
• All equipment must be checked before every use;
• Any faulty equipment should not be used and reported to the supervisor;
• The weight of load or object to be moved is known;
• The safe working limits (SWL) of all equipment is known;
• The SWL of all equipment is not exceeded

5.2         Steel Wire Rope (SWR)

Storage

• Steel wire rope and slings are used extensively for lifting
• Store wire rope clear of the ground in a clean, dry place
• Make sure that wire rope is not in contact with corrosive substances when it is stored
• Make sure that wire rope is properly lubricated before storage to minimise risk of corrosion.

Use of SWR

• Avoid reverse bends
• Use suitable packing to protect rope from sharp edges
• Do not expose wire rope to temperatures above 95ºC
• Do not lift with wire rope less than 5mm diameter
• Do not use a rope that should be discarded i.e.:
• Abrasion and core collapse;
• Wear caused by badly maintained or aligned sheaves;
• Corrosion – red oxide powder and loose springy wires can indicate serious erosion;
• Kinks or fractures from bending or reeving;
• Crushed or jammed strands;
• Bird caging;
• High stranding.

Note: All rope should be checked for wear and tear before and after each use.

5.3         Chains

Although chain is from five to six times heavier than steel wire rope it is more durable. It can withstand rough handling and can be stored without deterioration,

• Types:
• Chain used for Lifting must be Grade (T) - Most chain used for lifting is grade (T) or 80-alloy steel. It is stamped (T), 800, 80 or 8, HA, PWB or CM and various combinations of the above.
• Note: Grade (T) chain less than 5.6mm diameter not to be used for lifting.
• Grade (S) - Usually grade (S) or 60 alloy steel grade is marked (S), 60 or 06. It is generally used for transport lashing.
• Notes:
• There are many types of chains being manufactured and it is important to know those which are suitable for lifting.
• Each chain sling must have a tag stating manufacturer, grade, SWL of different applications and conditions of use.
• Any chain with a tag missing must be taken out of service until it can be identified and be re-tagged as per manufacturers’ specification.
• Wrought iron chain and proof coil are not graded and must not be used for lifting.

• Uses:        

A chain sling is only as strong as its weakest link. When making a chain sling always use chains, hooks, links, hammer locks and couplers of the same grade and SWL and that are in a good state of repair.

• Do not lift a load heavier than the SWL of the chain.
• Do not use a chain in which the links are stretched, locked or do not move freely.
• Do not use a chain with a nick or a cut greater than 10 cent of the diameter.
• Do not twist, kink or knot chain.
• Do not drag a chain from under a load.
• Do not drop a chain from a height.
• Do not roll loads over a chain.
• Use protective padding when using chain around sharp corners.
• Do not attempt to use chain when the temperatures exceed 260ºC.

• Storage and Inspection:
• Store in clean dry locations.
• Slings should be cleaned prior to inspection if required.
• Slings should be inspected regularly.
• Each link should be inspected for signs of wear, twisting, stretching, nicks or gouging.
• Cracks can be found by dusting with fine powder.
• Any worn links should be measured for degree of wear that must not exceed that allowed for by the manufacturer.
• Withdraw any chain from services immediately that has defects. Clearly mark the chain with an ‘Out of Service’ tag stating that it must not be used until the manufacturer can inspect it.
• Destroy any chain that cannot be repaired.
• Enter all inspection details into a lifting equipment inspection register (F-S-24_Lifting Equipment Inspection Register).

5.4 Fibre Rope

Fibre rope is not widely used for lifting. It has neither the strength nor versatility of steel wire rope, chain or synthetic slings.

• Uses:
• Fibre rope is used for relatively light loads that require gentle treatment.
• Fibre rope is used for steadying loads because of its flexible and non­conductive nature.
• Do not use a fibre rope that is less than 12mm diameter for lifting.
• Do no use a fibre rope that is less than 16mm diameter as a tag line.
• Ropes must be examined each time before and after use.
• No rope sling shall be used so that the included angle is greater than 150º between two legs.
• Keep away from heat greater than 65ºC, chemicals, corrosive substances, sharp objects and hot work activities.
• SWL of rope not to be exceeded.
• Storage:
• All ropes should be kept neatly coiled when stored either in or out of use.
• Be protected from falling or sharp objects.
• Kept dry and stored in a well-ventilated place out of direct sunlight and never in an airtight box.
• Stored away from acids or other corrosive substances such as ashes, clinker, coke, oils and grease.
• Away from vermin such as rats, mice and white ants.
• Protected from adverse effects of weather e.g. sun, rot and mildew.
• Kept clear of rust, sand, dirt or other foreign matter especially if it is abrasive.
• Inspection:
• Before use all fibre rope should be carefully inspected by sight and touch throughout its whole length.
• The interior of a used rope should be inspected more closely at intervals of approximately 1 metre by carefully checking each strand.
• This inspection could disclose the following defects:
• The effects of heat
• Sun rot
• Mildew
• Effects of acid or other corrosive agents
• Effects of overloading
• Excessive work over sheaves
• High standing
• Cuts, etc.
• Any defect rope should be taken out of service and cut up into small unusable lengths.

5.5 Synthetic (Man-made) Rope

There are many types of synthetic ropes available for use in industry but it is necessary to ensure that the right type is used for a specific task and also to ensure that the types are correctly identified.

• Advantages

It is generally claimed that synthetic rope as compared to fibre rope:

• Has a greater strength, size for size, than fibre rope;
• Greater elasticity or stretch;
• Better shock absorption because of elasticity;
• Better resistance to absorption;
• Some are resistant to acids, others to alkalis;
• Less water absorption than natural ropes.
• Disadvantages
• Greater elasticity or stretch are not of great value in lifting gear;
• In general, synthetic ropes are subject to ultraviolet degradation (i.e. sun rot);
• Some synthetic ropes have a greater tensile strength than fibre ropes but lack of positive identification could result in overloading the rope;
• Outer surface of the rope has a smooth slippery surface and this may cause slip and failure of any bends and hitches that may be used;
• Splicing requires two additional tucks (5) with all of the strands, to ensure that splice is secure.
• Types

The following lists of synthetic ropes generally available together wit a comparison of breaking strengths and abridged characteristics can be used as a rough guide.

The manufacturer or supplier should supply all relevant details as to the specification and safe storage, maintenance and use of any supplied material.

• Nylon
• polyamide filament) approximately 23 times the breaking strength of natural fibre ropes (size for size). It can be affected by linseed oil and mineral acids such as sulphuric and muriatic. Alkalis do not affect it to any great degree. Heat resistance to 250ºC but begins to char at 150ºC. Nylon is very elastic and has four times more stretch than fibre rope. It is resistant to rot and mildew.
• Dacron-Terylene
• (polyester filament) has approximately 2 times the breaking strain of natural fibre rope. Not as elastic as nylon but is resistant to mild acid conditions, rot and mildew. Heat or flame affects it as with nylon.
• Note: Exposure to alkaline conditions should be avoided.
• Taniklon
• (polyethylene filament) has approximately 1.45 times the breaking strain of fibre rope, similar features to Terylene.
• Silver Rope
• (flat split taniklon fibre) This is commonly used in industry and has approximately 1.16 times the breaking strain of natural fibre rope. It is 30% lighter than fibre rope or nylon. Does not absorb moisture and does not slip as easily as the other synthetics.
• Polypropylene
• (laid shattered fibre type) has approximately 1.6 times the breaking strain of natural fibre ropes. It is affected by heat (approximately 15%-30% at 65ºC). It will float in water and is unaffected by water, alkali or acid (except in concentrated form).

• Storage and Inspection

Storage for synthetic ropes should ensure that it is a dry orderly area.

Inspection should be as for the natural fibre rope and inspections should disclose the following effects:

• External wear;
• Local abrasion;
• Cuts, contusions, etc;
• Internal wear;
• Heavy loading;
• Chemical action;
• Sunlight deterioration;
• Heat effects;
• Any defective rope should be taken out of service and cut up into unusable lengths and disposed of.

5.6 Synthetic Slings

• Use of a sling:
• Flat and round synthetic slings are in common use in industry. They are made from nylon, polyester, polypropylene or aramid polyamide.
• Each sling must be labelled with the SWL. DO NOT lift if the label is missing and send the sling back to the manufacturer for testing and labelling.
• Synthetic slings are colour coded to indicate the working load limit (WLL) in tonnes. The normal range is from 1 tonne to 12 tonnes.
• Storage:

Synthetic slings must be stored:

• In a clean dry well ventilated place;
• Away from the ground or floor;
• Away from direct sunlight, ultra-violet light and fluorescent light;
• Away from extremes of heat;
• Away from sources of ignition;
• Away from atmospheric or liquid chemicals;
• Away from the possibility of mechanical damage.
• Inspection:

A competent person must inspect synthetic slings before each use at least once every month. If subjected to severe conditions these inspections shall be more frequent.

Slings should be sent for a breaking test at least every 12 months. An inspection would disclose the following effects:

• External wear such as abrasion, cuts or contusions;
• Internal wear that is often indicated by a thickening of the sling or the presence of grit and dirt;
• Damage to protective coating of the sling;
• Damage caused by high temperatures, sunlight or chemicals;
• Damage to labelling or stitching;
• Damage to the eyes or any terminal attachments or end fittings.
• Removal of a synthetic sling:

A sling shall be discarded if upon inspection it is found:

• It has lost more than 10% of its original breaking strength (manufacturers test);
• The label has been removed or destroyed;
• There is any damage to the sleeve or protective coating;
• A nylon sling comes into contact with acid;
• A polyester sling comes into contact with alkaline
  substances;
• A polypropylene sling comes into contact with an organic solvent such as paint, coal tar, or paint stripper;
• There are any visible cuts on the sling.

5.7 Accessories

From the hook to the load the lifting gear can be made up of many parts. All of these parts require safe storage inspection, maintenance and use. The safe workload of lifting gear is only as great as the part of the sling with the lowest SWL i.e. if the SWL of:

• The hook is two (2) tonnes;
• The shackle is two (2) tonnes;
• The ring is one (1) tonne;
• The rope is two (2) tonnes.

Then the SWL of the sling is one (1) tonne.

• Hooks
• Hooks should be fitted with safety catches. They are mostly 80-grade alloy steel and are stamped with the SWL.
• Crane hooks must rotate freely at all times.
• The opening should be wide enough to accept the largest rope, ring, link or shackle that has to be placed over the hook.
• The inside of the hook or ‘bight’ should be rounded so that it does not cut into or damage slings and fitting.
• Hooks stretched more than 5% of the throat opening must not be used.
• Bent, cracked or distorted hooks should be discarded.
• Welding must not be used to repair hooks and must not have fittings welded to them.
• Rings
• A ring must have the same SWL as the chain, hook and other parts of the sling. Discard any rings that have been stretched more than 5%. DO NOT place a ring (or shackle or eye bolt) unless it hangs freely.
• Shackles
• There are two main types of shackles – ‘D’ and ‘BOW’. Most shackles used for lifting are now 80-grade alloy steel and they are all stamped with the SWL.
• It is mandatory to use the correct type pin at all times.
• All shackles which are bent, deformed or damaged, shall be removed from service. Any shackle that is worn in the crown or pin by more than 10% should be discarded.
• Where several sling eyes are to be connected to a lifting hook a large bow shackle should be used.
• Eyebolts (there are collared and uncollared eyebolts)
• Uncollared eyebolts should only be used for vertical lifts. Eyebolts should be securely screwed into the ferrule of a load and should be tightened properly with a podgier bar.
• 80-grade high tensile eyebolts are eight sided to indicate the grade.
• DO NOT put a sling through two or more eyebolts, use two slings attached to the eyebolts with shackles.
• DO NOT attach sling to eyebolts with hooks.
• Chain blocks

An assessment should be made before using a chain block to ensure that:

• The weight of the object to be lifted is known;
• The structure of the attachment point for the chain block is capable of supporting the load;
• The hooks can be correctly secured to the anchor point;
• Check all aspects of lifting gear for faults;
• Avoid exceeding SWL factors such as side loading etc.
• Load should be raised a small distance to ensure brake is working correctly;
• Chain blocks used on crane hooks should be rated at twice the weight of the load to be lifted.

5.8 Dogging Procedure

The Workshop/Site Supervisor is to ensure a certificated dogman is available for the task. A dogman must carry out his duties in a safe and responsible manner. First consideration must at all times be directed towards the safeguarding of life and limb. This consideration must extend to all persons in the vicinity or likely to enter the vicinity.If required a JSA must be produced in conjunction with the supervisor dependant upon the work task.

A dogman’s duties should include:

• Inspect lifting gear for defects;
• Make common whippings, bends, hitches and splices in fibre ropes;
• Safely use the various types of ropes, slings, chains and accessories;
• Calculate the safe working loads of slings in various configurations;
• Assess the weights of loads;
• Safely sling loads of different weights and sizes;
• Understand crane load charts;
• Correctly pack outriggers for mobile cranes;
• Direct the crane operator in the movement of a load when the load is out of the operator’s view;
• Correctly give all hand signals and whistle signals for directing load movement.

A dogman may be required to assist in the supervision and training of trainee dogmen. The duties include making sure that adequate directions, training and monitoring are provided.

5.9 Rigging Procedure

The Site/Workshop Supervisor should satisfy himself that the task to be carried out has a JSA provided if it is relevant. He should also ensure that the person carrying out the rigging has the required level of certification for each specific task.

It would be an ideal situation to have all personnel who are involved with rigging and dogging to have either:

• An advanced rigging certificate (national level), or
• A Rigger 1 Certificate that would allow them to carry out dogging duties as well as the ones outlined below.

A basic rigging certificate allows a rigger, in addition to dogging, to carry out the following rigging work:

• Movement of plant and equipment;
• Correctly prepare rigging equipment including the splicing of wire rope;
• Safely erect structural steel to plans and specifications;
• Inspect, fit and safely use a safety harness;
• Work safely and confidently at heights;
• Placement of pre-cast concrete;
• Install safety nets and static lines;
• All hoists except hoists with jibs and self-climbing hoists;
• Mast climbers;
• Perimeter safety screens and shutters;
• Cantilevered crane-loading platforms;
• Calculate becket loads, fleet angles and lead ropes in winches;
• Safely set up and use purchase and tackles.

An immediate rigging certificate allows a rigger, in addition to basic rigging, to carry out the following rigging work:

• Correctly rig and de-rig cranes, conveyors, dredges, excavators and all hoists;
• Safely use equalising beams in dual lifts;
• Correctly sling tilt-up panels using equalising gear;
• Safely carry out demolition rigging.

An advanced rigging certificate allows a rigger, in addition to intermediate rigging, to carry out the following rigging work:

• Correctly set up flying foxes and cableways (including span ropes);
• Calculate tension in span ropes, guy ropes and suspension ropes;
• Correctly set up gin poles and shear legs;
• Calculate counterweights and rope breaking strain in suspended scaffolds;
• Safely install suspended scaffolds (including swing stages and boatswain’s chairs);
• Safely install fabricated hung scaffolds.

Riggers may be required to assist in the supervision and training of trainee riggers or dogmen. The duties would include making sure that adequate direction, training and monitoring are provided.

• AUDIT CRITERIA

The following are the audit criteria for this procedure:- F-S-24_Lifting and Slinging

• Do the slings have an inspection tie (coloured) for the current month on them?
• Have the fibre slings been inspected in the last month?
• Has the last inspection information been entered in the lifting equipment
• register?
• Do the lifting chains have weight identification tags on them?
• Have the chains been inspected in the last 6 months?
• Have the shackles been inspected in the last 6 months?
• Is the lifting equipment stored where it is not exposed to damage?
• Do the operators inspect all lifting equipment before every?
• Is damaged lifting taken out of service?

• STANDARDS

The following documents provide useful reference material when considering this procedure:-

• Australian Standards
• AS1 353 1•2        Flat Sling Webbing Slings
• AS1380 Fibre Rope Slings
• AS1666 Wire Rope Slings
• AS2317 Collared Eye Bolts
• AS2741 Shackles
• AS2759 Steel Wire Ropes
• AS3775 Chain Slings – Grade T
• AS3776 Lifting Components

• FORMS

F-S-24_Lifting Equipment Inspection Register

Date published: 25/07/2013

* -25/07/2013 12:27:06 PM