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Rigging And Planning Manual

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Contents Forward

i

Basic Mathematics

ii

Weight calculations

Section 1

Safe working loads calculations

Section 2

Trigonometry

Section 3

Centre of gravity calculation – Composite objects

Section 4

Centre of gravity calculation – Non-symmetrical

Section 5

Sling calculations – Non-symmetrical bridle

Section 6

Equalizer beam calculations

Section 7

Lifting in water calculations

Section 8

Wind Calculations

Section 9

Support system (mats) calculation

Section 10

Crawler crane imposed loading calculations

Section 11

Multi Crane Lifts (Tandam Lifting)

Section 12

Multi crane lifts – Head and tail weights

Section 13

Risk Assessments

Section 14

Legislation and ACOPs

Section 15

Types of Lifts in regards to lifting operations

Section 16

Selection of Personnel

Section 17

The management of lifting operations

Section 18

The Planning of Lifting operations

Section 19

Method Statements

Section 20

Hook Block Calculations

Section 21

Glossary

Section 22

Index

Section 23

This workbook is for guidance only. It and Mammoet Holding BV cannot be held responsible for any inaccuracy. All rights reserved, no part of this publication may be reproduced, stored in a database or retrieval system, or published, in any form or by any means, electronically, mechanically, by photo print. Or recording or otherwise without prior written permission from Mammoet holdings BV 1

Forward Since the first crane was used to lift water and building blocks for the great pyramids by the Egyptians and Leonardo de Vinci innovated cranes to help build some of the most fabulous cathedrals in Europe, some one, somewhere had to take charge, supervise and plan these lifts. With the intervention of the 21st century with cranes that are bigger, taller and stronger. There are more than ever the presents of a supervisor and planner. Whose sole responsibility is to ensure that the lifting operation goes to plan? With current ethos of safety legislation demanding it, there is a requirement that all lifting operations are carried out by trained and competent personnel. Irrespective of your normal job description or duties planning and supervising a lift is a very important task and therefore the concern for safety though out the lifting operation is paramount. We here at Mammoet training department, have devised a compact reference book for all appointed persons and would be planners of lifting operations. We believe many people have had an input into this book, and also from other sources and we are grateful for there help in devising such a prolific read and study aid With this in mind this book is a must for crane operators, supervisors and appointed persons, and important source of knowledge for riggers and other people who depend on mobile cranes for there day to day operations. However the information supplied in here does interface with most lifting appliances. The core aspect this manual covers is the use of mobile and crawler cranes.

2

Basic Mathematics Symbols and Definitions +

Plus

-

Minus

X

Multiply

÷

Divide

%

Percentage

.

Decimal point

:

Ratio

∏

Pi, or 3.14 or 22/7

If you are required to change a fraction into decimals divide top into the bottom Example 5/8 = .625 To calculate the area of a square, rectangle or circle the simply formula applies Square and rectangle are the same. L x B = m2 Example 4m long x 2m wide = 8m² 2m long x 2m wide =4m² Area of a circle ∏r2 or 3.14 x diam x diam ÷ 4 Example 3.14x2mx2m = 12.56m²

3

3.14 x 4mx4m ÷4 = 12.56m²

Weight Calculations Material Type

Weight in kg/m3

Oil

800

Magnesium

1750

Concrete

2440

Brickwork

2000

Water

1000

Steel

7700

Cast Iron

7200

Aluminium

2700

Earth

1600

Paper

1120

Copper

8800

Lead

11200

Soft Wood

600

Hard Wood

800

Greenheart

1200

1000kgs = 1 Tonne

2240lbs = 1 Tonne

NOTE: The figures above represent an average weight which has been rounded for ease of use. Figures may possibly change due to water content and composition.

4

5

Safe working loads calculations The importance is to understand the difference between multi legged chain and single accessories. Single accessories when paired or multiplied with an internal angle (alpha) or external angle (Beta) will now have new combined S.W.L

The new combined S.W.L could affect the load weight to be lifted. For Example: 5te

5te

10te

Example: 5te

5te 90º

7te

6

The reason for this is the relation of the S.W.L of the lifting accessories and the angle between the slings Using the chart below it can be explained 0º

0º

0.5te

30º 0.53te

0.58te

60º

0.7te

90º 1te

120º

Fig14

Load weight of 1te

Fig 14 The relation between angle and the force applied to the sling is constant through out the lifting operation. The greater the angle the more force applied to sling therefore it is of importance that you do not exceed the recommended maximum sling angle of 90º Note: specialist applications other angles can be used but a greater planning is required.

7

Example To find out what S.W.L our lifting accessories are now rated at. We take the safe working load of one accessory if they are all compactable in S.W.L or the lowest S.W.L if different lifting accessories are being used. Formula 5te S.W.L Nylon round sling x2 used at an angle of 90º Therefore using our chart (fig 14) we find our force-loading equal to our angle being used for this example of 90º it is equal to 0.7te per leg because we will be using 2 round slings the total force loading is equal to 1.4te. Formula S.W.L of 1 lifting accessory x Force loading = New S.W.L 5te x 1.4 = 7te However do not reverse this calculation because you will have a reduced S.W.L on your required lifting accessories. Load Weight x Force loading = S.W.L 7te x 0.7te = 4.9te The answer is now incorrect. This would mean that you could use a sling with a lower capacity this could be a contributing failing in the lifting operation.

8

But we do not always have the ability to lift an object on two points so therefore three or four could be used. The formula follows the same format as before the only figure that will require changing is our force loading. The principle of the force loading is the multiplying of the force relevant to the amount of legs in use.

0.7te

1.4te

2.1te

2.1te

The reason for the similarity in three and four legs is because of equal weight distribution on each leg and so in these calculations we cannot guarantee that the weight will be symmetrical throughout the lifting operations. The formula for calculating with three and four legs it would be as followed. Still using our 5te round slings and working at 90º the new combined S.W.L will be S.W.L of 1 x Force loading = New combined S.W.L 5te x 2.1 =10.5te

9

It is also important to remember when pairing 2-legged chain in order to carry out a lifting operation. Before we start our operation we must check all factors the first is compatibility of our lifting accessories and also that 2 legged chains are rated at a 2 dimensional angle when paired up a facilitating a 4 point lift you have a 3 dimensional angle but only 2 dimensional lifting accessories. To find our new S.W.L we multiply the S.W.L by a mode factor of 1.5 Example: 4.5te S.W.L x 1.5 =6.75te

10

Trigonometry Solution of right angled triangles

a b B

A

c

Designate sides a, b and c. then designate opposite angle A, B and C respectively, angle A opposite the hypotenuse a, is the right angle and therefore is always a known quantity. The remaining angles B and C are acute and will always total 90 degrees. The three angles of a triangle always total 180 degrees. If two of the variables are known, side lengths or angles, the remaining side lengths and angles can always be calculated. Sine B = cosine C Sine C = cosine B Tangent B = cotangent C Tangent C = cotangent B

11

Sides and/or Angles Known

Formula for sides and angles to be found

A = √ b² + c²

b Sin B = a c Sin C = a b Tan B = c

a and B

b = a x Sin B

c = a x Cos B

a and C

b = a x Cos C

c = a x Sin C

B = 90º - C

c = b x cot B

C = 90º - B

c = b x Tan C

B = 90º - C

c = c x Tan B

C = 90º - B

b = c x Cot C

B = 90º - C

a and b a and c b and c

b and B b and C c and B c and C

C = √ a² - b² B = √ a² - c²

a= b Sin B A= b Cos C a= c Cos B a= c Sin C

C = 90º - B B = 90º - C C = 90º - B C = 90º - B

To take this a little further: Some Old Hens – Cackle And Howell – Till Old Age Sine = Opposite Hypotenuse Cosine = Adjacent Hypotenuse Tangent = Opposite Adjacent Logarithms tables or calculators can be used.

12

Example Finding the hook and lifting point’s angles for the following:

True sling length 6.2m

Load Weight = 65te

4.8m

True Sling Length = 4.8m = 2.4m 2 √ (2.4²) + (6.2²) = √5.76 +38.44 = √44.2 = 6.6483 Sine of hook angle = 2.4 = 0.3609 6.6483

13

Example Cont: Refer to the natural sines table: look for a number equal to or less than 0.3609 = 0.3600 Read the degrees of the angle in the left-hand column this = 21º. Then read the minutes of the angle from the top of the 0.3600 column =6’. The difference between 0.3609 and 0.3600 = 0.0009 ignore the zeros and look for a figure in the right hand column as near to or greater than 9 =11 Read the additional minutes from the top of the 11 column = 4’ Formula set out as follows: Sine of Hook angle = 2.4 = 0.3609 6.6483 0.3609 = 0.3600 = 0.3609 0.3600 = 21º6’ 0.0009 = 4’ = 21º10’ Hook angle = 2 x 21º10’ = 42º20’ Lifting point angle = 90º - 21º10’ - 68º50’

14

Centre of gravity calculations – Composite objects

Example:

1. Split the load down into recognisable sections. 2. Identify the weight of each part Green (W1)

Pink (W2)

Yellow (W3)

3. Chose a datum Datum

4. Identify the distance from the datum to the centre of each part. L3 L2 L1

Formula: Centre of Gravity (CofG) (L1 x W1) + (L2 x W2) + (L3 x W3) (W1 + W2 + W3)

Example: 15

L3 L2 L1

Therefore Green = W1 = 3te Red = W2 = 2te Yellow = W3 = 2te Therefore L1 = 7m L2 = 36m L3 = 60m CofG = (7 x 3) + (36 x 2) + (60 x 2) 3 +2 + 2 Ans = 21 + 72 + 120 7 Ans = 213 = 30.428 = 30.5 metres from datum 7

Centre of gravity calculation – Non-symmetrical 16

= New centre line of lift

Example:

Section A (Red) = 8m x 2m x 4m = 64m³ Section B (Green) = 4m x 6m x 4m = 96m³ The load composite is of rolled steel (7929.2 Kg metre cu) Section A = 50.7te

Section B = 76.1te

Therefore divide section B by the combined weight of Section A& B Section B = 76.1te divided by 126.8te = Answer 0.600 x 100% = 60% Draw a line from CofG of Section A to CofG of Section B Distance between Section A CofG and Section B CofG = 6.2m The new CofG is now located 60% along this line from CofG 60% x 6.2m = 3.72m Therefore the new centre line of lift is directly over this point the new combined CofG

17

Sling Calculations Non-Symmetrical Bridle T2 SLING B

H2 L2

SLING A H1

D2

L1 D1 T1

L1 = 7.3M L2 = 2.5M

D1 = 4.9M D2 = 2.1M

13.6te

H1 = 5.3M H2 = 1.5M

Formula: Sling A = load x D2 x L1 D2 x H1 + D1 x H2= 13.6 x 2.1 x 7.3 2.1 x 5.3 + 4.9 x 1.5 = 208 18.5 =11.3te Sling B = load x D1 x L2 D2 x H1 + D1 X H2 = 13.6 X 4.9 X 2.5 2.1 X 5.3 + 4.9 X 1.5 = 167 18.5

=9te 18

Equaliser Beams Calculations To ensure that the lifting operations using a equaliser beam is carried out safely and using two crane we must ensure that, the total capacity of the cranes must be at least equal to or more than the total weight to be lifted including the load, lifting beams, rigging, hooks and attachments.

W

B

C

A

For Example B = A x (Net Capacity crane 2 – half the beam weight) (Net Capacity of crane 1 & 2 – beam weight In most cases the following example will be accurate enough B = A x (Net Capacity of crane 2) (Net capacity of cranes 1 & 2

19

Cont: LOAD ON HOOK OF CRANE 1 = C x (W + Rigging) + ½ beam A LOAD ON HOOK OF CRANE 2 = B x (W + Rigging) + ½ beam A Example

1.451te

W B

CRANE 1

C A 4.572m

113.3981te

CRANE 2 58.96701t

B =A x (Net Capacity of crane 2 – ½ beam weight) (Net Capacity of crane 1 & 2 – beam weight) =4.752m x (58.967te – 0.7255te) (113.3981te + 58.96701te – 1.451te) Ans = 1.619m 20

This is the lift point of the load on the beam To now determine the load on the cranes

1.451te

205kg

Wt 158.757te

1.619m

3.133m

4.752m

Load on hook on crane 1 = C x (W + Rigging) + ½ weight of beam A 3.133m x (158.757te + 205kg) + 0.7255te 4.752m 3.133m x 158.962te + 0.7255te 4.752m = 104.956te

21

Load on hook on crane 2 = B x (W + Rigging) + ½ weight of beam A 1.619m x (158.757te + 205kg) + 0.7255te 4.725m 1.619m x 158.962te + 0.7255te 4.752m =54.310te When calculating equalise beam configuration always ensure to following conditions of lift. 1. 2. 3. 4. 5. 6.

Calculate load on each crane separately. Know the location of C of G. Know the weight of the load. Locate lifting points. Establish location of fulcrum. Measurement lines to remain vertical.

22

Lifting in and out of Water

Above water load on hook = weight of lift

23

In water load on hook = weight of lift – weight of displaced water Weight of displaced water = Volume of lift x unit weight of water Unit weight of pure water =999.6 kg/ cu metre Unit weight of sea water = 1026.5 kg/cu metre Example Weight of block = 1.8m x 1.5m x 1.2m = 3.24m³x 2370.7 kgs Ans = 7.68te

A Concrete block Weight of block in water = 7.68te – 1.8m x 1.5m x 1.2m x 999.6kgs Ans =3.23te

24

Wind Calculations The wind speed restrictions within lifting operations are a factor that is overlooked. The wind is an everyday factor that cannot be controlled but can be managed by proper planning. A majority of cranes have anemometer and a maximum permissible wind speed for lifting using this information and calculations we can obtain a more accurate reading or a permissible wind load. The wind surface depends on the aerodynamic force coefficient (CF) of the load. The surface are of a load, which provides wind resistances, must not be greater than a value set against the lifting capacity. A set value of 1m² per tonne (10.8ft²/lbs = 1m²/t). If the value of (cf) is above 1.2 and wind surface, which are larger than 1m² per tonne of the lifting capacity, the wind surface of the load must be reduced proportionally. All concerned within the lifting operation must agree this. Formula Vred = V. √ 1.2 Cf. A Vred – Reduced permissible wind speed in m/s V - Max permissible wind speed according to loads charts in m/s Cf – actual aerodynamics force coefficient in m²/t A – Actual specific surface area of the load in m²/t Example 14m/s x √ 1.2 1.5 x 15m² (act load area) = 10t (act load weight)

1.2 2.25

=√0.533 =0.730 = 14 x 0.730 =10.22 New permissible wind speed = 10.22m/s

Support system (mats) calculations

25

Due to the adverse ground conditions that can occur on site at a lifting operation. A priority is for the crane to be supported fully through out the entire operation. There is a requirement to obtain relevant information on the type of ground the imposed loading of the crane being used on can withstand; the ground conditions can be resourced from the principal contractor or from geo-technical engineer. The imposed loading relating to the lifting appliances are available from computer programs from manufactures or from crane hire companies that you have hired the machine from. These imposed loading are important factors in the whole operation. The imposed loads do vary through out the lifting operation so a worstcase scenario will be implemented. The imposed loadings variation will be highlighted when the counterweight is added, when the fly jib is added the boom is raised and lowered in relation to the radius. Also slewing and variation in load weight of the load

The Formula we use is: 26

Imposed loadings = ground bearing pressure (GBP) Area of mat used In order to support the crane during the lifting operation a support system must be in place. The design of this support system can vary in accordance with designer and input factors and values. The support system can be made from concrete pad (also reinforced), timber mats, proprietary mats, steel grillage and piled foundations. To determine the size and type of mat or foundation required, it is necessary to make an assessment of the ground bearing capacity. To make the correct assessment first of all we must obtain the right information this would first of all the imposed loadings the crane creates. This can be obtained from the crane hire company and is freely available or can be calculated using relevant formulas. See fig15 and fig 16 these are example of information that can be resourced by the person planning the lifting operation (Appointed Person). The other information required is the construction of ground where the crane is going to be position during the lifting operation; this can be sourced at other location and other geological reference books.

Fig 15

27

Fig 16

28

Fig 17 Site investigation report

29

Description / Face

Tarmacadam

Reduced level

9.3 9.25

Legend

Depth (Thick)

(0.05) 0.05

Depth

0.20

Samples / Test Type No Test

D

Field Records

1

30

MADE GROUND: Brown slighty clayey very sandy gravel with occasional half to full bricks present. Gravel is subangular and subrounded fine to coarse brick, ash, tarmacadam and concrete. Occasional coble sized fragments of tarmac from 0.8m

(0.65)

8.60

MADE GROUND: Dark browm slightly clayey to locally clayey slightly gravelly fine to coarse sand. Gravel is subanggular and subrounded fine to coarse brick, ash, tarmacdam and concrete

MADE GROUND: Brown slightly gravelly fine to coarse sand. Gravel is subangular fine to coarse brick, concrete and flint

0.80

D

2

1.50

D

3

2.00

D

4

3.00

D

5

(0.50)

8.10 MADE GROUND: (Soft) dark grey sandy organic clay with occasional rootlets (diameter > 5mm). Gravel is subangular fine to coarse brick and sandstone

0.70

1.20 (0.40)

7.70

1.60 (0.60)

7.10

(Soft to Firm) brown very sandy slightly gravelly CLAY with ocassional rootlets (diameter > 5mm). Gravel is subangular and subrounded fine to coarse sandstone and flint (CLAYGATE BEDS)

2.20

(1.50 pen)

5.60

3.70

TRIAL PIT ENDS AT 3.70M

 Special attention to ground near surface Fig 18 Soil description GRANULAR

COHESIVE

VERY LOOSE – SPT = 4 Blows /

VERY SOFT – Cu = KN/m2 31

300mm

LOOSE – SPT – 4-10

SOFT – Cu = 20-40

Can be loosened with a spade easily. 50mm wooden peg can be easily driven

Can be moulded easily by light finger pressure

MEDIUM = SPT – 10-30

FIRM – Cu = 40-75

Can be excavated with a spade with effort

Can be moulded by finger pressure, however, can be indented by thumb

DENSE = SPT – 30-50

STIFF – Cu = 75-150

Requires a pick for excavation. 50mm wooden peg is hard to drive.

Cannot be moulded by finger pressure, however, can be indented by thumb

VERY DENSE = SPT – 50

VERY STIFF – Cu = 150

SPT = Standard Penetration Test

Cu = Undrained (immediate shear strength)

32

Further information on site investigation practice can be obtained from standard publications.

Fig 19 Soil Description

33

FOS = 3.0 used where minimum ground information available FOS = 2.0 Most site and ground conditions Now that all the relevant information has been collated we then can determine the size of our support system or type.

34

For Example If the ground bearing pressure is 30tem² and the outrigger loadings for a crane is 216tem² the two sets do not match and therefore an accident is inevitable to happen. So by contacting your hirer or supplier you decide what size of support you require and are available. Therefore as an example if we take the outrigger loading of 216tem² and a support mat that is 7.5m², we would achieve our ground bearing pressure. 216te = 28.80tem² 7.5m² Ans = 28.80tem² > 30tem² If our calculations resulted in a imposed loading greater than the permissible ground bearing pressure the solution would to increase the size of your support system, but this would only be feasible if you have space but also take into consideration the pyramid effect of 45 degrees and distribution of weight over a substantial large area the support mat will not carry out the task in question.

Crawler Crane imposed loading calculations A crawler crane works on the same basic principles as a mobile crane where it needs to be operated on a level surface. The crane itself has 35

no levelling mechanism (but in some exceptions and customer requirements it is available). The imposed loading created by the crawler tracks can be viewed in several different ways, first of all the loading created and forms a trapezoids under the tracks depending on the position of the main boom this will relate to over the front, rear and corner. However if the main boom is positioned over the side the imposed loading is displaced along the track base and will be more on the lifting track than the car body track. This can be equalized out with the use of ballast tray or derricking ballast. However the track tipping fulcrum is a key factor to the displacement and are correctly calculated from the shaft of the first track roller, you can calculate beyond the first track roller if you plate under the drive sprocket or idler the thickness of the plate will be specified by the manufactures in conjunction to the size of the crane. The procedure described above is called block plating. Once you have sourced the information from all parties i.e the crane manufacture, hirer and the principal contractor you the can calculate a support system that is required for the lifting operation, it is important to remember when a multi crane lift and the cranes in close proximity the possibility of a higher imposed loading.

Fig 20 Crawler Crane Loadings

36

37

Multi Crane Lifts (Tandem Lifting) Multi crane lifts are an extremely dangerous and complicated operation and requires a great deal of planning. Due to the possibility of overloading one or the other cranes, the S.W.L of each crane may be reduced by a safety factor. The safety factor (%) can vary due to condition of lift also environment which the lifting operation is taking place i.e. petrol-chemical site. The basic value is 20% but can be more. This helps to take into account any tendency for ropes to be slightly out of vertical during the lift, or any dynamic loadings. When planning such a complex lifting operation the appointed person should remember the following points. 1. Cranes should be of similar capacities and performance. 2. All movements should be as slow as possible, with no sudden motions. 3. The operating motion speeds of each crane should match. 4. The centre of gravity of the load should be calculated so that the lifting points can be chosen correctly. 5. Good communications are imperative, with one responsible person in charge. Some International standards explain in detail the requirements of the complex lift. Note tower cranes should not be used for multiple lifting.

38

Multi Crane Lifts – Head & Tail Weight Calculations (Fig 1)

39

40

Multi Crane Lifts – Head & Tail Weight Calculations (Fig 2) Example: 1. Using the centre of gravity as information and calculations we can

reassign the proportions of the load. Head

Tail L3 L1

L2 = Calculated CofG

Formula: Tail weight of the load = Tail = L1 x Wt L3 Head weight of load = Head = L2 x Wt L3

Example: Head

14.75m 3.25m

Tail

11.50m

Load weight = 65te

41

Example Cont. Tail = 3.25m x 65te 14.75m = 211.25 14.75m Ans = 14.32te Head =11.5m x 65te 14.75m Ans = 747.5 14.75m Ans = 50.68te

42

RISK ASSESSMENTS RISK RATING (R)

LIKELIHOOD OF OCCURRENCE (L)

Likelihood (L) X Severity (S) Very Unlikely A freak combination of factors would be required for an accident/incident to result. Unlikely A rare combination of factors would be required for an accident/incident to result. Possible Could happen when additional factors are presented but otherwise unlikely to occur. Likely Not certain to happen but an additional factor may result in an accident/incident. Very Likely Almost inevitable that an accident/incident would result.

HAZARD SEVERITY (S) Negligible Negligible injury, No absence from work

Slight Minor injury Requiring first aid treatment

Moderate Injury leading to a lost time accident

High Involving a single death or serious injury

Very High Multiple deaths

LOW

LOW

LOW

LOW

MEDIUM

LOW

LOW

LOW

MEDIUM

MEDIUM

LOW

LOW

MEDIUM

MEDIUM

HIGH

LOW

MEDIUM

MEDIUM

HIGH

HIGH

MEDIUM

MEDIUM

HIGH

HIGH

HIGH

LOW RISK May be acceptable; however review task to see if risk can be reduced further. MEDIUM Task should only proceed with appropriate consultation with specialist personnel and safety team. Where possible the task should be refined to take account of the hazards involved or the risk should be reduced further prior to task commencement. HIGH Task must not proceed. It should be redefined or further control measures put in place to reduce risk. The controls should be re-assessed for adequacy prior to the commencement of the task.

43

RISK EVALUATION Likelihood of occurrence (L) = How often could the hazard occur? Consider the task frequency, duration, method of work, employees involved. Hazard Severity (S) = How serious would the hazards effect be if realised. Consider the type of hazard, biological, ergonomic, physical and chemical. To evaluate the likelihood and severity will produce a Risk Rating (R). Risk(R) = Likelihood (L) X Severity (S) The Risk Assessment Matrix provides guidance in determining the risk ratting. Therefore, if the likelihood of occurrence is possible and the hazard severity is given as moderate, then the risk rating would be medium. MEDIUM = POSSIBLE X MODERATE

44

A common list of Legislation and Approved Codes of Practice Health and Safety at Work Act 1974 Management of Health and Safety at Work 1999 Provision and use of work Equipment Regulations 1998 Lifting Operations Lifting Equipment Regulations 1998 BS7121 part 1:2006 “Safe use of Cranes” BS7121 part 2:2003 “Inspection and testing & Examinations” BS7121 part 3: “Mobile Cranes (including Crawler Cranes)” BS7121 part 4: “Lorry Loaders” BS7121 part 5: “Tower Cranes” BS ISO 15513: 2000 “Crane-competency requirements for crane operators, slingers, signallers and assessors HSE Guidance Note GS39 “Training of crane drivers and slingers” In accordance with today’s legislation it bears the simple phase “that all lifting operations must be planned and carried out in a safe manner”; Quote from LOLER 98 Regulation 8 (1)Every employer shall ensure that every lifting operation involving lifting equipment is: (a)Properly planned by a competent person: (b)Appropriately supervised: (c)Carried out in a safe manner In order to carry out the above mentioned we need to have an understanding of the basic fundamentals in which lifting operation should be carried out.

45

Types of lifts in regards to lifting operations With reference to BS7121 part 3 Safe uses of cranes Mobile specific it categorises the types of lift in accordance with the complexity. These are: 1) Basic Lift 2) Standard Lift 3) Complex Lift 1) Basic Lift: If the weight of the load(s) can be simply established, and they’re no hazards or obstructions with in the area of the operation, then the duties of the appointed person should include the following: (a)Establishing the weight. This can be by a reliable source of information done in the way of calculations or weighing the load in question. Note: Always allow for inaccuracies when calculating the weight of the load. (b)Selection of the crane, based on the weight of the load that includes the crane hook block and lifting accessories: the maximum height of lift and the maximum radius required. Also current test certificates and thorough examination reports  4 yearly examination reports for the crane.( Customer Req)  12 monthly certificates for the crane.  6 monthly certificate for the crane (man riding duties)  Lifting accessories certificates  Lifting accessories thorough examination report. Note: a competent person must carry out all examinations of lifting equipment and associated accessories. (c) Consideration of the location of the operation and to take into account the access and egress of the Lifting appliance (cranage) and the suitability and stability of the ground in relation to loading and imposed loadings during the lifting operation.

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(d)Ensue a reporting system is in place for both appliances and accessories. (e)The selection of appropriate lifting accessories, this should include the method of attachment to the load. (Protection of lifting accessories should be taken into consideration to prevent damage and unsafe lifting practices). (f) Briefings of all personnel involved in the lifting operation and ensure effective communication via a method statement. (g)Check that if numerous loads are to be lifted over a long period of time, to ensure that no changes are required to the safe system of work (method statement). (h)Ensure that there is a supervisor (crane) to direct personnel and to carry out the lifting operation in accordance with the method statement. Note: The appointed person and the crane supervisor should be aware of the limits of their knowledge and experience concerning lifting operations and should understand when to seek further advice.

2) Standard Lift The standard lift is normally coincide with the lifting of persons but however some aspect must be adhered to in order to complete the appropriate planning to allow this type of lift to go ahead. If there are hazards, either within the working area of the crane or the access and egress route to the working area. Standard lift does not cover multi crane lift. The person planning the lift should take into consideration all aspects covered in the basic lift and in addition the following: (a)Invest all hazards within the lifting operation area; these could include the area for erection and dismantling of the crane. This may come in the form of crawler crane erection and

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dismantling or mobile crane fly jib erection or dismantling or a small luffing fly jib. (b) Take into account the increased risk involved if the load is being lifted from a structure, which is at a height above the cranes set up position. Note: Other risks may arise if the crane operator is working blind to the lift and is preparing to inch the load. A common factor called jib deflection may arise causing: i) Overload due to an increase of radius ii) The load not to be lift level or plum iii) The load can be lifted but cannot be lowered safely or repositioned (c) Appropriate planning in liaison with local authorities to ensure a safe system is implemented therefore reducing the hazards within a lifting operation. (d)The interface and relation your lifting operation has with the surrounding property and or person’s including the general public. This should coincide with current legislation and statute. (3) Complex Lift If your lifting operation requires more than one crane to lift the load or the cranes will be using load enhancement attachments (super lift or maxi lift). Also if the lifting operation is taking place in a location of exceptional hazards (e.g. at a petrochemical plant) the person planning the lifting should take into account all the information and detail, required for the basic lift and standard lift but in addition the information listed below:

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(a)The weight of the load is known. (b)The lifting points provided on the load are strong enough for the loads applied. (c) The proportion of the weight taken by each crane throughout the whole lifting operation is known accurately to with in +/-2%. (d)The cranes are of compatible in lifting characteristics and safety margins within the RC (rated capacity) of each crane to allow additional weight transferral from one crane to another. Also if all factors cannot be accurately evaluated, an appropriate down rating of the cranes of at least 20% should be applied. (e)The lifting operations are set out so that there is no contact between component parts of the crane(s) and the load. (f) The method statement includes access, ground suitability and conditions, erection and a sequence of operations when the load is being lifted. (g)Geotechnical information may be required in order to ascertain where the ground will withstand force applied during the lifting operation and the close proximity of the cranes whilst in operation. (h)The monitoring of the hoist rope during the lifting operation in order to maintain a vertical lift and level lift. Now that we have a understanding of the three types of lift that can be carried out and what detail is required then the next step is to see how we you are going to carry out your lifting operation

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Selection of personnel (a)The Appointed Person Definition: An Appointed Person is a person with training, practical and theoretical knowledge and experience. When you are selecting and assessing an appointed person the organisation should consider the variety and complexity of the lifting operation and all other hazards and problems that arise. The appointed person should be notified formally in writing and given the authority to carry out the duties involved. Note: Different types of lifting operations require different levels of expertise, training and experience, and that imposes different duties on the appointed person. (b)The Roles of Appointed person The appointed person takes total responsibility for the lifting operation from conception to completion. He or she also has the responsibility in the selection, provision and use of suitable crane(s) and equipment. He or she is also responsible from when the crane arrives at the site entrance; for its passage through the site to the erection position, for the erection of the crane(s), the lift and the dismantling of the crane(s) and its egress from site. He or she is responsible for complying with all relevant acts, regulations and approved codes of practice and producing the necessary risk assessments and method statements. He or she is responsible for the selection of all personnel involved, including determining their competence to complete designated tasks. He or she is responsible for ensuring the safety of personnel not involved in the lifting operation. He or she is responsible for seeking expert advice where his or her knowledge may be limited. He or she is responsible for implementing a safe system of work.

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He or she is responsible for ensuring that the safe system of work is communicated to all personnel involved, usually done by the method statement. Note: The Appointed person may delegate the task of, or a task from the lifting operations but not the responsibility. (c) The Crane Supervisor Definition: A Crane Supervisor is a person who controls the lifting operation, and ensures that it is carried out in accordance with the appointed person’s safe system of work. When selecting and authorising a crane supervisor for your lifting operations he or she should be able to: i.

Fully conversant with the duties of all personnel involved in the lifting operation.

ii.

Able to give clear, unambiguous instructions to all other members of the team.

iii.

Able to assess the danger to the lifting operation, from changed circumstances on site, and call a halt to the lifting operation, if the risks become unacceptable so that the appointed person can be informed and further instructions can be sort form the appointed person.

Note: The appointed person does not have to be on site but the appointed person for that lift must carry out any changes to the lifting operation.

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Note: If the crane supervisor is also a crane driver, then he or she should not operate any crane involved in the lifting operation but supervise. (c)The Roles of the Crane Supervisor. The crane supervisor should direct and supervise the lifting operation. He or she should ensure that the lifting operation is carried out in accordance with the method statement. He or she should be competent and suitably trained and should have sufficient experience to carry out his or her relevant duties. He or she should have sufficient authority to stop the lifting operation if they think it is dangerous to proceed. Note: The appointed person may decide to undertake the duties of the crane supervisor or delegate the duties to another person with appropriate expertise for the lifting operation. (d)The Crane operator Definition: Person who operates the crane to position loads or to assemble the crane (e)The Slinger / Signaller (Banksman) Definition: Is a person who attaches and detaches the load of lifting equipment from the crane and the selection of the correct lifting accessories for the lifting operation. He or she also is responsible for directing the crane operator to carry out a safe system of work or lifting operation. Note: the crane operator and slinger/signaller (banksman) should carry out his or her role in accordance with local standards and legal requirements and should be in possession of a certificate or operators card for this position.

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The Management of lifting operations In order to carry out a good lifting operation a safe system of work must be established. A system of work applies to individual lifts or a group of repetitive lifts. A safe system of work should include the following: i. ii. iii. iv. v. vi. vii. viii. ix. x.

Risk assessments. Planning of the lifting operation. Preparation of a method statement. Selection, provision and use of a suitable lifting appliance and equipment. Preparation of the site (If required). Provision of properly trained and competent personnel. Supervision carried out by properly trained and competent personnel with authority Ensuring that all test certificates and any other relevant documents are available. Preventing the unauthorised use and movement of the lifting appliances. The consideration of personnel not involved in the lifting operation.

Note: In controlling a lifting operation the provision of an appointed person does not lessen the legal responsibilities of the employing organisation for ensuring safety. Also the appointed person may have other duties and is not necessarily a direct employee of the employing organisation. The way in which a safe system of work is communicated is through a method statement.

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The planning of a lifting operation In order to implement your safe system of work via your method statement there are information that should be considered: (f) The load characteristics and the method in which the load or item is to be lifted. (g)Selection of lifting appliances for the operation. (h)The selection of lifting accessories, this should take into account the weight of accessories on the total load on the lifting appliances. (i) The position of the crane(s) and the load before and during and after the lifting operation. (j) The site for the lifting operation and the areas of concern for example proximity hazards, space and the suitability of the ground or foundations. (k) The rigging and de-rigging of the crane(s). (l) Any environmental conditions at the site. Note: For routine lifting operations an initial lift plan may only be required once but there is a need to review it occasionally to make sure that nothing has changed and the lift plan remains valid. For more complex lifting operations you need to plan the task each time it is carried out. Method Statements Definition: Document produced for or the appointed person to describe how should carry out, the lifting operation including any contingency plans if the operation becomes interrupted (e.g. weather, breakdown etc) A method statement is away of communicating your safe system of work, in order to this efficiently and effectively. A method statement is a step-by-step description of how the lifting operation is going to be carried out. 54

When producing your method statement remember how and who is going to communicate to the lifting operation team, also in some cases the method statement could have been written several months before the lifting operation is to take place Depending on the nature of the lifting operation will have an effect on the context of your method statement the diverse (complex) the lifting operation the more information attained in your method statement? The more routine (basic) the lifting operation the reduced amount of information required. When preparing your method statement it should include at least the following: (a)The schedule of responsibilities (type of hire, road closure, base / ground preparation and the isolation of live services). (b)Full details of the crane(s) (c) Details of Ancillary equipment. (d)Details of lifting accessories. (e)The name of the Appointed person. (f) The name of the crane supervisor (who may be the appointed person). (g)Sequence of operations (site preparation, arrival, erection, positioning, lifting the load, dismantling and departure). (h) Tool box talk. (i) Ground loading. (j)

Wind speeds limitations.

(k) Radio communication (if being used). (l)

Possible drawing.

(m) Risk assessments and any other relevant / reference documentation.

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Common Hand Signal

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Basic Crane Sizing Chart

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Lifting Accessories Charts 1

2

3

4

5

6

7

Material

Single leg in lin e

Single le g ch ok ed

Single leg bask et

Single leg bac k hoo ked

Single leg halsh ed

Endless in line

1 1 1 1 NA

0.8 1 0.8 0.8 NA

1.4 1.4 1.4 1.4 NA

1 1 NA 1 NA

NP 2 NP 1.6 NA

NP NP 1 1 1

Chain Wire Rope Webbing Fibre Rope Round sling

8

9

Endless choke d

1 1 0.8 0.8 0.8

Endless basket 0-90o

NP 1.4 1.4 1.4 1.4

Flat Web Accessorie s and Round Slings

Assembly Mode Mode Factor W.L.L.

COLOUR

1.0 1.5 2.0 3.0 4.0 5.0 6.0 8.0 10.0 12.0

Violet White Green Yellow Grey Red Brown Blue Orange Orange

Straight

Choke

1.0

0.8

Parallel Basket 2.0

Basket 90o 1.4

2-Leg 0-90o 1.4

4-Leg 0-90o 2.0

MODE OF ASSEMBLY – SWL IN TONNES

1.0 1.5 2.0 3.0 4.0 5.0 6.0 8.0 10.0 12.0

0.8 1.2 1.6 2.4 3.2 4.0 4.8 6.4 8.0 9.6

2.0 3.0 4.0 6.0 8.0 10.0 12.0 16.0 20.0 24.0

1.4 2.1 2.8 4.2 5.6 7.0 8.4 11.2 14.0 16.8

12.0 3.0 4.0 6.0 8.0 10.0 12.0 16.0 20.0 24.0

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Calculation of the required hook block weight It is important that when carrying out lifting operations the correct hook block is used, not only in size, shape and capacity but it self weight. The reason behind this is to maintain tension on our hoisting line and to not to exceed our parameters set with in our load charts or duty charts. Explained below is a simple calculation that can be use in order to ascertain the correct hook block weight. Formula G=LxMxNxF G = Hook Block weight L = Boom Length (overall) in metres M = Hoist Rope weight in kilogram’s per metre N = Fall of rope / parts of line F = Factor of safety Table 1 ROPE DIAMETER (MM)

HOIST ROPE WEIGHT PER METER (KG/M)

23 25 28 30 32 40

2.61 3.08 3.85 4.35 5.01 7.83

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Table 2 FALLS OF ROPE

FACTOR

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

1.31 1.34 1.36 1.39 1.41 1.44 1.46 1.49 1.52 1.54 1.57 1.60 1.63 1.65 1.68 1.71 1.74 1.77 1.80 1.83 1.87 1.90 1.93 1.96 2.00 2.03 2.06 2.10 2.13 2.17

The source of basic information we require can come from the operator’s manual, method statements, lift plans and drawings. For the information about our hoist rope dimensions and measurements we can obtain from rope certificates or measure the hoist rope ourselves. Or our last resort would be the load chart book or even the manufactures marketing brochure and operator’s manual.

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The example we are going to use using the drawing above. The crawler crane is configured with an overall boom length of 98 metres, the hoist rope diameter is 28mm and has be reeved up with 12 falls of rope. With the information in table 1 and 2 we can now calculate the following

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Example 98metres x 3.85 x 12 x 1.60 = 7244 kg Therefore the hook block weight we would require is 7244kg or 7.2 te. However some crawler cranes are able to reeved up with 2 hoist lines on 1 hook block, in order for to achieve the correct weight we also have calculate using the same formula but with additional information. Because we are running 2 hoist ropes the formula is a multiply of that number. Example G=2xLxMxNxF 2 x 98metres x 3.85 x 8 x 1.60 = 9658.8 kg Therefore in this application the hook block weight we would require is 9659kg or 9.7te

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Index A A.C.O.Ps 44 Appointed Person 49,50 B Basic Lift 45,46 Basic Mathematics 3 Basic sizing chart 56 C Calculating Area 3 Centre of Gravity composite 15,16 Centre of Gravity Non-symmetrical 17 Complex Lift 47, 48 Crane Supervisor 50,51 Crawler Crane imposed loading 35 Crawler Crane loading (fig 20) 36 D E Equaliser Beam Calculations 20,21,22,23 External Triangle rule of thumb 57 F Forward 2 G Glossary 63 H Hand Signals 55 Head and Tail weight calculations 40,41 I J 64

K L Legislation 44 Lifting Accessories Chart 56 Lifting In and Out of Water 24,25 LICCON Planner (fig 16) 30 M Management of Lifting Operations 52 Method Statements 53,54 Multi Crane Lift 37,38,39 N Non-symmetrical Bridle 18,19 O Outrigger Loading (fig 15) 29 P Planning of Lifting Operations 53 R Risk Assessments 42,43 S Safe Working Load 6,7,8,9,10 Sin Table 12 Sin Calculation 13,14 Site Investigation Report (fig 17) 31 Soil Description (fig 18,19) 32,33 Standard Lift 46 Support System 27,28,34 T Tandem Lifting 37,38,39 Trigonometry 11 U Uniform loading 7

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V Volume Formulas 5 W Weight Calculations 4 Wind Calculations 26 Y

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